Baker hughes Apollo 3 User manual

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Copyright 2020 Baker Hughes Company. All rights reserved. 
Page 2 of 277 
 
 
Contents 
Apollo 3 Intelligent Control System User Manual....................................................................................................................14 
1 
Quick Start Guide..............................................................................................................................................................14 
1.1 
Log on to Access Drive Configuration ................................................................................................................ 14 
1.2 
Quick Start.............................................................................................................................................................. 14 
2 
I Want To.....................................................................................................................................................................................................................21 
2.1 
Set Pump Speed....................................................................................................................................................21 
2.2 
Change Color Scheme.......................................................................................................................................... 21 
2.3 
Log In/Access the Main Menu..............................................................................................................................21 
2.4 
Set the Date and Time..................................................................................................................................................22 
2.5 
Change the Passwords.........................................................................................................................................22 
2.6 
Set the Pump Direction.........................................................................................................................................22 
2.7 
Set the Well Name/Site Name.............................................................................................................................22 
2.8 
Set the Motor Overload.........................................................................................................................................22 
2.9 
Set the Motor Underload.......................................................................................................................................22 
2.10 
Set the Drive Mode..............................................................................................................................................22 
2.11 
Set the Transformer Ratios ................................................................................................................................23 
2.12 
Setup a Downhole Tool..............................................................................................................................................................23 
2.13 
Setup Restarts .....................................................................................................................................................23 
2.14 
Setup Pump Curve..............................................................................................................................................23 
2.15 
Set the Control Source........................................................................................................................................23 
2.16 
Add Apollo I/O Board .......................................................................................................................................... 23 
2.17 
Add a Data Display Screen to the Level 1 Data Rotation..............................................................................23 
2.18 
Add a Setting to the Settings Rotation..............................................................................................................24 
2.19 
Change the Automatic Screens......................................................................................................................... 24 
2.20 
Log In to Level 3 from Level 2 ...........................................................................................................................24 
2.21 
Add a Limit to a Channel.................................................................................................................................... 24 
2.22 
Add a Digital Output to a Trigger.............................................................................................................................24 
2.23 
Communicate with the drive using SCADA .....................................................................................................24 
2.24 
Communicate with the drive using the Remote User Interface..................................................................... 24 
3 
System Overview.............................................................................................................................................................. 24 
3.1 
Introduction............................................................................................................................................................. 24 
3.2 
Hardware................................................................................................................................................................. 25 
3.2.1 
Apollo HMI (Human Machine Interface)..................................................................................................25 
3.2.2 
Apollo I/O Board Assembly....................................................................................................................... 29 
3.2.3 
Downhole Sensor Interface (DSI) Assembly.......................................................................................... 32 
3.2.4 
RSTi Expansion I/O Module......................................................................................................................34 
3.2.5 
Backspin Probes.........................................................................................................................................45 
3.2.6 
Block Diagram–Apollo System in a Vector VII or Vector Plus ESP Application.................................47 
3.2.7 
Block Diagram–Apollo System in a Switchboard Application ..............................................................48 
3.2.8 
Block Diagram–Apollo System in a Vector VII or Vector Plus SPS Application.................................49 
3.3 
Hardware Installation ............................................................................................................................................49 
3.3.1 
Mechanical Installation –Non-Vector Plus Applications....................................................................... 50 
3.4 
System Concepts and Definitions ....................................................................................................................... 56 
3.4.1 
Inputs............................................................................................................................................................56 
3.4.2 
Channels...................................................................................................................................................... 57 

 
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3.4.3 
Triggers.........................................................................................................................................................57 
3.4.4 
Outputs.........................................................................................................................................................57 
3.4.5 
Example –Input / Channel / Trigger / Output..........................................................................................57 
3.4.6 
Templates............................................................................................................................................................58 
3.4.7 
Configuration Wizards................................................................................................................................59 
3.5 
Drive Modes............................................................................................................................................................59 
3.5.1 
Manual Frequency Mode...........................................................................................................................59 
3.5.2 
Current Control Mode.................................................................................................................................60 
3.5.3 
PID Speed Control Mode...........................................................................................................................60 
3.5.4 
Analog Follower Mode................................................................................................................................60 
3.6 
User Interface Conventions..................................................................................................................................61 
3.6.1 
LEDs.............................................................................................................................................................61 
3.6.2 
Function Buttons.........................................................................................................................................62 
3.6.3 
Arrow Buttons..............................................................................................................................................62 
3.6.4 
Start/Stop Buttons.......................................................................................................................................62 
3.6.5 
System State ...............................................................................................................................................62 
3.6.6 
Trigger Ticker......................................................................................................................................................64 
3.7 
User Levels.............................................................................................................................................................64 
3.7.1 
Level 1 Users “Logged-out” .......................................................................................................................65 
3.7.2 
Level 2 Users “Logged-in” .........................................................................................................................65 
3.7.3 
Level 3 Users “Advanced” .........................................................................................................................65 
3.8 
Screen Types..................................................................................................................................................................66 
3.8.1 
Home Screen...............................................................................................................................................66 
3.8.2 
Data Display Screens.................................................................................................................................67 
3.8.3 
Downhole Screen........................................................................................................................................67 
3.8.4 
Digital I/O Screen........................................................................................................................................68 
3.8.5 
Analogs Screen...........................................................................................................................................70 
3.8.6 
Amp Chart Screen ......................................................................................................................................71 
3.8.7 
Other Screens .............................................................................................................................................72 
3.9 
Settings....................................................................................................................................................................72 
3.9.1 
Setpoint Screens.........................................................................................................................................72 
3.9.2 
Color Scheme..............................................................................................................................................75 
3.9.3 
Other Settings..............................................................................................................................................76 
3.9.4 
Graph Screens ............................................................................................................................................79 
3.9.5 
USB Menu Screen......................................................................................................................................81 
3.9.6 
Automatic Screens......................................................................................................................................82 
4 
Basic Setup Sequence .....................................................................................................................................................85 
4.1 
Log In.......................................................................................................................................................................85 
4.2 
Settings Screen (Logged In).................................................................................................................................88 
4.3 
Main Menu...............................................................................................................................................................88 
4.4 
Other Initial Setup Menu .......................................................................................................................................90 
4.4.1 
Set Date/Time..............................................................................................................................................92 
4.4.2 
Set Well and Site Names...........................................................................................................................93 
4.4.3 
Set Global Restart Time...................................................................................................................................96 
4.4.4 
Set DHXFormer Ratio ................................................................................................................................97 
4.4.5 
Setup Power Fail Restarts.........................................................................................................................99 
4.4.6 
Setup Password Protection.....................................................................................................................101 
4.4.7 
Setup Com2 SCADA................................................................................................................................103 

 
 
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4.5 
Configure Drive Settings.....................................................................................................................................104 
4.6 
Set Drive Mode .....................................................................................................................................................111 
4.7 
Configure Motor Overload...................................................................................................................................111 
4.8 
Configure Motor Underload................................................................................................................................ 114 
4.9 
Configure Downhole Limits ................................................................................................................................ 118 
4.10 
Enable Autostart ................................................................................................................................................125 
4.11 
Adjust Setpoint...................................................................................................................................................125 
5 
Additional Setups............................................................................................................................................................126 
5.1 
Add I/O Board.......................................................................................................................................................126 
5.2 
Setup a Downhole Tool..............................................................................................................................................................127 
5.3 
Install RSTi I/O Module.......................................................................................................................................129 
5.4 
Setup Analog Inputs............................................................................................................................................132 
5.5 
Setup Digital Inputs .............................................................................................................................................138 
5.6 
Setup Drive Mode................................................................................................................................................139 
5.6.1 
Manual Frequency Mode.........................................................................................................................142 
5.6.2 
Current Control Mode ..............................................................................................................................144 
5.6.3 
PID Speed Control Module .....................................................................................................................146 
5.6.4 
Analog Follower Mode.............................................................................................................................150 
5.7 
Setup Restarts......................................................................................................................................................152 
5.8 
Communication Parameters...............................................................................................................................155 
5.9 
Control Source .....................................................................................................................................................159 
5.10 
Pump Curve Setup............................................................................................................................................160 
5.11 
PLC Analog Control...........................................................................................................................................162 
5.12 
2-Wire Run/Stop ................................................................................................................................................162 
5.13 
Drain Mode.........................................................................................................................................................163 
5.14 
PID Speed Control Mode..................................................................................................................................163 
5.15 
Add a 2nd IO Board...........................................................................................................................................165 
5.16 
Edit a Screen......................................................................................................................................................165 
5.17 
Add a Data Display Screen to the Level 1 Data Screen Rotation ..............................................................169 
5.18 
Add or Delete a Setting in the Settings Rotation...........................................................................................169 
5.19 
Change the Drive State Automatic Screens..................................................................................................174 
5.20 
Add a Trigger to a Channel..............................................................................................................................178 
5.21 
Add a Digital Output to a Trigger...........................................................................................................................182 
5.22 
Load a Template........................................................................................................................................................185 
5.23 
Miscellaneous Settings.....................................................................................................................................185 
5.24 
SPS Setup..........................................................................................................................................................187 
6 
Apollo Simulator..............................................................................................................................................................190 
6.1 
Introduction...........................................................................................................................................................190 
6.2 
Installation/ Licensing..........................................................................................................................................190 
6.3 
Simulation Features ............................................................................................................................................195 
6.4 
File Operations.....................................................................................................................................................196 
6.5 
Online Training.....................................................................................................................................................196 
6.6 
Using the Simulator to Configure a Pumping System....................................................................................198 
7 
Apollo Archive Viewer.....................................................................................................................................................198 
7.1 
Introduction...........................................................................................................................................................198 
7.2 
Installation and Learning.....................................................................................................................................199 
7.3 
Importing Apollo Data..........................................................................................................................................202 
7.4 
Displaying the Archive Data...............................................................................................................................205 

 
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7.5 
Channel Menu ......................................................................................................................................................206 
7.6 
Changing Displayed Channels...........................................................................................................................207 
7.7 
Displaying Previously Imported Data ................................................................................................................208 
7.8 
E-mailing or transferring Apollo Archive Data..................................................................................................209 
8 
Apollo Applications..........................................................................................................................................................211 
8.1 
Switchboard Application......................................................................................................................................211 
8.1.1 
Equipment Needed...................................................................................................................................211 
8.1.2 
Electrical Wiring.........................................................................................................................................211 
8.1.3 
Configuration .............................................................................................................................................214 
8.2 
Vector VII / Vector Plus ESP Application..........................................................................................................215 
8.2.1 
Equipment Needed...................................................................................................................................215 
8.2.2 
Electrical Wiring.........................................................................................................................................215 
8.2.3 
Configuration .............................................................................................................................................217 
8.3 
Vector VII/Vector Plus SPS Application.............................................................................................................217 
8.3.1 
Equipment Needed...................................................................................................................................217 
8.3.2 
Electrical Wiring Table...................................................................................................................................................218 
8.3.3 
Configuration .............................................................................................................................................219 
9 
Apollo Motor Overload Protection.................................................................................................................................220 
9.1 
I2T Motor Overload Algorithm............................................................................................................................221 
9.2 
Advantages of the I2T Motor Overload Algorithm...........................................................................................222 
10 
Trigger Definition...........................................................................................................................................................225 
10.1 
Trigger Definition................................................................................................................................................225 
10.2 
Basic Trigger Settings .......................................................................................................................................226 
10.3 
Trigger Types (Basic).........................................................................................................................................228 
10.4 
Trigger States .....................................................................................................................................................228 
10.5 
Trigger Actions (Basic)......................................................................................................................................230 
10.6 
Enable States .....................................................................................................................................................230 
10.7 
Trigger Screens..................................................................................................................................................231 
10.8 
Trigger Types (full list) .......................................................................................................................................233 
10.9 
Trigger Actions (Full List)..................................................................................................................................235 
10.10 
Special Triggers...............................................................................................................................................238 
10.10.1 
Internal Triggers....................................................................................................................................238 
10.10.2 
Motor Control State Triggers...............................................................................................................240 
11 
Pump Curves .................................................................................................................................................................241 
11.1 
Pump Curve Terminology........................................................................................................................................242 
11.2 
Apollo Pump Curve............................................................................................................................................243 
11.3 
How Apollo Uses the Pump Curve to Protect the Pump..............................................................................245 
11.4 
Setting up the Pump Curve...............................................................................................................................246 
11.5 
Pump Curve Screen...........................................................................................................................................249 
11.6 
Pump Thrust Screen..........................................................................................................................................250 
11.7 
Updating Pump Database.................................................................................................................................251 
11.8 
Creating a Custom Pump..................................................................................................................................252 
11.9 
Installing/Selecting a Custom Pump on Apollo..............................................................................................255 
12 
Appendix A–Full Installation of Apollo Software.......................................................................................................258 
12.1 
Install Apollo .......................................................................................................................................................258 
12.2 
Load a Template (If Required)..........................................................................................................................259 
12.3 
Reset Drive To Defaults (If Required) .............................................................................................................261 
12.4 
System Setup and Operation...........................................................................................................................263 

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12.5

Updating a Configuration from Apollo 2.x ......................................................................................................263

Appendix B.....................................................................................................................................................................264

13.1

USB Menu ..........................................................................................................................................................264

13.1.1

Historical Data Text File Setup Screen................................................................................................272

13.1.2

Event Log Text File Setup Screen........................................................................................................273

 
Copyright 2020 Baker Hughes Company. All rights reserved. 
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List of Figures 
 Main Menu Display.......................................................................................................................................................................14 
Apollo HMI .....................................................................................................................................................................................25 
Apollo HMI Terminal Locations (Rear View)..............................................................................................................................26 
SPI Data Flash..............................................................................................................................................................................28 
Apollo I/O Board Assembly Terminal Locations........................................................................................................................30 
DC Input Relay Install...................................................................................................................................................................32 
ESP Downhole Sensor Interface (DSI) Assembly (Part Number 197146)............................................................................33 
8 Channel RTD Setup ..................................................................................................................................................................37 
ST-3704Interface Design............................................................................................................................................................39 
ST-3708Interface Design............................................................................................................................................................39 
ST-1218Interface Design............................................................................................................................................................40 
ST-7588Interface Design............................................................................................................................................................40 
ST-3218Interface Design............................................................................................................................................................41 
ST-4112 Interface Design ............................................................................................................................................................41 
ST-1214Interface Design............................................................................................................................................................42 
ST-2324Interface Design............................................................................................................................................................42 
ST-2744Interface Design............................................................................................................................................................43 
ST-3214Interface Design............................................................................................................................................................43 
Backspin Probes-Drawing 1........................................................................................................................................................45 
Backspin Probes-Drawing 2........................................................................................................................................................46 
Apollo System in a Vector VII or Vector Plus ESP Application...............................................................................................47 
Apollo System in a Switchboard Application.............................................................................................................................48 
Apollo System in a Vector VII or Vector Plus SPS Application...............................................................................................49 
Remove Amp Chart......................................................................................................................................................................51 
Insert Apollo HMI ..........................................................................................................................................................................51 
Tighten Center Studs....................................................................................................................................................................52 
Side brackets on Studs................................................................................................................................................................52 
Clear Safety Shield Attached ......................................................................................................................................................53 
Window Kit Installed .....................................................................................................................................................................53 
Apollo I/O Board/ESP DSI Panel Assembly (Part Number 197207)......................................................................................54 
ZenithConfiguration-Drawing1..................................................................................................................................................55 
ZenithConfiguration-Drawing2..................................................................................................................................................56 
Various Structures in a Well Control System.............................................................................................................................58 
Apollo User Interface....................................................................................................................................................................61 
Home Screen.................................................................................................................................................................................66 
DownholeScreen..........................................................................................................................................................................67 
Digital I/O Screen..........................................................................................................................................................................68 
Analog I/O Screen ........................................................................................................................................................................70 
Amp Chart Screen ........................................................................................................................................................................71 
Setpoint Screen (Manual Frequency Model).............................................................................................................................72 
Setpoint Screen (PID Speed Control Mode) .............................................................................................................................73 
Setpoint Screen (Current Control Mode)...................................................................................................................................73 
Setpoint Screen (Analog Follower Mode)..................................................................................................................................74 
Setpoint Screen (I-Limit Controlling Pump Speed)...................................................................................................................74 
Color Scheme Setting Screen.....................................................................................................................................................75 

 
 
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 Event Log Screen.........................................................................................................................................................................76 
Relevant Triggers Screen ...........................................................................................................................................................77 
Graphs Screen ............................................................................................................................................................................. 80 
USB Menu..................................................................................................................................................................................... 81 
Fault Status Screen .....................................................................................................................................................................83 
Fault Status Screen with Auto-Start Warning.................................................................................................................................84 
Fault Status Screen with Restart Countdown..........................................................................................................................84 
Home Screen................................................................................................................................................................................ 85 
Setting Function Button............................................................................................................................................................... 86 
Login Function Button..................................................................................................................................................................86 
Login Screen.................................................................................................................................................................................87 
Select Ok on Login Screen.........................................................................................................................................................87 
Menu Function Button ................................................................................................................................................................. 88 
Main Menu..................................................................................................................................................................................... 88 
Main Menu-Screen 2 ...................................................................................................................................................................89 
Main Menu-Screen 3 ...................................................................................................................................................................89 
Select Function Button ................................................................................................................................................................90 
Other Initial Setup Menu ............................................................................................................................................................. 91 
Other Initial Setup Menu-Screen 2............................................................................................................................................91 
Other Initial Setup Menu-Screen 3............................................................................................................................................92 
Apollo Clock Display....................................................................................................................................................................92 
Select Time Zone and Set the Time Screen.............................................................................................................................93 
Set Well Name-Screen 1............................................................................................................................................................. 94 
Set Well Name-Screen 2............................................................................................................................................................. 95 
Initial Setup Updated Well Name Screen.................................................................................................................................95 
Initial Setup Updated Site Name Screen..................................................................................................................................96 
Global Restart Edit Screen......................................................................................................................................................... 97 
DHXFormer Ration Edit Screen.................................................................................................................................................98 
Menu Initial Setup Screen...........................................................................................................................................................98 
Power Fail Rst Screen.................................................................................................................................................................99 
Restarts/Allowed Edit Screen...................................................................................................................................................100 
Power Fail Restart Menu...........................................................................................................................................................100 
Updated Power Fail Restart Screen........................................................................................................................................101 
Password Protection Menu.......................................................................................................................................................102 
Other Initial Setup Menu ...........................................................................................................................................................103 
Com 2SCADA Setup Menu ......................................................................................................................................................103 
Main Menu...................................................................................................................................................................................104 
Drive Settings Screen................................................................................................................................................................105 
Drive Settings-Screen #2..........................................................................................................................................................108 
Drive Settings Menu .................................................................................................................................................................. 110 
Motor Overload Menu.................................................................................................................................................................111 
Overload Menu-Screen 2.......................................................................................................................................................... 113 
Motor Underload Menu.............................................................................................................................................................. 115 
Underload Menu-Screen 2........................................................................................................................................................ 117 
Downhole Limits Menu.............................................................................................................................................................. 119 
Trigger Info Screen..................................................................................................................................................................... 119 
220°F Example...........................................................................................................................................................................120 
Save Change Screen ................................................................................................................................................................120 

 
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Downhole Limits Screen............................................................................................................................................................121 
Download Limits-Screen 2 ........................................................................................................................................................123 
Selecting Manual StartOnly.......................................................................................................................................................125 
Frequency Setpoint Screen.......................................................................................................................................................126 
DH Tool Menu..............................................................................................................................................................................127 
Motor Temp Screen....................................................................................................................................................................130 
Setting Up Limits for a Channel................................................................................................................................................130 
Selecting a Trigger..............................................................................................................................................................................131 
Trigger Info Screen Indicating the Trigger is “Not In Use”.....................................................................................................131 
Trigger Info Screen Indicating the Trigger with Limit Set to 250°F ......................................................................................132 
Channel Information Screen.....................................................................................................................................................132 
Edit Name Screen ......................................................................................................................................................................133 
Trigger Name Change Screen..................................................................................................................................................133 
Channel Info Screen For The Configured Analog Input........................................................................................................134 
Calibration Screen......................................................................................................................................................................134 
Calibration Screen- Screen 2....................................................................................................................................................135 
Channel Info Screen ..................................................................................................................................................................135 
Highlight the Trigger Name........................................................................................................................................................136 
Trigger Info Screen.....................................................................................................................................................................136 
Changing the Trigger Parameters............................................................................................................................................137 
Resulting Trigger Info Screen ...................................................................................................................................................137 
Channel Info Screen for 1st Digital I/O on the Apollo I/O Board..........................................................................................138 
Murphy Switch Trigger-Example 1...........................................................................................................................................138 
Murphy Switch Trigger-Example #2.........................................................................................................................................139 
Set Drive Mode Menu ................................................................................................................................................................139 
Drive Mode Menu-Screen 2......................................................................................................................................................140 
Frequency Mode Screen...........................................................................................................................................................143 
Current Control Mode Screen...................................................................................................................................................144 
PID Speed Control Mode-Screen 1 .........................................................................................................................................147 
PID Speed Control Mode-Screen 2 .........................................................................................................................................147 
PID Speed Control Mode-Screen 3 .........................................................................................................................................148 
Analog Follower Mode Screen .................................................................................................................................................151 
Follower Src Channel Info Screen ...........................................................................................................................................152 
Communication Parameters Menu-Screen 1.........................................................................................................................156 
Communication Parameters Menu-Screen 2.........................................................................................................................156 
Port Configured-Screen 1..........................................................................................................................................................158 
Port Configured-Screen 2..........................................................................................................................................................158 
Control Source Screen ..............................................................................................................................................................160 
How to Customize–Screens 1 ..................................................................................................................................................166 
How to Customize–Screens 2 ..................................................................................................................................................166 
How to Customize Screens–Screen 3.....................................................................................................................................167 
How to Customize–Screens 4 ..................................................................................................................................................167 
How to Customize–Screens 5 ..................................................................................................................................................168 
How to Customize–Screens 6 ..................................................................................................................................................168 
Adding Screens to Level 1 Data Screen.................................................................................................................................169 
Edit Mode Screen.......................................................................................................................................................................170 
Add the Motor Underload Limit To The Level 1 Settings Rotation.......................................................................................171 
Object Selection Screen............................................................................................................................................................171 

 
 
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Add the Motor Underload Limit To The Level 1 Settings Rotation-Screen 2.....................................................................172 
Add the Motor Underload Limit To The Level 1 Settings Rotation-Screen 3.....................................................................172 
Add the Motor Underload Limit To The Level 1 Settings Rotation-Screen 4.....................................................................173 
Add the Motor Underload Limit To The Level 1 Settings Rotation-Screen 5.....................................................................174 
Edit Mode Change–Screen 1...................................................................................................................................................175 
Pump Curve Screen Change–Screen 1 .................................................................................................................................176 
Select Object–Screen 1.............................................................................................................................................................176 
Select Object–Screen 2.............................................................................................................................................................177 
Pump Curve Screen Change–Screen 2 .................................................................................................................................177 
Osiris Motor Temperature .................................................................................................................................................................178 
Add a High Temperature Warning Trigger.....................................................................................................................................179 
Low or High Limit Screen..........................................................................................................................................................179 
Temperature High Warning...............................................................................................................................................................180 
Final Trigger Info Screen...........................................................................................................................................................180 
Final Channel Info Screen ........................................................................................................................................................181 
Motor Temperature High Warning Trigger.....................................................................................................................................181 
Motor Temperature High Warning Trigger–Screen 2 ............................................................................................................182 
Highlight the Drive a Digital Output .........................................................................................................................................183 
Select the M3–M4 Ouput ..........................................................................................................................................................183 
Digital Output Screen ................................................................................................................................................................184 
Final Trigger Info Screen...........................................................................................................................................................184 
SPS Configuration Utility...........................................................................................................................................................189 
Apollo Simulator .........................................................................................................................................................................190 
Apollo 3 Simulator Setup Wizard.............................................................................................................................................191 
Confirm Installation Screen.......................................................................................................................................................191 
Select Installation Folder Screen.............................................................................................................................................192 
Installation Complete Screen ...................................................................................................................................................192 
Computer Desktop Shortcut.....................................................................................................................................................193 
License Request Code Screen ................................................................................................................................................193 
Pasted License Response Code Screen................................................................................................................................194 
License Validated Screen..........................................................................................................................................................195 
Simulation Screens....................................................................................................................................................................196 
Simulator and Online Training Window...................................................................................................................................197 
Navigation Panel........................................................................................................................................................................197 
Apollo Archive Viewer................................................................................................................................................................199 
Desktop shortcut for Archive Viewer.......................................................................................................................................200 
License Request Code-Screen 1.............................................................................................................................................200 
License Response Code-Screen 2..........................................................................................................................................201 
License Validated Screen..........................................................................................................................................................202 
Importing Apollo Data-Screen 1...............................................................................................................................................203 
Import Apollo Data-Screen 2....................................................................................................................................................204 
Import Data-Screen 3................................................................................................................................................................205 
Graph Screen .............................................................................................................................................................................206 
Channel Menu ............................................................................................................................................................................207 
Viewing Previously Imported Data...........................................................................................................................................208 
Selecting Previously Imported Well Data................................................................................................................................208 
Choose the Well Data (on USB Drive)....................................................................................................................................209 
Creating a Zip File......................................................................................................................................................................210 

 
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The Field Data Transfer Folder.................................................................................................................................................211 
Motor Overload Setup Menu-Screen 1....................................................................................................................................220 
Motor Overload Setup Menu–Screen 2...................................................................................................................................221 
I2T Motor Overload Algorithm...................................................................................................................................................221 
Apollo Overload Simulator.........................................................................................................................................................223 
125% of Overload Threshold (Left), 250% of Overload Threshold (Right) ........................................................................224 
How Overload Affects Time To Overload................................................................................................................................225 
Rigger Logic Flowchart..............................................................................................................................................................226 
Trigger Info-Screen 2 .................................................................................................................................................................232 
Edit Trigger-Screen 3.................................................................................................................................................................233 
Pump Curve.................................................................................................................................................................................242 
Apollo Pump Curve Labeled.....................................................................................................................................................244 
Home Screen ..............................................................................................................................................................................245 
Setup Pump Curve Wizard........................................................................................................................................................247 
Pump Curve Setup Menu..........................................................................................................................................................248 
Pump Curve Screen...................................................................................................................................................................249 
Pump Curve Screen...................................................................................................................................................................250 
Pump Thrust Screen..................................................................................................................................................................251 
USB Menu ...................................................................................................................................................................................252 
Update Pump Database Screen...............................................................................................................................................252 
Pump Test Results for TE-5500 S/N 203F2210P ..................................................................................................................253 
Custom Pump Data Entry..........................................................................................................................................................254 
Custom Pump Screen................................................................................................................................................................254 
Install a Pump Curve File from USB Disk Screen..................................................................................................................255 
Make New Pump Available Screen..........................................................................................................................................256 
Selecting New Pump Screen....................................................................................................................................................256 
Highlight Desired Pump Screen ...............................................................................................................................................257 
Final Custom Pump Screen......................................................................................................................................................257 
Updated Initial Setup Pump Curve Screen.............................................................................................................................258 
Fault Screen................................................................................................................................................................................259 
Home Screen ..............................................................................................................................................................................260 
Select Template Screen.............................................................................................................................................................260 
New Configuration Loaded Screen..........................................................................................................................................261 
Home Screen ..............................................................................................................................................................................262 
Main Menu Drive Settings.........................................................................................................................................................262 
30 Second Cycle Power ............................................................................................................................................................263 
On-Screen Instructions..............................................................................................................................................................264 
USB Menu ...................................................................................................................................................................................265 
USB Menu-Screen 2 ..................................................................................................................................................................269 
Historical Data Text File Setup..................................................................................................................................................272 
Event Log Text File Setup..........................................................................................................................................................273 

 
 
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List of Tables 
 Quick Start Parameters for Vector Plus and Vector VII Applications.....................................................................................15 
Quick Start Parameters for Switchboard Applications............................................................................................................. 19 
DIP Switches.................................................................................................................................................................................27 
Module Part Numbers..................................................................................................................................................................28 
USB Devices Part Number..........................................................................................................................................................28 
Other USB Devices...................................................................................................................................................................... 29 
DIP Switches.................................................................................................................................................................................31 
Digital Input and Output Modules...............................................................................................................................................31 
DSI Switches.................................................................................................................................................................................34 
RSTi Expansion I/O Module........................................................................................................................................................ 34 
DIP Switch Settings......................................................................................................................................................................37 
PowerConnections...................................................................................................................................................................... 38 
CommunicationConnections...................................................................................................................................................... 38 
ST-3704RTDConnections ......................................................................................................................................................... 43 
ST-3708RTDConnections ......................................................................................................................................................... 44 
Templates
...................................................................................................................................................................................................................... 
58 
ConfigurationWizards.................................................................................................................................................................. 59 
LED Status .................................................................................................................................................................................... 61 
System State Values.............................................................................................................................................................................63 
Color Scheme ...............................................................................................................................................................................75 
Event Type..............................................................................................................................................................................................77 
Parameters
..................................................................................................................................................................................................... 
105 
Need Title Name..........................................................................................................................................................................111 
Motor Overload Menu Common Installations ......................................................................................................................... 112 
Motor Overload Menu Common Installations Screen 2......................................................................................................... 113 
Motor Underload Menu Common Installations....................................................................................................................... 115 
Underload Menu #2 Common Installations............................................................................................................................. 118 
Download Limits Common Installations ..................................................................................................................................121 
Download Limits #2 Common Installations.............................................................................................................................124 
Apollo Serial Communication Ports .........................................................................................................................................128 
Sensors
 ........................................................................................................................................................................................................... 
128 
Drive Mode Menu.......................................................................................................................................................................140 
Drive Mode Menu #2..................................................................................................................................................................141 
Frequency Mode Parameters ...................................................................................................................................................143 
Current Control Mode Parameters...........................................................................................................................................145 
PID Speed Control Mode Parameters.....................................................................................................................................148 
Analog Follow Mode Parameters.............................................................................................................................................151 
Setup Restart..............................................................................................................................................................................153 
Serial Communication Ports .....................................................................................................................................................157 
AutomaticScreens.....................................................................................................................................................................174 
Templates
.................................................................................................................................................................................................................... 
185 
MiscellaneousSettings..............................................................................................................................................................186 
Equipment
........................................................................................................................................................................................................ 
211 
Apollo HMI...................................................................................................................................................................................212 
Apollo I/O Board .........................................................................................................................................................................212 

 
Copyright 2020 Baker Hughes Company. All rights reserved. 
Page 13 of 277 
 
 ESP DSI Board...........................................................................................................................................................................214 
Vector VII/Vector Plus ESP Application...................................................................................................................................215 
Equipment....................................................................................................................................................................................215 
Apollo I/O Board (If Needed).....................................................................................................................................................216 
ESP DSI.......................................................................................................................................................................................217 
Equipment....................................................................................................................................................................................217 
Apollo HMI...................................................................................................................................................................................218 
Apollo I/O Board (if needed) .....................................................................................................................................................218 
RSTi I/O Module (if needed) .....................................................................................................................................................219 
Basic Trigger Settings................................................................................................................................................................226 
Trigger Types (basic)..................................................................................................................................................................228 
Trigger States..............................................................................................................................................................................228 
Trigger Actions (basic)...............................................................................................................................................................230 
Enable States..............................................................................................................................................................................231 
Trigger Types (full list)................................................................................................................................................................234 
Trigger Actions (full list) .............................................................................................................................................................235 
Internal Triggers..........................................................................................................................................................................238 
Motor Control State Triggers.....................................................................................................................................................240 
Pump Curve Terminology..................................................................................................................................................................242 
USB Menu Options.....................................................................................................................................................................266 
USB Menu #2 Options...............................................................................................................................................................269 

Page 14 of 277

APOLLO 3 INTELLIGENT CONTROL SYSTEM USER MANUAL

Quick Start Guide

This section will guide your drive configuration for a basic Baker Hughes ESP installation. Please see Section 4:

Basic Setup Sequence, page 85.

1.1

Log on to Access Drive Configuration

If another screen is displayed, press “Home” to display the Home Screen.

Starting at the home screen press “Settings”.

From the Settings screen press “Login”.

password is 8.

Press “OK” and the Main Menu is displayed (see Figure 1: Main Menu Display , page 14.)

Figure 1: Main Menu Display

1.2

Quick Start

Highlight Quick Start on the Main Menu and press the “Select” function button, the first Quick Start setting is

displayed.

Use the Settings button (F3) to navigate through the list of Quick Start settings.

Change the settings as appropriate for the pumping application.

Use Table 1: Quick Start Parameters for Vector Plus and Vector VII Applications, page 15 to navigate the

quick start parameters.

Page 15 of 277

Table 1: Quick Start Parameters for Vector Plus and Vector VII Applications

Parameter Name

Default

Information

Date and Time

None

Set the time zone, date, and time.

Use the Left and Right Arrow

buttons to select a digit to change.

Use the Up and Down Arrow

buttons to change a value. Use

the F1 and F5 function buttons to

navigate between screen fields.

Well Name

Blank

Well Name. Up to 15 characters.

Use the Left and Right Arrow

buttons to move the insert

location. Use the Up and Down

Arrow buttons to change the letter

to the right of the insert position.

Note that Apollo supports USB

Keyboards which simplifies text

entry.

Site Name

Blank

Up to 15 characters. Use the

Left and Right Arrow buttons to

move the insert location. Use the

Up and Down Arrow buttons to

change the letter to the right of the

insert position. Note that Apollo

supports USB Keyboards which

simplifies text entry.

DriveMaxVolts

480 Volts

Vector Plus Drive output voltage

when running at Maximum

Frequency. Usually set to the

drive power source voltage.

Page 16 of 277

Table 1: Quick Start Parameters for Vector Plus and Vector VII Applications (cont'd.)

Parameter Name

Default

Information

DHXFormer Ratio

0.00

Transformer Ratio of the step

up transformer used to drive the

medium voltage motor from the

low voltage drive. Calculated

by dividing the transformer

tap voltage by the transformer

rated input voltage (usually

480 Vac). For example, if a

480 Vac transformer is tapped for

2400 Vac, set the DHXFormer

Ratio to 2400 Vac/480 Vac = 5.0.

Note that the default setting of

0.00 requires this parameter be

set prior to running the drive.

Min Frequency

30.0 Hz

Minimum speed, in Hertz, of

the Vector Plus drive in the

current pumping application.

Min Frequency should be set to

ensure adequate fluid is pumped

past the pump for cooling. For

ESP applications, Min Frequency

settings lower than 30 Hz are not

recommended.

Max Frequency

60.0 Hz

Maximum speed, in Hertz, of

the Vector Plus drive in the

current pumping application.

Max Frequency should be set

to prevent overstressing the

pumping system components.

Accel Seconds

5.0 Seconds

Acceleration ramp time, in

seconds, for the Vector Plus drive

from 0 Hz (stopped) to Maximum

Frequency. For ESP applications,

maximum recommended Accel

Seconds is 10.0.

Page 17 of 277

Table 1: Quick Start Parameters for Vector Plus and Vector VII Applications (cont'd.)

Parameter Name

Default

Information

Decel Seconds

5.0 Seconds

Deceleration ramp time, in

seconds, for the Vector Plus drive

from Max Frequency to stopped.

For ESP applications, maximum

recommended Decel Seconds is

10.0.

Motor Overload

0.0 Amps

Set to motor nameplate amps.

This setting is used to protect

the motor from heat damage

associated with excess loading.

Note that the default setting of 0.0

Amps requires this parameter be

set prior to running the drive.

Motor Underload

-9,999 Amps

This setting is used to protect

the motor from heat damage

associated with the loss of cooling

fluid moving by the motor caused

by well pump-off. Note that the

default setting of -9999 Amps

requires this parameter be set

prior to running the drive.

Motor Temp High Limit

0.0 °F

DownholeToolMotorTemperature

High Limit. Drive will Fault if the

Motor Temperature exceeds the

specified limit. Note that the

trigger is Not In Use by default.

The trigger will be set to “In Use”

automatically when the Limit is

changed.

Intake Temp High Limit

0.0 °F

Downhole Tool Intake

Temperature High Limit. Drive will

Fault if the temperature exceeds

the specified limit.

IntakePressLow Limit

0.0 Psi

Downhole Tool Intake Pressure

Low Limit. Drive will Fault if the

Intake Pressure drops below the

specified limit.

Page 18 of 277

Table 1: Quick Start Parameters for Vector Plus and Vector VII Applications (cont'd.)

Parameter Name

Default

Information

Global Restart

60 Minutes

The default auto-restart time, in

minutes,forallsystemfaults. Note

that the restart time for any trigger

(fault detection mechanism) can

be customized from the Trigger

Info screen.

PwrFail SysStop

Restart delay after a power loss

Restarts/Allowed

when running. The default value

is the global restart time. When

the value is changed, the user

can specify whether the new

value applies only to the PwrFail

SysStop trigger or if the global

restart time should be changed.

PwrFail SysStop Restart Delay

G60 Minutes

Restart delay after a power loss

when running. The default value

is the global restart time. When

the value is changed, the user

can specify whether the new

value applies only to the PwrFail

SysStop trigger or if the global

restart time should be changed.

No-Load Test Mode

G60 Min

Set to No-Load Test if you plan to

run no-load tests.

Drive Setpoint

Drive Mode Dependent

Adjust the setpoint as desired.

Note that changes to the setpoint

are applied immediately.

ManualStartOnly

True

When set to true, the drive will

only start when the Start button

on the keypad is pressed. When

set to false, the drive will also start

on automatic restarts and SCADA

start commands. By default,

ManualStartOnly is set to true any

time a configuration or a template

is loaded to prevent unexpected

startup.

Page 19 of 277

Setting ManualStartOnly to false enables automatic starts without warning and may cause

equipment damage, injury to personnel or death.

Table 2: Quick Start Parameters for Switchboard Applications

Parameter Name

Default

Information

Date and Time

None

Set the time zone, date, and time.

Use the Left and Right Arrow

buttons toselect a digit tochange.

Use the Up and Down Arrow

buttons to change a value. Use

the F1 and F5 function buttons to

navigate between screen fields.

Well Name

Blank

Well Name. Up to 15 characters.

Use the Left and Right Arrow

buttons to move the insert

location. Use the Up and Down

Arrow buttons to change the letter

to the right of the insert position.

Note that Apollo supports USB

Keyboards which simplifies text

entry.

Site Name

Blank

Up to 15 characters. Use the

Left and Right Arrow buttons to

move the insert location. Use

the Up and Down Arrow buttons

to change the letter to the right

of the insert position. Note that

Apollo supports USB Keyboards

which simplifies text entry.

CT Ratio

0.0 A

Input Amps required to yield 5

Amps on the output of the CT.

PT Ratio

0.0 VoltsAC

Input AC Voltage required to yield

120 volts on the output of the PT.

Motor Overload

0.0 Amps

Set to motor nameplate amps.

This setting is used to protect

the motor from heat damage

associated with excess loading.

Note that the default setting of 0.0

Amps requires this parameter be

set prior to running the drive.

Page 20 of 277

Table 2: Quick Start Parameters for Switchboard Applications (cont'd.)

Parameter Name

Default

Information

Motor Underload

-9,999 Amps

This setting is used to protect

the motor from heat damage

associated with the loss of cooling

fluid moving by the motor caused

by well pump-off. Note that the

default setting of -9999 Amps

requires this parameter be set

prior to running the drive.

Motor Temp High Limit

0.0 °F

Downhole Tool Motor

Temperature High Limit. Drive will

Fault if the Motor Temperature

exceeds the specified limit. Note

that the trigger is Not In Use by

default. The trigger will be set to

“In Use” automatically when the

Limit is changed.

IntakePressLow Limit

0.0 Psi

Downhole Tool Intake Pressure

Low Limit. Drive will Fault if the

Intake Pressure drops below the

specified limit.

D/H VibrationHi Limit

10.00 G’s

Downhole Tool Vibration High

Limit. Drive will Fault if the

Vibration exceeds the specified

limit.

Global Restart

60 Minutes

The default auto-restart time, in

minutes, for all system faults.

Note that the restart time for

any trigger (fault detection

mechanism) can be customized

from the Trigger Info screen.

PwrFail SysStop

Restart delay after a power loss

Restarts/Allowed

when running. The default value

is the global restart time. When

the value is changed, the user

can specify whether the new

value applies only to the PwrFail

SysStop trigger or if the global

restart time should be changed.

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