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 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
13 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

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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-3704 Interface Design ............................................................................................................................................................ 39
ST-3708 Interface Design ............................................................................................................................................................ 39
ST-1218 Interface Design ............................................................................................................................................................ 40
ST-7588 Interface Design ............................................................................................................................................................ 40
ST-3218 Interface Design ............................................................................................................................................................ 41
ST-4112 Interface Design ............................................................................................................................................................ 41
ST-1214 Interface Design ............................................................................................................................................................ 42
ST-2324 Interface Design ............................................................................................................................................................ 42
ST-2744 Interface Design ............................................................................................................................................................ 43
ST-3214 Interface 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
Zenith Configuration-Drawing 1 .................................................................................................................................................. 55
Zenith Configuration-Drawing 2 .................................................................................................................................................. 56
Various Structures in a Well Control System ............................................................................................................................. 58
Apollo User Interface .................................................................................................................................................................... 61
Home Screen................................................................................................................................................................................. 66
Downhole Screen.......................................................................................................................................................................... 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
Power Connections ...................................................................................................................................................................... 38
Communication Connections ...................................................................................................................................................... 38
ST-3704 RTD Connections ......................................................................................................................................................... 43
ST-3708 RTD Connections ......................................................................................................................................................... 44
Templates ...................................................................................................................................................................................................................... 58
Configuration Wizards.................................................................................................................................................................. 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
Automatic Screens ..................................................................................................................................................................... 174
Templates ....................................................................................................................................................................................................................185
Miscellaneous Settings .............................................................................................................................................................. 186
Equipment ........................................................................................................................................................................................................ 211
Apollo HMI ................................................................................................................................................................................... 212
Apollo I/O Board ......................................................................................................................................................................... 212

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 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

Copyright 2020 Baker Hughes Company. All rights reserved. Page 13 of 277
 APOLLO 3 INTELLIGENT CONTROL SYSTEM USER MANUAL
1 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.

1. Starting at the home screen press “Settings”.
2. From the Settings screen press “Login”.
3. Login as Level 2, the default password is 9. Advanced users may want to log in at Level 3, the default
password is 8.
4. 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.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 14 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.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 15 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.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 16 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 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.
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.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 17 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, 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 0 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.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 18 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 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.
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.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 19 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 0 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.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 20 of 277
 Table 2: Quick Start Parameters for Switchboard Applications (cont'd.)

Parameter Name Default Information

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.
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.

Setting ManualStartOnly to false enables automatic starts without warning and may cause
equipment damage, injury to personnel or death.

2 I Want To...
2.1 Set Pump Speed

See Section 4.11 Adjust Setpoint, page 125.

2.2 Change Color Scheme

From the Home Screen, repeatedly press the Settings function button until the Color Scheme setting
window appears. Use the Right and Left Arrow buttons to select the desired color scheme. Press the
Save function button and then confirm the change.

2.3 Log In/Access the Main Menu

You must be logged in to access the Menu. From the Home Screen, press the Settings function button
and then the Log In function button. By default, the level 2 password is 9 (just press the Down Arrow
button one time). After logging in, the Log In function button is replaced by Menu. Press the Menu function
button to access the main menu.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 21 of 277
 2.4 Set the Date and Time

See Section 4.4.1 Set Date/Time, page 92.

2.5 Change the Passwords

Best practice is to change the passwords from the defaults to protect the system configuration from
unauthorized changes. From the Main Menu, select Other Initial Setup and then Setup Password
Protections. Set values for the Level 2 and Advanced passwords as desired.

2.6 Set the Pump Direction

The Pump Direction setting is available in the “Logged In” settings rotation and in the Config Drive Settings
menu. To access in the settings rotation, from the Home Screen repeatedly press the Settings function
button. If a window appears asking you to log in, log in and then continue to press the Settings function
button until the Forward/Reverse parameter is shown. Set the direction as desired and press the Save
function button. Confirm the change.
To access from the Config Drive Settings menu, from the Main Menu select the Config Drive Settings option.
Select Forward/Reverse and change the setting as described above.
See Section 4.5 Configure Drive Settings, page 104 for more information.

2.7 Set the Well Name/Site Name

See Section 4.4.2 Set Well and Site Names, page 93.

2.8 Set the Motor Overload

See Section 4.7 Configure Motor Overload, page 111 for additional details.
The Motor Overload limit is also available in settings rotation if you are logged in. To access in the settings
rotation, from the Home Screen repeatedly press the Settings function button. If a window appears asking
you to log in, log in and then continue to press the Settings function button until the Motor Overload
parameter is shown. Set the limit as desired and press the Save function button. Confirm the change.

2.9 Set the Motor Underload

See Section 4.8 Configure Motor Underload, page 114 for additional details.
The Motor Underload limit is also available in the “Logged In” settings rotation. To access in the settings
rotation, from the Home Screen repeatedly press the Settings function button. If a window appears asking
you to log in, log in and then continue to press the Settings function button until the Motor Underload
parameter is shown. Set the limit as desired and press the Save function button. Confirm the change.

2.10 Set the Drive Mode

See Section 5.6 Setup Drive Mode, page 139 for additional details.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 22 of 277
 The Drive Mode setting is also available in the “Logged In” settings rotation. To access in the settings
rotation, from the Home Screen repeatedly press the Settings function button. If a window appears asking
you to log in, log in and then continue to press the Settings function button until the Drive Mode parameter is
shown. Set the mode as desired and press the Save function button. Confirm the change.

2.11 Set the Transformer Ratios

See Section 4.4.4 Set DHXFormer Ratio, page 97.

In a Switchboard application, transformer ratios for the CT and PT transformers will need to be set. In the
Switchboard template, use the Quick Start procedure to set the CT and PT transformer ratios.

2.12 Setup a Downhole Tool

See Section 5.2 Setup a Downhole Tool, page 127.

The Wizard will allow the user to select the type of downhole tool, select the units for pressure and
temperature, and set the most commonly used limits.

2.13 Setup Restarts

General Restart Information—See Section 5.7 Setup Restarts, page 152.

The Wizard will allow the user to select the type of downhole tool, select the units for pressure and
temperature, and set the most commonly used limits.

2.14 Setup Pump Curve

See Section 5.10 Pump Curve Setup, page 160.

2.15 Set the Control Source

The Control Source determines the source of Start commands and set speed commands. Selections are
SCADA + Keypad, SCADA only, and Keypad only.
See Section 5.9 Control Source, page 159.
The Control Source setting is also available in the “Logged In” settings rotation. To access in the settings
rotation, from the Home Screen repeatedly press the Settings function button. If a window appears asking
you to log in, log in and then continue to press the Settings function button until the Control Source
parameter is shown. Set the limit as desired and press the Save function button. Confirm the change.

2.16 Add Apollo I/O Board

See Section 5.1 Add I/O Board, page 126.

2.17 Add a Data Display Screen to the Level 1 Data Rotation

See Section 5.17 Add a Data Display Screen to the Level 1 Data Screen Rotation, page 169.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 23 of 277
 2.18 Add a Setting to the Settings Rotation

See Section 5.18 Add or Delete a Setting in the Settings Rotation, page 169.

2.19 Change the Automatic Screens

See Section 5.19 Change the Drive State Automatic Screens, page 174.

2.20 Log In to Level 3 from Level 2

Select the Log In or Log Out screen from the Main Menu. Enter the Level 3 password. By default, the
Level 3 password is 8.

2.21 Add a Limit to a Channel

Limits are added to a channel by connecting a trigger to the channel. See Section 5.20 Add a Trigger to
a Channel, page 178.

Analog and digital input option channels come pre-configured with triggers (limits). You need only
navigate to the Channel Info screen, select the trigger, and then set the trigger limit.

2.22 Add a Digital Output to a Trigger

See Section 5.21 Add a Digital Output to a Trigger, page 182.

2.23 Communicate with the drive using SCADA

See the Apollo 3/Vector Plus Communications Manual, UM-00014.

2.24 Communicate with the drive using the Remote User Interface

See the Apollo 3/Vector Plus Communications Manual, UM-00014.

3 System Overview
3.1 Introduction

The Apollo™ Intelligent Control System consists of up to 4 different electronic assemblies that can be used
to control a Variable Speed Drive (VSD), a Switchboard/Full Voltage Motor Starter (SWB), or a Solid State
Reduced Voltage Motor Starter (Soft Start). Apollo was designed for use in a variety of different applications
including Electrical Submersible Pumps (ESP) and Surface Pumping Systems (SPS). Apollo can monitor
process sensors and switches including Downhole sensors. Apollo uses the information it gathers from
the pumping system to provide increased protection for pumps and other equipment. It can also be
programmed to control specific process variables such as pressure, tank level, or motor current, etc. The

Copyright 2020 Baker Hughes Company. All rights reserved. Page 24 of 277
 information that Apollo gathers is logged and stored in the HMI or the information can be communicated
to a remote monitoring site.
The 4 electronic assemblies that make up the Apollo Intelligent Controls System are the Apollo HMI (Human
Machine Interface), the Apollo I/O Board Assembly, the RSTi Expansion I/O Module and the Downhole
Sensor Interface (DSI) Assembly.

3.2 Hardware

3.2.1 Apollo HMI (Human Machine Interface)

The Apollo HMI functions as both a graphical user interface and as the system master controller.
It also functions as a motor drive interface, a flash file-based database, and as an interface to the
other control boards that comprise the Apollo system. Features include:
• Full Color Graphical Display with Operator Keypad
• Run/Stop/Fault Lights (LEDs)
• USB Port
• ModBus Communications Port (SCADA Interface)
• Ethernet Port (Supports Wireless Router or Cell Modem for SCADA or Remote User Interface)
• Drive Communications Port
• Apollo Sub-System RS-485 Interface (Apollo I/O Board, Osiris Downhole Sensor Interface,
RSTi Module)

Figure 2: Apollo HMI

Copyright 2020 Baker Hughes Company. All rights reserved. Page 25 of 277
 Figure 3: Apollo HMI Terminal Locations (Rear View)

The DIP switches on the controller are as follows:

Copyright 2020 Baker Hughes Company. All rights reserved. Page 26 of 277
 Table 3: DIP Switches

Designator Description Default

SW1 Boot Select 1 Off
Boot from SPI Data Flash 2 On
Leave at default 3 On
No SD Card is used in this 4 Off
configuration.
*SPI Data Flash is required!
SW1 Boot Select 1 Off
Boot from SD Card 2 Off
Leave at default 3 On
A SD Card with the 4 Off
appropriate boot file is
required in this configuration.
SW2 Isolated RS-485 Termination 1 On
1. Shield Termination (Gnd) 2 Off
2. 120 Ohm A to B Bus 3 On
Termination
4 On
3. 4.7K Ohm Bus Pull-up
4. 4.7K Ohm Bus Pull-down

*The SPI Data flash is found on the back of the HMI board at position U7 (see Figure
4: SPI Data Flash , page 28).

Copyright 2020 Baker Hughes Company. All rights reserved. Page 27 of 277
 Figure 4: SPI Data Flash

The Expansion Port (COM2) can be configured as RS-232 or RS-485 by installing the
appropriate Expansion Port Module. Module part numbers are:

Table 4: Module Part Numbers

Module Part Number

Expansion Port Module RS-232 129112
Expansion Port Module RS-485 800638

The Apollo system comes with the RS-232 port module pre-installed unless
special-ordered.
The following USB devices have been tested with the Apollo HMI and have been given a part
number.

Table 5: USB Devices Part Number

Device Part Number

Wireless mini-keyboard 197705
4GByte USB Flash Drive 810280
USB to WIFI Adapter 197350
USB to RS-232 Serial Adapter 197349

Copyright 2020 Baker Hughes Company. All rights reserved. Page 28 of 277
 Table 5: USB Devices Part Number (cont'd.)

Device Part Number

USB to USB Adapter 197351
(Allows use of the USB to WIFI Adapter inside plastic door)

Other USB devices that can be used with the Apollo HMI include:

Table 6: Other USB Devices

Device Description
Other flash drives Most USB flash drives will work with the Apollo
HMI. If you are unable to use the 810280
device, the SanDisk Cruzer is recommended.
USB Keyboard/Mouse Standard USB keyboards and mice work with
the Apollo HMI.

Users are strongly discouraged from using any USB device not listed above. Such
devices will likely not work and could impair system functionality.

3.2.2 Apollo I/O Board Assembly

The Apollo I/O Board Assembly provides an I/O interface for the Apollo system. It communicates
the information it gathers to the CPU Board via the Apollo Sub-System RS-485 Communication
port. Features include:
• Quantity 8-12 bit Analog Inputs (0-5V, 0-10V, 4-20mA)
• Quantity 12- Digital I/O (can be programmed as either inputs or outputs) (AC or DC modules)
• Quantity 2- 12 bit Analog Outputs (0-10V)
• Backspin inputs
• PT Voltage Inputs (3 Phase AC)
• CT Current Inputs (3 Phase AC)

The Apollo I/O Board Assembly is not always required since the Vector VII and Vector
Plus power modules have enough I/O for many ESP applications.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 29 of 277
 Figure 5: Apollo I/O Board Assembly Terminal Locations

The DIP switches on the Apollo I/O Board are as follows:

Copyright 2020 Baker Hughes Company. All rights reserved. Page 30 of 277
 Table 7: DIP Switches

Designator Description Default

SW2 Board Address 1 Off
Leave at default unless 2 Off
multiple I/O boards are being
used. See Section 5.15 Add
a 2nd IO Board, page 165
for more information.
SW13 Diagnostics/Programming 1 Off
Leave at default 2 Off
3 Off
4 Off
AN1-AN8 Analog Function Select Use the table below to set the
appropriate input ranges.
Used to program the analog
range for analog inputs 1 – 8. Switch Switch Range
1 2
Off Off 0-5V
On Off 0-10V
Off On 4-20mA

Digital Input and Output Modules for the I/O board are available as follows:

Table 8: Digital Input and Output Modules

Description Part Number Voltage Range Max Output Color

Current Input
Impedance
DC Input Module 129130 3.3 to 32 Vdc 1000 Ohms White
DC Output 129131 3 to 60 Vdc 1.5 Amperes Red
Module
AC/DC Input 129132 90 to 28 K Ohms Yellow
Module 140 Vac/Vdc
AC/DC Input 801632 180 to 75 K Ohms Yellow
Module 280 Vac/Vdc

Copyright 2020 Baker Hughes Company. All rights reserved. Page 31 of 277
 Table 8: Digital Input and Output Modules (cont'd.)

Description Part Number Voltage Range Max Output Color

Current Input
Impedance
AC Output 800864 24 to 280 Vac 1.5 Amperes Black
Module
Relay (Dry 801633 120 Vac/100 Vdc 1.5 Amperes Red
Contract) Output
Module

These modules are installed in the IO 1–IO 12 sockets on the I/O board. The picture below
shows how a DC Input Relay module would be installed.

Figure 6: DC Input Relay Install

The Digital I/O is configured as inputs or outputs in the Apollo System. By default, Digital I/O
are configured in the Apollo system as inputs¹. Set an I/O as an output by connecting it to the
desired Trigger using the “Connect this Trigger to a Digital Output” selection on the Trigger Info
screen. See Section 5.15 Add a 2nd IO Board, page 165 for more details.
¹There is an exception to the “input by default” rule. In the switchboard template, Digital I/O 7
is set by default as an output and connected to the Contactor On trigger used to start and
stop the motor.

3.2.3 Downhole Sensor Interface (DSI) Assembly

The Osiris Downhole Sensor Interface (DSI) Assembly works in conjunction with a Baker
Hughes supplied Osiris Downhole Tool to acquire well information and communicate that
information to

Copyright 2020 Baker Hughes Company. All rights reserved. Page 32 of 277
 the Apollo HMI via the Apollo Sub-System RS-485 Communication port. Apollo also supports
an interface for the following downhole tools:
• Zenith E-Series Sensors using ZIU or the Zenith Surface Panel
• GRC Tools using SPS1500 or Scout 3000 panels
• Centinel
By default, the “Standard” template is pre-configured for the Osiris Downhole Sensor displaying
pressures as PSI and temperatures as Degrees F. To remove Osiris, interface with a different
sensor, or to change engineering units for downhole channels, See Section 5.2 Setup a
Downhole Tool, page 127.

The Osiris Downhole Sensor Interface (DSI) Assembly is only required for ESP
applications that employ a Baker Hughes Osiris Downhole Sensor. It is not required in
applications that do not employ a Downhole Sensor. It cannot be used as an interface
to Downhole Sensors manufactured by others.

Figure 7: ESP Downhole Sensor Interface (DSI) Assembly (Part Number 197146)

The switches on the DSI are as follows:

Copyright 2020 Baker Hughes Company. All rights reserved. Page 33 of 277
 Table 9: DSI Switches

Designator Description Default

SW2 Operating Mode (16 position Should be set based on
rotary switch)a application.
0 = Vector VII or CTI RTU
6 = Apollo
SW3 Diagnostics/Programming 1 Off
Leave at default 2 Off
3 Off
4 Off

aTheboard must be powered off and back on after the Operating Mode has been
changed.

3.2.4 RSTi Expansion I/O Module

Apollo is especially suited for complex Surface Pumping System (SPS) applications. Many SPS
systems include Resistance Temperature Detectors (RTDs) to monitor several locations within
the motor and thrust chamber. To fulfill this requirement, the Apollo system supports the BH
Intelligent Platforms RSTi Expansion I/O modules. Current support is limited to up to 16 RTD
inputs using the 4 and 8 input RTD Modules shown in Table 10: RSTi Expansion I/O Module,
page 34. The system can use any combination of these two modules limited to 16 inputs.
RSTi I/O Components include:

Table 10: RSTi Expansion I/O Module

Description BH AL Part BH IP Part Number Notes

Number
Network Adapters
I/O Network Adapter, 3000341 Modbus I/O Module
GE,Modbus -485 – Required in all
systems
Power Distribution
Modules

Copyright 2020 Baker Hughes Company. All rights reserved. Page 34 of 277
 Table 10: RSTi Expansion I/O Module (cont'd.)

Description BH AL Part BH IP Part Number Notes

Number
I/O Remote, GE, 3000338 ST-7588 Potential Distribution
RSTI, Common Module common for
Module 0 and 24 Vdc
Required for systems
that need to provide
24 Vdc power for
field sensors.
Digital Inputs
I/O Remote, GE, 3000337 ST-1218 GE RSTI 8x Digital In
RSTI, 8CH Dig In 12/24 Vdc positive
logic
RSTI, 4x, Digital 3004919 ST-1214 GE RSTI 4x Digital In
In, (12/24V) 12/24 Vdc positive
logic
Digital Outputs
RSTI, 4x, Digital Out, 3004920 ST-2324 GE RSTI 4x Digital
(12V, 0.5A) Out (12V, 0.5A)
RSTI, 4x, DIGITAL 3004923 ST-2744 GE RSTI 4x Digital
OUT, 230 Vac/2A, Out 230 Vac/2A,
24 Vdc/2A 24 Vdc/2A
Analog Inputs
I/O Remote, GE, 3000336 ST-3704 4 Channel RTD
RSTI, 4CH RTD Module
Requires Breakout
Box (see below)
I/O Remote, GE, 3000340 ST-3708 8 Channel RTD
RSTI, 8CH RTD Module
Requires Breakout
Box (see below)
I/O 3000339 ST-3218 GE RSTI 8x Analog
Remote,GE,RSTI,8CH , In 4~20mA 12bit
4-20 Analog In
RSTI, 4x, Analog 3004924 ST-3214 GE RSTI 4x Analog
In, Module In 4~20mA 12bit

Copyright 2020 Baker Hughes Company. All rights reserved. Page 35 of 277
 Table 10: RSTi Expansion I/O Module (cont'd.)

Description GE AL Part GE IP Part Number Notes

Number
Analog Outputs
RSTI, 2x, Analog 3004918 ST-4112 GE RSTI 2x Analog
Out, 0-20mA Out 0-20mA
Other Components
Module,interface 3003172 Breakout Box – One
Screw/Ribbon Conn required for each 8
or 4 channel RTD
module.
Each Breakout Box
requires one of the 3
cables listed below.
Ribbon,Cable Flat 3003169 Connects Field Wiring
20PIN FEM 18INCH Block to RTD Module
RSTi
Ribbon,Cable Flat 3003170 Connects Field Wiring
20PIN FEM 10INCH Block to RTD Module
RSTi
Ribbon,Cable Flat 3003171 Connects Field Wiring
20PIN FEM 6INCH Block to RTD Module
RSTi

Copyright 2020 Baker Hughes Company. All rights reserved. Page 36 of 277
 Figure 8: 8 Channel RTD Setup

A typical 8 channel RTD setup is shown in Figure 8: 8 Channel RTD Setup, page 37. The
breakout box is not shown.
Settings:

Table 11: DIP Switch Settings

Description Setting
Comm Settings Switch Switch 1-4 ON
Switch 5-8 OFF
X10 Dial 0
X1 Dial 2

The DIP switch settings above define the following configuration:

• 115,200 baud, Watchdog On, N81, Modbus RTU mode.
• Modbus address is 2.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 37 of 277
 Table 12: Power Connections

Position Connection Sub-System I/O Bus

0 System Power (+24V) +24 Vdc
1 System Power (0V) GND
2 Ground
3 Ground
4 Field Power (0V) External 24V Supply – GND
5 Field Power (0V) External 24V Supply – GND
6 Field Power (+24V) External 24V Supply ±24V
7 Field Power (+24V) External 24V Supply ±24V

Communication Connections:
Communication Connections Apollo communicates with the RSTi I/O using the Sub-System
communication port (COM3) which can be shared with the Apollo I/O board.

Table 13: Communication Connections

Position Connection Sub-System I/O Bus

1 (Top) Data + A
2 Data - B
3 Ground/Signal Common GND
4 Shield SHIELD
5 (Bottom) Field Ground

Sensor Types:
The RSTi I/O is compatible with Platinum PT-100 RTDs.

If RSTi analog input modules are used, they need to be connected to the Modbus
Network Adapter before all other modules.
Figure 9: ST-3704 Interface Design, page 39 shows the interface design for ST-3704.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 38 of 277
 Figure 9: ST-3704 Interface Design

Figure 10: ST-3708 Interface Design, page 39shows the interface design for ST-3708.

Figure 10: ST-3708 Interface Design

Copyright 2020 Baker Hughes Company. All rights reserved. Page 39 of 277
 Figure 11: ST-1218 Interface Design, page 40 shows the interface design for ST-1218.

Figure 11: ST-1218 Interface Design

Figure 12: ST-7588 Interface Design, page 40 shows the interface design for ST-7588.

Figure 12: ST-7588 Interface Design

Copyright 2020 Baker Hughes Company. All rights reserved. Page 40 of 277
 Figure 13: ST-3218 Interface Design, page 41 shows the interface design for ST-3218.

Figure 13: ST-3218 Interface Design

Figure 14: ST-4112 Interface Design, page 41 shows the interface design for ST-4112.

Figure 14: ST-4112 Interface Design

Copyright 2020 Baker Hughes Company. All rights reserved. Page 41 of 277
 Figure 15: ST-1214 Interface Design, page 42 shows the interface design for ST-1214.

Figure 15: ST-1214 Interface Design

Figure 16: ST-2324 Interface Design, page 42 shows the interface design for ST-2324.

Figure 16: ST-2324 Interface Design

Copyright 2020 Baker Hughes Company. All rights reserved. Page 42 of 277
 Figure 17: ST-2744 Interface Design, page 43 shows the interface design for ST-2744.

Figure 17: ST-2744 Interface Design

Figure 18: ST-3214 Interface Design, page 43 shows the interface design for ST-3214.

Figure 18: ST-3214 Interface Design

Table 14: ST-3704 RTD Connections

Pin No. Description

1 RTD Ch#0+
2 RTD Ch#0-

Copyright 2020 Baker Hughes Company. All rights reserved. Page 43 of 277
 Table 14: ST-3704 RTD Connections (cont'd.)

Pin No. Description

3 RTD Ch#1+
4 RTD Ch#1-
5 RTD Ch#2+
6 RTD Ch#2-
7 RTD Ch#3+
8 RTD Ch#3-
9 AGND
10 AGND

Table 15: ST-3708 RTD Connections

Pin No. Description

1 RTD Ch#0+
2 RTD Ch#0-
3 RTD Ch#1+
4 RTD Ch#1-
5 RTD Ch#2+
6 RTD Ch#2-
7 RTD Ch#3+
8 RTD Ch#3-
9 AGND
10 AGND
11 RTD Ch#4+
12 RTD Ch#4-
13 RTD Ch#5+
14 RTD Ch#5-
15 RTD Ch#6+
16 RTD Ch#6-
17 RTD Ch#7+
18 RTD Ch#7-

Copyright 2020 Baker Hughes Company. All rights reserved. Page 44 of 277
 Table 15: ST-3708 RTD Connections (cont'd.)

Pin No. Description

19 AGND
20 AGND

3.2.5 Backspin Probes

ESP motors do not immediately come to a stop when power is removed. Instead the column of
fluid from the top of the pump to the surface falls back down the tubing causing the pump to spin
backwards. Starting the ESP motor during this “backspin” can cause damage to the pump or
motor. Backspin Probes provide Apollo the ability to detect when backspin is occurring. Apollo
can then be programmed to wait until the backspin has ended before starting the ESP motor.
A motor in backspin generates a voltage back up the motor lead cables to the transformer.
Backspin Probes measure this motor voltage at the output of the step-up transformer. The
probes are connected to the Apollo EIO board via three AC inputs and are installed inside an
external enclosure mounted to the VSD as shown in Figure 19: Backspin Probes-Drawing
1, page 45. Part Number 197543 consists of the external enclosure and the backspin probe
assembly. Currently, backspin input is not supported by RSTi.

Figure 19: Backspin Probes-Drawing 1

Copyright 2020 Baker Hughes Company. All rights reserved. Page 45 of 277
 Figure 20: Backspin Probes-Drawing 2

Copyright 2020 Baker Hughes Company. All rights reserved. Page 46 of 277
 3.2.6 Block Diagram–Apollo System in a Vector VII or Vector Plus ESP Application

Figure 21: Apollo System in a Vector VII or Vector Plus ESP Application

• The Apollo I/O Board is not required in applications where the drive module provides
sufficient I/O.
• The ESP Downhole Sensor Interface (DSI) is only required for ESP applications that
employ a Baker Hughes Osiris Downhole Sensor.
• The voltage sensing PTs and current sensing CTs are seldom used in drive
applications.
• Apollo version 3 also works with the BH Vector Plus VSD.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 47 of 277
 3.2.7 Block Diagram–Apollo System in a Switchboard Application

Figure 22: Apollo System in a Switchboard Application

Copyright 2020 Baker Hughes Company. All rights reserved. Page 48 of 277
 3.2.8 Block Diagram–Apollo System in a Vector VII or Vector Plus SPS Application

Figure 23: Apollo System in a Vector VII or Vector Plus SPS Application

• The RSTi I/O is only required in systems with RTD sensors.

• Apollo version 3 also works with the BH Vector Plus VSD.

3.3 Hardware Installation

The Apollo Intelligent Control System can be installed in new Baker Hughes manufactured Vector Plus
Variable Speed Drives. It can also be provided in component form suitable for installation in existing Baker
Hughes legacy drives.
New Vector Plus Variable Speed Drives equipped with the Apollo Intelligent Control System will have
the Apollo HMI installed at the factory. For new Vector Plus drive applications that require additional I/O
or a Baker Hughes Downhole sensor, the Apollo I/O Board Assembly and ESP DSI Assembly will
usually also be installed at the factory.
The Apollo Intelligent Control System can be added to an existing Vector VII drive if that Vector VII drive is
equipped with the new style Vector VII Operator Control Panel.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 49 of 277
 The Apollo Intelligent Control System cannot be added to a Vector VII drive equipped with a “Blue
Box” type Operator Panel. Retrofit Kits (Part Numbers 810283, 810286, 810215) are available to
convert existing Vector VII drives with “BlueBox” type Operator Panels to the new style Vector VII
Operator Control Panel. The Apollo Intelligent Control System can only be added to an existing
Vector VII drive with a “Blue Box” type Operator Panel after the existing drive has been converted
to a Vector VII drive with the new style Operator Control Panel.
• Part Number 810283– Vector VII “Blue Box” Retrofit Kit (Includes new style Operator Control
Panel, Memory Stick with Firmware Upgrade Files, and all cables required to upgrade firmware
in both the DriveModule and the Operator Control Panel.
• Part Number 810286– Same as 810283 except it is stainless steel.
• Part Number 810215– Vector VII Operator Panel Replacement Kit (Includes new style Operator
Control Panel only). This is for use by those who already have a copy of the needed firmware
files and all the cables required to upgrade firmware in both the Drive Module and the Operator
Control Panel.
Adding the Apollo Intelligent Control System to an existing Vector VII drive (one equipped with the new style
Operator Control Panel) requires a “full install” of the Apollo Operating System. For additional information on
how to perform a “full install”, see Section 12: Appendix A–Full Installation of Apollo Software, page 258 .

3.3.1 Mechanical Installation – Non-Vector Plus Applications

Apollo HMI Installation

The Apollo HMI can be easily mounted into an existing Variable Speed Drive, Switchboard, or
other panel that has an existing cutout for an Amp Chart Recorder (13 9/16” High x 10 5/16”
Wide). For these applications select Part Number 197144 which is the Apollo HMI suitable for
mounting in an Amp Chart Opening.
1. Remove Amp Chart and clean surface of the Amp Chart cut-out opening.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 50 of 277
 Figure 24: Remove Amp Chart

2. Insert Apollo HMI (Part Number 197144) into Amp Chart opening.

Figure 25: Insert Apollo HMI

3. Use fender washer and nut to tighten center studs from panel onto the door.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 51 of 277
 Figure 26: Tighten Center Studs

4. Place side brackets on studs and tighten down.

Figure 27: Side brackets on Studs

5. Attach clear safety shield to outside of brackets with supplied hex head hardware.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 52 of 277
 Figure 28: Clear Safety Shield Attached

6. Install Window Kit on the outside of the enclosure.

Figure 29: Window Kit Installed

For applications where an Apollo HMI will be mounted into an existing Vector VII drive with the
old “Blue Box” HMI, use Part Numbers 810283, 810215, or 810286 (depending on existing
mounting arrangement) and follow the mounting instructions provided with those items. See
Section 3.3 Hardware Installation, page 49 to determine the appropriate part number.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 53 of 277
 Apollo I/O Board/ESP DSI Panel Assembly

Part Number 197207 is the Apollo I/O Board/ESP DSI Panel Assembly. It consists of a Mounting
Panel that includes both the Apollo I/O Board Assembly (Part Number 197148) and the ESP DSI
Assembly (Part Number 197146). The panel dimensions are 14” x 20” with the mounting holes
lined up on 12” vertical and 18” horizontal centers.
This Mounting Panel is designed to mount on the inside of the door of a Vector Plus drive in
the area reserved for options mounting. It can also be used as a convenient mounting panel
for use in applications where an Apollo Intelligent Control System is being added to an existing
Variable Speed Drive, Switchboard, or Soft Start product. When using this assembly with a
product other than the Vector Plus, always make sure that adequate space is available to mount
this panel. See Figure 30: Apollo I/O Board/ESP DSI Panel Assembly (Part Number 197207),
page 54 for mounting dimensions.

Figure 30: Apollo I/O Board/ESP DSI Panel Assembly (Part Number 197207)

Two other versions of this Mounting Panel Assembly are available for applications that may not
require both the Apollo I/O Board and the ESP Downhole Sensor Interface.
• Part Number 197209 consists of the Mounting Panel with the Apollo I/O Board Assembly only.
• Part Number 197208 consists of the Mounting Panel with the ESP DSI Assembly only.
The Apollo I/O Board Assembly and the ESP DSI Assembly are also available as standalone
items. Each item is provided with its own compact mounting plate.
• Part Number 197148 is the Apollo I/O Board Assembly only.
• Part Number 197146 is the ESP DSI Assembly only.
The Apollo I/O Board Assembly is also available with the Zenith Sensor Interface as shown in
Figure 31: Zenith Configuration-Drawing 1, page 55.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 54 of 277
 • Part Number 3000252 consists of the Mounting Panel with the Apollo I/O Board Assembly
and Zenith Interface Unit.
• Part Number 810822 is the Zenith Interface Unit only.
The Zenith Interface Unit card connects to the Apollo I/O Board via a Serial/USB adapter (PN
197349).

Figure 31: Zenith Configuration-Drawing 1

Copyright 2020 Baker Hughes Company. All rights reserved. Page 55 of 277
 Figure 32: Zenith Configuration-Drawing 2

3.4 System Concepts and Definitions

3.4.1 Inputs

Inputs are information sources from the well site (like a pressure gauge). These sources can be
Analog or Digital Inputs, Downhole Sensor data, or Drive data.
Examples of Inputs:
• Pressure sensor connected to an analog input
• Vibration sensor connected to a digital input
• Drive frequency read from the drive using a serial link
• Motor temperature read from a downhole tool using a serial link
How inputs are used in the Apollo system:
• Input data is collected periodically (polled). Polling rate is about 10 times per second for inputs
on the I/O board, about 5 times per second for drive data, once a second for RSTi modules
and about every 5 seconds for downhole data.
• Channel values are formed when input data are scaled, and an algorithm is applied.
• The Apollo system handles all digital and analog inputs the same, whether the inputs are on
the Apollo HMI, the Vector VII drive, the Apollo I/O board, or the downhole sensor.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 56 of 277
 3.4.2 Channels

Channels are real-time information collected and displayed by the system. Often, channels are
based on a system input that is scaled to engineering units (like Tank Level scaled to feet).
However, channels can also be based on other channels (derived channels).
Examples of Channels:
• Channel based on an analog input (Tank Level, Flowline Pressure)
• Channel based on a downhole tool input (Intake Pressure)
• Derived channel (Average Motor Amps)
Using derived channels and the flexible menu of algorithms provided by the Apollo system allows
for complex control to be programmed without resorting to a PLC.

3.4.3 Triggers

Triggers monitor channel information. They signal significant events or conditions concerning
the pumping system. They are called triggers because they can be used to trigger various
shutdowns, warnings, and other actions. For example, a High Limit trigger tests the value of a
channel against a limit. If the limit is exceeded the trigger is activated (set) and the system state
is affected (depending on the Trigger Action).
Examples of Triggers:
• Tank Level High Trigger-Starts motor if a tank level exceeds the programmed threshold.
• Intake Pressure Low Trigger-Stops the motor if the downhole pump intake pressure is less
than the specified value.
See the Section 10: Trigger Definition, page 225 of this manual for more information.

3.4.4 Outputs

Outputs connect channel and trigger values to other systems or devices outside the Apollo
system. For example, a digital output could be connected to the Motor Temperature High
trigger. The output could activate a signal to inform a user that the motor had stopped due to
a high temperature.
Select “Connect this TRIGGER to a DIGITAL OUTPUT” from any Trigger Info screen to attach
an output to a trigger. Or, go to Main Menu, see Section 4.3 Main Menu, page 88 and select
“Connect a Trigger to Dig Out”. See Section 5.15 Add a 2nd IO Board, page 165 for more
information.

3.4.5 Example – Input / Channel / Trigger / Output

The diagram below shows a simple example of the various structures in the Well Control System.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 57 of 277
 Figure 33: Various Structures in a Well Control System

3.4.6 Templates

A template is a set of channel, trigger, and output configurations that define the functionality for
an application. For example, the Standard template includes predefined channels and triggers
needed in a basic ESP pumping system.
The purpose of a template is to define the functionality of the system. Templates allow the
Apollo system to be pre-configured for a variety of applications, thus minimizing the manual
setup required by the installer.
The following templates are available:

Table 16: Templates

Template Use
SWB Use in switchboard and soft-start applications.
Standard Installed by default. Used in all Vector VII
and Vector Plus applications.
Analog Use in variable speed drives that Apollo
does not support via a serial (RS-232,
RS-485) connection.
A1KBasicIHM Mimics the Vector VII (white screen) user
interface. Note that it also Limits Apollo’s
functionality to that of the Vector VII. Not
recommended for new installations and only
when requested by the customer.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 58 of 277
 Templates are loaded from the Load a New Template selection on the Figure 60: Main
Menu-Screen 2, page 89.

3.4.7 Configuration Wizards

Configuration Wizards are automated procedures that lead the user through the steps necessary
to accomplish various configuration tasks in the Apollo system. Commonly used Configuration
Wizards include:

Table 17: Configuration Wizards

Wizard Name Wizard Function

Add 1st IO Board Add support for the Apollo I/O board.
Menu/Other Initial Setup->Page 2
Setup DH Tool Select a downhole tool to use, pressure and
temperature units, and limits. Menu/Other
Initial Setup->Page 2
Setup Pump Speed PID Set up the parameters needed to use
the pump speed control PID. Menu/Drive
Mode/PID Mode
Setup Pump Curve Set the parameters needed to activate the
Pump Curve monitoring capabilities of Apollo.
Menu/Other Initial Setup->Page 2/Pump
Curve Setup/Setup Pump Curve
SPS Setup Converts the Standard Template for use
in an SPS application. Menu/Other Initial
Setup->Page 2/SPS Setup

Other wizards are available at Menu/Initial Setup->Page 3/Configuration Wizards.

New Configuration Wizards can be added to the system using a USB Flash drive. New
Wizards will be made available via the Support Central Drives and Controls Product
Support website.

3.5 Drive Modes

This section includes an overview of the available drive modes. For additional information, see Section 5.6
Setup Drive Mode, page 139.

3.5.1 Manual Frequency Mode

Control mode in which the drive runs at a programmable speed.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 59 of 277
 3.5.2 Current Control Mode

Control mode in which the drive speed is varied in an attempt to provide a fixed output current.
Current Control is sometimes used in gassy wells, when a pump encounters a gas pocket, the
load will be reduced, and the output current of the drive will drop. The drive will speed up in an
attempt to clear the gas pocket from the pump. If the gas pocket clears, the load will return, and
the drive speed will slow back to the speed needed to maintain the specified current setpoint.

3.5.3 PID Speed Control Mode

Control mode in which the drive speed is varied in an attempt to keep a system parameter
(referred to as the control or feedback parameter) at a specified level.
Common control parameters include:
• Pump Intake Pressure (ESP system)
• Tank Level (SPS system)

3.5.4 Analog Follower Mode

Control mode in which the drive speed is based on a scaled analog input. Analog Follower mode
is often used in situations in which another controller, such as a PLC, dictates the speed at
which the drive should run.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 60 of 277
 3.6 User Interface Conventions

Figure 34: Apollo User Interface

3.6.1 LEDs

Three high intensity LEDs are located just above the LCD screen. These can be used “at a
glance” to determine the operating state of the Apollo system. The table below relates the
LED status to the drive state.

Table 18: LED Status

Drive State Stop (Red) Fault (Amber) Run (Green)

Locked Out On Off Off
Fault On On Off
Ready On Off Off
Restart (More than On Flash Off
1 minute)
Restart (Less than Flash Flash Off
1 minute)

Copyright 2020 Baker Hughes Company. All rights reserved. Page 61 of 277
 Table 18: LED Status (cont'd.)

Drive State Stop (Red) Fault (Amber) Run (Green)

Prepare to Start (SPS Off Off Flash
start sequence or
ESP Backspin)
Running Off Off On
Running with Warning Off Off Flash

3.6.2 Function Buttons

Function buttons F1-F5 are defined by the labels located above them. For example, in the image
above function button F3 will take the user to the Settings screen.

3.6.3 Arrow Buttons

The arrow buttons are used for navigation and editing. Their use is screen dependent and will be
described in the Screen Types section. For most screens, Up/Down is used to select a screen
object (you must be logged in) while Left/Right is used to move to the Previous or Next page. On
editing screens, Left and Right are often used to select the digit to be modified while Up and
Down increment and decrement the value.

3.6.4 Start/Stop Buttons

The Stop button is used to stop a running drive and to put it in the Locked Out state. The Start
button is used to advance the drive from its current drive state toward a running state. The Start
button may have to be pushed more than one time to advance the drive to the Running state.
For example, a locked out drive will require one Start to clear the lockout. A second Start may
be required to actually start the system. Warning: Pushing the Start Button may advance the
System State and cause the system to automatically start.

3.6.5 System State

The System State shows the up-to-date state of the Apollo system. The System State is
displayed in the upper left corner of most drive screens.
Values for the System state include:

Copyright 2020 Baker Hughes Company. All rights reserved. Page 62 of 277
 Table 19: System State Values

System State Description

No Drive Comm Communications between the drive controller
and the drive power module have not been
established.
The drive will not start in the No Drive Comm
state.
No IO Comm In a Switchboard application, this state
indicates that communications with the IO
board have failed.
The drive will not start in the No Drive Comm
state.
Locked Out* Drive is locked out.
The drive will not start until the lock-out is
cleared by a local operator or remotely via
SCADA.
Fault Drive is stopped. A fault is active.
When the fault clears, the drive will enter the
Ready state (if Restarts are not enabled) or
the Restart State (if Restarts are enabled).
The drive will not start in the Fault state.
Ready-Manual Drive is stopped. No faults are active. The
system goes to this state only when the
ManualStartOnly parameter is set to TRUE.
The drive will not start without user intervention
by a local operator.
Ready Drive is stopped. No faults are active.
Restarts are enabled.
The drive may start automatically from this
state.
Prepare2Start The drive is performing pre-run checks. An
example of a pre-run check is a backspin
check in an ESP system.
The drive will start automatically when the
pre-run checks are complete.
StartSequence In an SPS system, this state will be labeled
StartSequence.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 63 of 277
 Table 19: System State Values (cont'd.)

System State Description

Starting The drive has started and is ramping up to the
Start Frequency.
Running The drive is running.
Run Mode 2 The drive is running in an alternate run mode.
These modes must be set up by Level 2 or
Level 3 users.
The mode name may be changed to better
reflect the operation being performed. For
example, Run Mode 2 could be programmed
to run the drive for a fixed amount of time at a
higher drive frequency to drain off excess fluid
in the well. “Run Mode 2” could be renamed
“Draining” to better reflect the operation being
performed.
Run Mode 3 The drive is running in an alternate run mode.
These modes must be set up by Level 2 or
Level 3 users.
The mode name may be changed to better
reflect the operation being performed.
Stopping The drive is stopping.

*Timed and/or Triggered restarts may occur if the drive is not locked-out. Do
not clear a lock-out until it is safe to start the drive.

3.6.6 Trigger Ticker

The Trigger Ticker is shown on select screens. The Trigger Ticker is a changing 1 line marquee
that includes relevant information including Drive Name, Drive Control Mode, Motor Direction,
and the first five items from the Relevant Triggers screen.

3.7 User Levels

The Apollo system supports three user levels denoted Level 1, Level 2, and Level 3. Each user level
has specific privileges.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 64 of 277
 3.7.1 Level 1 Users “Logged-out”

The lowest level of privilege in the Apollo system is Level 1. This level is designed for operators
who need to run the drive and monitor its performance but are not trained to configure the
drive. Level 1 users are not required to log in.
Level 1 users have the following permissions:
• View data on a limited number of data display screens
• View the Event Log and Relevant Triggers screens
• View graphical data associated with the parameters displayed on a data display screen
• Make very limited changes to the system operation. The system changes allowed in the
default configuration are:
– Start the drive
– Stop the drive
– Adjust the drive speed setpoint
– Select the drive display color scheme
• Collect historical data and events on a USB Flash drive

3.7.2 Level 2 Users “Logged-in”

Level 2 access requires a login. This level is designed for service personnel who need to setup
the drive at installation or modify the drive’s configuration to optimize its performance. Many of
the information screens are simplified at this level in comparison to Level 3 Users.
Level 2 users have the following permissions:
• All Level 1 permissions
• View all data display screens
• View all Trigger screens
• Access configuration menu
• Configure the drive

3.7.3 Level 3 Users “Advanced”

Level 3 access requires a login. This level is designed for experts who need to add functionality
to the drive.
Level 3 users have the following permissions:
• All Level 2 permissions
• Advanced editing of Channels and Triggers

Copyright 2020 Baker Hughes Company. All rights reserved. Page 65 of 277
 • Configure New Channels and Triggers

3.8 Screen Types

3.8.1 Home Screen

Figure 35: Home Screen

Function:
The Home Screen is the default screen when the drive is powered up. It displays the data
most relevant to the user.
Keypad Functions:
F1: “Data” – Used to view available data display screens.
F2: “Home” – Closes the current screen and displays the Home screen.
F3: “Settings” – Access drive settings that can be changed.
F4: “Events” – Activates the Event Log screen containing the 4096 newest events.
F5: Graphs” – View historical graphs of the data shown on this page.
Arrows: When logged in, arrow keys allow selection of a screen object which brings up an
info screen for the selected object.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 66 of 277
 • Level 2 and Level 3 users can customize the data on this screen. See Section 5.16
Edit a Screen, page 165.
• Default data shown in image is for an ESP system. SPS and Switchboard applications
have different default data.

3.8.2 Data Display Screens

Level 1 users access Data Display screens by pressing the Data function button from the Home
Screen. Repeatedly pressing the Data function button allows the user to view all of the available
data display screens.
By default, Data Display Screens include the Downhole screen, Digital and Analog I/O screens,
and the Amp Chart screen.
A list of all the Data Display screens appears when a Level 2 or Level 3 user presses the Data
function button on the Home Screen. The user can then highlight the desired screen using the up
and down arrows and navigate to the highlighted screen by pressing the Select function button.
Additional screens are also added based on the configuration. For example, if a level 2 user
configures the pump curve parameters, the pump curve screen will be added to the Data
Display screens.

3.8.3 Downhole Screen

Function
The Downhole screen displays the data from the downhole sensor (usually Baker Hughes’ Osiris downhole sensor).
This screen will not be available if there is no downhole tool configured in the system.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 67 of 277
 Figure 36: Downhole Screen

3.8.4 Digital I/O Screen

Figure 37: Digital I/O Screen

Function:
The Digital I/O screen displays the state of all the digital inputs in the system. Figure 37: Digital
I/O Screen, page 68 a minimal configuration. If an Apollo Extended I/O board is configured in the
system, its digital I/O will be shown on this screen. This screen cannot be edited.
Screen Data:

Copyright 2020 Baker Hughes Company. All rights reserved. Page 68 of 277
 Screen data on the Digital IO screen shows the current state of all the digital inputs and outputs
in the system.
• Digital I/O Name
– V7 Dig In x indicates an input on the drive power module.
– HMI Dig In x indicates an input on the HMI.
– EIO Dig Opt x indicates a digital I/O on the Apollo I/O board.

The Digital I/O Name will normally be changed to reflect the meaning of the input
or output.
• Value Field Digital Inputs
– False: Digital Input is in its inactive state (e.g., a Normally Open contact is open, or
a Normally Closed contact is closed.)
• True – Digital Input is in its active state (e.g., a Normally Open contact is closed, or a
Normally Closed contact is open.) Digital Outputs
– 0 indicates the relay is OPEN. If the Digital Output is configured as Normally Open, the
controlling trigger is CLEAR. If the Digital Output is configured as Normally Closed, the
controlling trigger is SET.
– 1 indicates the relay is CLOSED. If the Digital Output is configured as Normally Open,
the controlling trigger is SET. If the Digital Output is configured as Normally Closed, the
controlling trigger is CLEAR.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 69 of 277
 3.8.5 Analogs Screen

Figure 38: Analog I/O Screen

Function:
The Analogs screen displays the values of all analog inputs in the system. The screen above
shows a minimal configuration. If an Apollo Extended I/O board is configured in the system, its
analog inputs will also be shown on this screen.
Screen Data:
Screen data on the Analogs screen shows the current values of all the analog inputs in the
system.
• Input Label – The label assigned to the analog input (e.g., Tubing Pressure.)
• Input Value – The input value assigned to the corresponding label (e.g., 140.0 psi.)

Copyright 2020 Baker Hughes Company. All rights reserved. Page 70 of 277
 3.8.6 Amp Chart Screen

Figure 39: Amp Chart Screen

Function:
The Amp Chart screen displays one day or seven days of drive output current data in the familiar
circular format. Data is saved based on a dead band algorithm up to once per second.
Screen Data:
Screen data on the Amp Chart screen shows the drive output current in Amps.
• Amp Chart Date
• Graphical Output
• Outer Ring – Amps at the outer ring of the chart
• Each Ring – Amps per minor division
Keypad Functions:
F1: “Data” – Display the next data display screen.
F2: “Home” – Closes the current screen and displays the Home screen.
F3: “Settings” – Access drive settings that can be changed.
F4: “Events” – Activates the Event Log screen containing the 4096 newest events.
F5: “Graphs” – View historical graphs of the data shown on this page.
Arrows:
• Up, Down – Change the chart format between 1 and 7 days.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 71 of 277
 • Right, Left – View the amp chart for a different date.

3.8.7 Other Screens

Some applications or customers may require level 1 users to access other data display screens.
Level 2 and Level 3 users can add other screens to the sequence as needed.

3.9 Settings

Settings Screens provide easy access to commonly modified parameters. By default, only the Pump Speed
and the Color Scheme are the only Settings Screens available without logging in.
Additional Settings Screens can be added as needed to give non-logged in persons access to specific
settings.
After logging in, users access a wider range of Settings Screens using the Settings button.

3.9.1 Setpoint Screens

The Setpoint screen allows the user to change the setpoint for the currently active drive mode.
The settings screen can be accessed by pressing the Settings function button from the home
screen. Repeatedly pressing the Settings function button will allow the user to access all
available settings. The data displayed on this are:
• Drive Status-The current state in which the drive is operating.
• Drive Mode Dependent Setpoint Screen
• Manual Frequency Drive Mode: The Frequency Setpoint will be displayed.

Figure 40: Setpoint Screen (Manual Frequency Model)

Copyright 2020 Baker Hughes Company. All rights reserved. Page 72 of 277
 • PID Speed Control Drive Mode: The PID setpoint will be displayed. By default, the
setpoint is labelled "DHPrsSetpoint" (Downhole Pressure Setpoint). This label can be
given an application specific name when the PID is configured.

Figure 41: Setpoint Screen (PID Speed Control Mode)

• Current Control Drive Mode: The Drive Output Current setpoint (iMode Setpoint) will be
displayed.

Figure 42: Setpoint Screen (Current Control Mode)

• Analog Follower Drive Mode: No setpoint is displayed. Instead, a notice is shown explaining
that the user cannot modify the drive speed in Analog Follower mode.

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 Figure 43: Setpoint Screen (Analog Follower Mode)

• Limit: I-Limit is not a drive mode. However, if the I-Limit has been set and is currently
controlling the drive frequency, the I-Limit setting is displayed instead of the current drive
mode setpoint screen.

Figure 44: Setpoint Screen (I-Limit Controlling Pump Speed)

Keypad Functions:
F1: “Exit” – Exits the settings screen.
F2: “Home” – Closes the current screen and displays the Home screen.

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 F3: “Settings” – Display the next setting that can be changed.
F5: “Menu” – If Logged-in or “Login” If Logged-out.
Arrows:
• Up, Down – Change the digit to the right of the flashing insertion point.
• Right, Left – Move the insertion point.

3.9.2 Color Scheme

Figure 45: Color Scheme Setting Screen

Function:
The Color Scheme settings screen allows the user to change display’s color scheme. Choosing
a different color scheme may make the display easier to read in bright sunlight.
Screen Data:

Table 20: Color Scheme

Color Scheme Description

Color On Black Different system structures are displayed in
different colors on a black background. The
colors provide additional information, but the
screen is harder to read in direct sunlight.
White on Black White text appears on a black background.
This is the default setting.
Black on White Black text appears on a white background.

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 3.9.3 Other Settings

As programmed by Level 2.
Other settings available to Level 2 and Level 3 users are configuration dependent and can be
programmed by users at Level 2 or above.

Figure 46: Event Log Screen

Function:
The event log is a time and date stamped list of the most recent 4095 system events. The
newest events are at the top of the list. Move forward in the list (use Right Arrow to advance to
Next Page) to view older events.
Screen Data:

Copyright 2020 Baker Hughes Company. All rights reserved. Page 76 of 277
 Table 21: Event Type

Event Type Description

System State Transition System states are denoted by square brackets
[ ].
Trigger Activation Events Triggers are activated whenever the system
detects a monitored system event. For
example, “U-Load PreTrig” and “Underload
Stop” are trigger activations in the screen shot
above. Underload Stop caused the drive to
stop at 16:24:52.
Trigger Clear Events Some triggers also create an event when they
transition from SET to CLEAR. The “Vibration
Clear” event in the screenshot above is an
example.

Keypad Functions
F1: “Exit” - Exits the settings screen.
F2: “Home” - Closes the current screen and displays the Home screen.
F4: “Triggers” - Display the Relevant Trigger screen.
Arrows:
• Up, Down - Login required to select objects.
• Right, Left - Page through events to view older or newer events.

Figure 47: Relevant Triggers Screen

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 Function:
Relevant triggers are system events that are currently affecting the system state of the drive.
If a drive won’t start, it is highly recommended to review the relevant triggers to identify what
is keeping the drive from starting.
Screen Data:
Triggers that are currently affecting the system state of the drive.
In the above example, the drive shut down and locked out on an underload. The underload is no
longer set (the underload state can only be active when the drive is running). As there are no
triggers on the Relevant Trigger screen that show “Set”, pressing the Start button should start
the drive startup sequence.
Relevant Trigger – The fault which triggered the change in drive state Each relevant trigger
consists of a trigger name, trigger state, and a trigger detail.
• Trigger Name – “Underload” in the screenshot. Name of the relevant trigger.
• Trigger State – “Clr” (Clear) in the screenshot. Clear (Clr) indicates that the condition that
caused the trigger to occur is not currently present. Set indicates that the condition that caused
the trigger to occur is still present.

A trigger is Clear if it is not enabled in the current drive state.

• Trigger Detail – “Locked Out” in the screenshot. The Trigger Detail describes
– Needs Limit Set: The trigger will prevent the drive from running until its limit is set. This
prevents the drive from running before important protections, such as motor overload,
are configured.
– Locked Out: The trigger locked out the drive. A locked out drive cannot be started without
user interaction.
– Clr Dly xx:yy: The trigger is set, but the condition that caused the trigger is no longer active.
The trigger will clear when the clear delay counts down to 0.
– Rstrt xx:yy: The trigger restart countdown completes in xx minutes, yy seconds.
– Shutdown: The trigger shut down the drive.
– Not Enabled:The trigger is not enabled in the current drive state.
– Hold: The trigger is holding the drive in the Prepare2Start state.
– No Start: The trigger is preventing the drive from starting.

The only trigger screen available to Level 1 users is the Relevant Trigger screen.

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 Level 2 users will rotate through the following trigger screens:
• Relevant Triggers – described above
• Active Triggers – triggers in the Set state
• Stop Triggers – triggers with an action of Stop->Fault
• AutoStart Triggers – triggers with restarts allowed
• Stop-Ready Triggers – triggers with an action of Stop->Ready
• Start Triggers – triggers with an action of Start Motor
• Hold Triggers – triggers with an action of Hold in Prestart
• In Use Triggers – all triggers currently in use by the system
• All Triggers – all 256 triggers
Keypad Functions:
F1: “Exit” – Exits the settings screen.
F2: “Home” – Closes the current screen and displays the Home screen.
F4: “Next Type” – Displays the next trigger screen in the sequence.
Arrows:
• Up, Down – Select Event (Login required) to view more info.
• Right, Left – Page through relevant triggers if there is more than 1 page.

3.9.4 Graph Screens

Pressing F5 “Graph” from most display screens will display a graph screen as shown below
depicting historical data from the first graphable channel on the screen. Pressing F5 again
will show the next channel.

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 Figure 48: Graphs Screen

Function:
The Graph Screen displays the historical data in a graphical format. Each parameter on the data
display screen is shown on a separate graph.
Screen Data
Historical data for the system parameter shown on the top of the screen is shown on the graph.
In the example shown, the Motor Temperature (y-axis) is graphed against time (x-axis).
• Numeric Value – The current value of the parameter is displayed just below the parameter
name.
• Graphical Value – The value of the parameter being measured is graphed along the y-axis
• Range – The range of time of the parameter being measured is graphed along the x-axis
Keypad Functions:
F1: “Exit” – Returns to the calling data display screen.
F2: “Home” – Closes the current screen and displays the Home screen.
F5: “Graphs” – Displays the graph screen for the next parameter on the calling data display
screen.
Arrows:
• Up, Down – Zoom In/Zoom Out of the graph. The shortest graph displayed is 5 minutes. The
longest graph displayed is 14 days.

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 • Right, Left – Move forward/backward in time. When scrolled all the way to the right, the graph is
labeled “REAL-TIME” and new data will be automatically displayed. When not in “REAL-TIME”,
the graph will show “HISTORIC” and new data will not automatically be displayed.

3.9.5 USB Menu Screen

Basic information needed to capture history for troubleshooting is included in this section.
See Section 13.1 USB Menu, page 264 for more USB information.

Figure 49: USB Menu

The USB Menu is automatically displayed when a USB Flash disk is inserted into the drive. The
USB Menu allows a user to transfer data to and from the USB Flash drive. Level 1 users will use
the USB Menu to collect data from the drive for archiving or troubleshooting purposes. The “Get
Archive Files” option is highlighted by default when the USB menu is displayed. Press the Select
function button. The files will be copied to the USB Flash drive.
The file path on the USB Flash drive is \Site Name\Well Name\archived data.
Where Site Name and Well Name are the site and well names assigned during configuration.

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 To send files to BH for review or troubleshooting, do the following:
• Insert the USB Flash drive into your computer.
• Navigate to the folder \Site Name on the USB Flash drive.
• Right-click the folder Well Name and select the Sent To option and then select
“Compressed (zipped) folder from the pop-up menu.
• Wait for the data to be compressed.
• Send the file Well Name.zip to BH at: http://bench.ge.com/559607/portal/66642 with a
description of the problem the pumping system is experiencing.
• If the compressed file is too big to send by e-mail (current limit
is 10MB), use the following link and Upload the zip file:
http://bench.ge.com/559607/portal/66642.

3.9.6 Automatic Screens

Drive State transitions can be programmed to display screens automatically. By default, the
following automatic screen transitions are active.
Drive State: Lock Out
On a state transition to lock out, the Fault Status screen is automatically displayed.
The fault or faults that caused the lock out will be displayed.
This screen will be shown if restarts are disabled (ManualStartOnly is set to true) or if all the
restarts for the fault have been used.

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 Figure 50: Fault Status Screen

Drive State: Stopped-FAULT

On a state transition to Stopped-FAULT, the Fault Status screen is automatically displayed.
The active fault or faults will be displayed.
The screen will have a Flashing warning displayed informing the user that the drive will automatically restart
after the listed fault(s) clear.
When the fault(s) clear, the drive will enter the restart state and the Restart Automatic screen will be
displayed.

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 Figure 51: Fault Status Screen with Auto-Start Warning

Restart
On a state transition to Restart, the Fault Status screen is automatically displayed.
The fault or faults whose restarts are counting down will be displayed.
The screen will have a FLASHING Restart warning displayed that counts down the time until the restart.

Figure 52: Fault Status Screen with Restart Countdown

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 Run/Ready

On a state transition to a Running or Ready state, the standard Home Screen will be automatically displayed.

Figure 53: Home Screen

Level 2 and Level 3 users can change the screens automatically displayed as needed for specialized
applications.

4 Basic Setup Sequence

The Basic Setup Sequence allows a Level 2 user to quickly configure a simple ESP application. This process is more
complete than the Quick Start (see Section 1: Quick Start Guide , page 14), allowing access to complete menus
instead of individual parameters. Like the Quick Start, the Basic Setup Sequence assumes no I/O is present in the
system. See the Section 5: Additional Setups, page 126 for information on configuring I/O.

4.1 Log In

The Apollo Control System provides password protection to prevent unauthorized configuration changes.
Access the log in screen from the Home Screen by pressing the Settings function button and then the
Login function button.

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 Figure 54: Setting Function Button

Figure 55: Login Function Button

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 Figure 56: Login Screen

1. Use the up and down arrow buttons on the keypad to change the value of the selected digit. Use the left
and right arrow buttons on the keypad to select a digit.
2. The rightmost digit is selected by default.
3. The default Level 2 password is 9. Simply press the down arrow 1 time to change the value to 9.
4. Press the OK function button to log in.

Figure 57: Select Ok on Login Screen

The Login function button on the Settings Screen is changed to Menu and the Main Menu is displayed.

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 The default Advanced Level password is 8. Advanced level is only required to access Channel and Trigger
Edit screens and is not needed for normal installation and configuration tasks.

4.2 Settings Screen (Logged In)

If you are already logged in, the Settings screen appears as shown in Figure 58: Menu Function Button,
page 88. The Menu is accessed by pressing the Menu function button.

Figure 58: Menu Function Button

4.3 Main Menu

Figure 59: Main Menu

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 The Main Menu consists of 3 screens (pages). Press the right and left arrow buttons to navigate between
the pages of the menu. Use the up and down arrow buttons to select a submenu to access or a parameter
to change. The image shown below is the second screen of the Main Menu. See Figure 60: Main
Menu-Screen 2, page 89.

Figure 60: Main Menu-Screen 2

The image shown in Figure 61: Main Menu-Screen 3, page 89 is the third screen of the Main Menu. See Figure 61:
Main Menu-Screen 3, page 89.

Figure 61: Main Menu-Screen 3

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 The last page of the Main Menu shows several important system values, including the Apollo Revision
(CPU SoftwareRev) and the installed Template.

4.4 Other Initial Setup Menu

The Quick Start is discussed in Section 4: Basic Setup Sequence, page 85 of this manual.
From the first page of the Main Menu, access the Other Initial Setup menu by using the up and down arrows
to highlight Other Initial Setup and then press the Select function button.

Figure 62: Select Function Button

The Other Initial Setup menu is shown in Figure 63: Other Initial Setup Menu, page 91.

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 Figure 63: Other Initial Setup Menu

The Other Initial Setup menu is composed of 3 screens (pages). Generally, this menu provides access
to settings that are modified during the initial setup of the pumping system and further adjustment is not
required unless the pumping system is reconfigured. The first page includes the setups required in almost
all installations. Use the left and right arrow buttons to navigate between the three pages.
The second screen of the Other Initial Setup menu is shown in Figure 64: Other Initial Setup Menu-Screen
2, page 91. It contains a number of setups that are required on some installations.

Figure 64: Other Initial Setup Menu-Screen 2

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 The 3rd screen of the Other Initial Setup menu is shown in Figure 65: Other Initial Setup Menu-Screen
3 , page 92. Less common setups are included.

Figure 65: Other Initial Setup Menu-Screen 3

Use the left arrow button to navigate back to the 1st screen of the Other Initial Setup menu.

Figure 66: Apollo Clock Display

4.4.1 Set Date/Time

Use the up and down arrow buttons as needed to highlight Set Clock. Press the Select function
button. The clock screen is displayed. Verify or correct the Time Zone, date, and time. Use the
F1 and F5 function buttons to move between vertical fields. Use the left and right arrow buttons to

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 move between sections of a field. Use the up and down arrow buttons to change a setting. Press
the Set function button to set the new time or time zone. Always check the Local Time setting for
correctness before leaving the screen. Sometimes, if the time has been lost (see note below),
the first time the clock is set, the Local Time will be one hour off and will need to be set again.

Apollo’s Clock runs on a rechargeable “super cap” and is designed to keep time/date
without external power for 2 to 3 months. The Apollo display may lose the time/date
settings if the unit is in storage or is unpowered for longer. It takes several hours to
fully charge the super cap.

Figure 67: Select Time Zone and Set the Time Screen

4.4.2 Set Well and Site Names

Use the up and down arrow buttons as needed to highlight Well Name. Press the Select function
button to activate the edit screen.

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 Figure 68: Set Well Name-Screen 1

Use the up and down arrows to change the character to the right of the cursor. Use the right and
left arrows to select different letters in the name.
• Moving to the right of the name adds a character to the name.
• Use the down arrow from a blank to access numbers and symbols.
• Use the up arrow from a blank to access capital and then lower case letters.
• Use the <- function button to delete the current character.
Also note that a USB keyboard can be used to ease name entry. Plug the USB keyboard into the
USB port on the front of the drive.
A wireless mini-keyboard is available from BH AL, Part Number 197705

Copyright 2020 Baker Hughes Company. All rights reserved. Page 94 of 277
 Figure 69: Set Well Name-Screen 2

Press the Save function button. Acknowledge the confirmation screen by pressing the Yes
function button. Press the Exit function button to return to the Other Initial Setup menu. The
Other Initial Setup menu screen now reflects the well name you entered.

Figure 70: Initial Setup Updated Well Name Screen

Repeat to set the Site Name. A Site Name is not required but can be used to group well data
from a specific field in one folder.

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 Figure 71: Initial Setup Updated Site Name Screen

4.4.3 Set Global Restart Time

The restart time is the delay between when a trigger stops the Apollo system and the Apollo
system will automatically try to restart. Note that for the system to automatically restart, the
trigger that stops the system has to have a restarts/allowed count > 0. Also note that the system
will never try to restart if the ManualStartOnly parameter is set to true.
Each trigger in Apollo has its own restart time. However, by default, all restart times are set to
the Global Restart time. Best practice is to set the Global Restart time to the normal restart time
on the system (for an ESP system, this is likely the fluid fallback – backspin time). Then change
the restart time on individual triggers only where necessary. For example, in a slow recovering
well, Underload (due to pumping off all the fluid in the well bore) may require a restart time
significantly longer than the fluid fallback time.
Use the up and down arrow buttons as needed to highlight Global Restart. Press the Select
function button to activate the edit screen.
Use the left and right arrow buttons to select a digit. Use the up and down arrow buttons to
change the selected digit. Note that the selected digit is just to the right of the insert in the field.
Change the Global Restart to the desired value.

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 Figure 72: Global Restart Edit Screen

Press the Save function button. Acknowledge the confirmation screen by pressing the Yes
function button. Press the Exit function button to return the Other Initial Setup menu.

4.4.4 Set DHXFormer Ratio

A step-up transformer is used in ESP applications. Program the transformer ratio in terms of the
volts out of the transformer for each volt in. For example, if a transformer is rated at 480 Volts
and you have selected a tap reading 2256 Volts, then set the transformer to 2256/480 = 4.70.
Use the up and down arrow buttons as needed to highlight DHXFormer Ratio. Press the Select
function button to activate the edit screen.
Use the left and right arrow buttons to select a digit. Use the up and down arrow buttons to
change the selected digit.

The selected digit is just to the right of the insert in the field.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 97 of 277
 Figure 73: DHXFormer Ration Edit Screen

Press the Save function button. Acknowledge the confirmation screen by pressing the Yes
function button. Press the Exit function button to return to the Other Initial Setup menu.

The Other Initial Setup menu reflects the changes you have made.

Figure 74: Menu Initial Setup Screen

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 4.4.5 Setup Power Fail Restarts

A common feature of well control systems is the ability to automatically restart if power is lost
while the system is running. By default, this feature is disabled in the Apollo Well Control System.
Do the following to enable the power fail restart function.
Use the up and down arrow buttons as needed to highlight Setup Power Fail Restarts. Press the
Select function button to activate the Power Fail Restarts menu.

Figure 75: Power Fail Rst Screen

Use the up and down arrow buttons to select Restarts/Allowed. Press the Select function button.
The edit screen will appear.

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 Figure 76: Restarts/Allowed Edit Screen

Use the left and right arrow buttons to select a digit. Use the up and down arrow buttons to
change the selected digit.

The selected digit is just to the right of the insert in the field.

Figure 77: Power Fail Restart Menu

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 In this example, the restarts/allowed value has been set to 50. Press the Save function button.
Acknowledge the confirmation screen by pressing the Yes function button. Press the Exit
function button to return to the Power Fail Restart menu.

The Power Fail Restart menu reflects the changes you have made.

Figure 78: Updated Power Fail Restart Screen

If it is necessary to change the restart delay for the power fault restart, select Restart Delay
and change the value using the edit screen.
Press the Exit function button to return to the Other Initial Setup menu.

4.4.6 Setup Password Protection

By default, there are 3 passwords pre-programmed into the Apollo Control System. If the system
is accessible to non-authorized personnel, it is recommended that you change the passwords to
prevent unauthorized access to the drive configuration.
Use the up and down arrow buttons as needed to highlight Setup Password Protection. Press
the Select function button to activate the Password Protection menu.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 101 of 277
 Figure 79: Password Protection Menu

Using the techniques you learned when editing the transformer ratio and the power fail restart
restarts/allowed values, change the Level 2 and Advanced Passwords as needed to prevent
unauthorized access to the configuration.

• Advanced Password 3 is not currently used.

• A password of 65535 indicates disabled.
• Record new passwords. It’ll be a pain to log back in if you forget the passwords!
• Low Level Password logs in to User Level 2. Typically used by installers. No access
to Edit Channel and Edit Trigger screens.
• Advanced Passwords log in to User Level 3. Full access to all Apollo features.
Press the Exit function button when the desired password changes are complete to return to the
Other Initial Setup menu.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 102 of 277
 Figure 80: Other Initial Setup Menu

4.4.7 Setup Com2 SCADA

By default, communication port COM2 is set up for serial SCADA communication. Use the
Com2SCADA Setup screen to configure as needed. See the Vector Plus/Apollo Communication
manual, UM-00014,l for detailed information regarding communications.
Use the up and down arrow buttons as needed to highlight Com 2SCADA Setup. Press the
Select function button to activate the Com 2 SCADA Setup menu.

Figure 81: Com 2SCADA Setup Menu

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 In most cases, the only changes required are the Modbus Address and the Baud rate. Set both
as needed to work with your SCADA system. Use the F1 and F5 function buttons to navigate
between fields. Use the Up and Down Arrow buttons to change values.
When complete, press the OK function button to return to the Other Initial Setup menu.
Press the Exit function button again to return to the Main Menu.

Figure 82: Main Menu

4.5 Configure Drive Settings

Note that you are probably well versed at highlighting an item on a menu and pressing Select
at this time. This manual will use the phrase “Select xxx” to designate that the specified menu
entry should be highlighted using the up and down arrows and that the Select function button
should then be pressed.
Use the Drive Settings menu to configure parameters associated with low level drive (power module)
operations. Select Config Drive Settings from the Main Menu. The first page of the Drive Settings menu
is shown in Figure 83: Drive Settings Screen, page 105. This page contains the parameters that are
most often changed in an install.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 104 of 277
 Figure 83: Drive Settings Screen

Table 22: Parameters

Parameter Default Description

Min Frequency 30Hz Minimum frequency the drive is to
run. Set based on well conditions
to ensure adequate flow of well
fluids across motor to ensure
adequate cooling. For ESP
applications, Min Frequency
settings below 30 Hz are not
recommended.
Max Frequency 60Hz Maximum frequency the drive is
to run. The V/F curve will ensure
that the drive operates at the
DriveMaxVolts when running at
Max Frequency. This parameter
may NOT be changed while the
drive is running.
Accel Seconds 5 Seconds Time in seconds for the drive
to ramp up from 0 Hz to
Max Frequency. For ESP
applications, maximum
recommended Accel Seconds
is 10.0.

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 Table 22: Parameters (cont'd.)

Parameter Default Description

Decel Seconds 5 Seconds Time in seconds for the drive to
ramp down from Max Frequency
to 0 Hz. For ESP applications,
maximum recommended Decel
Seconds is 10.0.
Forward/Reverse Run Forward Direction of Motor Rotation.
V/F Curve Select 60Hz Std Torque Select 1 of 6 preset V/F curves.
These include Standard, Medium,
and High Torque settings for 50Hz
and 60 Hz operation. Standard
torque is default. Use medium
or high torque when faced with
a hard starting motor. Medium
and high torque settings apply a
voltage boost to the V/F curve at
low frequencies. This parameter
may NOT be changed while the
drive is running.
V/F CurveVBias 0.0 Volts Applies a voltage bias to the
drive’s V/F curve AT MAX
FREQUENCY. The bias is linearly
interpolated at frequencies less
than Max Frequency.
DriveMaxVolts 480 Volts Drive voltage output at Max
Frequency. This parameter may
NOT be changed while the drive
is running.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 106 of 277
 Table 22: Parameters (cont'd.)

Parameter Default Description

I-Limit 2000 Amps Maximum current output allowed
by the drive. When the drive
exceeds the specified I-Limit, the
drive frequency will be slowed to
reduce the output current. The
I-Limit function will not slow the
drive to less than Min Frequency.
I-Limit is usually used to try to
prevent Overload faults. See
Enhanced I-Limit on Figure 87:
Overload Menu-Screen 2

Coast To Stop True By default, the drive will

immediately release the motor
when the drive is stopped.
Recommended setting for ESP
applications is “True”. Setting
Coast To Stop to false will cause
the drive to ramp down from
the running frequency to 0 Hz
when the drive is stopped. This
parameter may NOT be changed
while the drive is running.

Navigate between pages of the menu by pressing the Left Arrow and Right Arrow buttons. The second page
of the Drive Settings menu is shown in Figure 84: Drive Settings-Screen #2, page 108.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 107 of 277
 Figure 84: Drive Settings-Screen #2

Table 23:

Parameter Default Description

No-LoadTestMode Normal Mode Set this to “No Load Test” when
running the drive unloaded to
prevent Output Phase Loss faults
(designated LF) and to disable
Underload detection. Be sure to
set back to Normal Mode when
you complete no load testing to
re-enable the protections.
Enhanced I-Limit I-Limit is activated whenever Enhanced I-Limit is a function in
current exceeds the i-Limit which the I-Limit protection is only
threshold. activated if the drive is nearing
overload. When the overload
bucket is low – indicating that
the motor is not yet very hot
– I-Limit will not be enforced.
When the motor starts heating up
(the overload bucket gets above
a limit), the I-Limit function is
enabled. Select Enhanced I-Limit
to run a wizard that will walk you
through setting the limit.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 108 of 277
 Table 23: (cont'd.)

Parameter Default Description

Setup Drive Port (Menu) None Contains the settings Apollo
uses to communicate with the
drive power module. These
settings should not be changed
without consulting with Controls
Engineering.
Config Drive Lockouts (Menu) None Provides access to the triggers
activated when the drive power
module shuts down on an internal
fault. It is strongly advised
that only the Restarts Allowed
and Restart Delay be changed
for these triggers. Changing
parameters for these triggers will
not prevent shutdowns.
Config Drive Fault Restarts None Provides access to the triggers
(Menu) activated when the drive power
module shuts down on an internal
fault. It is strongly advised
that only the Restarts Allowed
and Restart Delay be changed
for these triggers. Changing
parameters for these triggers will
not prevent shutdowns.
Drv Model (Amps) None This is not a settable parameter.
Shows the drive rated amps of the
drive power module. Consult field
support if this does not properly
reflect the drive size.
Drv Firmware None You cannot set this parameter.
Shows the firmware revision of
the drive power module firmware.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 109 of 277
 Table 23: (cont'd.)

Parameter Default Description

Linear List None Activates the Linear List editing
function used to change internal
drive power module parameters.
Note that an “L” to the right of a
parameter indicates that it is in
use by Apollo and is locked in the
Linear List.
RstDrv2Defaults False Set to True to reset the drive
power module to its default
settings. After setting to True and
acknowledging the change, wait
30 seconds and then power cycle
the system.

Navigate between pages of the menu by pressing the Left Arrow and Right Arrow buttons. The third screen
of the Drive Settings menu is shown below in Figure 85: Drive Settings Menu, page 110.

Figure 85: Drive Settings Menu

Copyright 2020 Baker Hughes Company. All rights reserved. Page 110 of 277
 Table 24: Need Title Name

Parameter Default Description

Drive Stability 0 Activates/Deactivates the drive
power module hunting prevention
select function. Set to 0 for
ESP systems. Set to 1 for SPS
systems.

The SPS Configuration Wizard will automatically change the value to 1.

Select any parameter that needs to be changed and make the necessary changes. Press the Save function
button. Acknowledge the confirmation screen by pressing the Yes function button. Press the Exit function
button to return the Drive Settings menu.
When all the necessary changes have been made, press the Exit function button to return to the Main Menu.

4.6 Set Drive Mode

See Section 5.6 Setup Drive Mode Section 5.6, page 139 for detailed information.

4.7 Configure Motor Overload

Select Motor Overload from the Main Menu. The first screen of the Motor Overload menu is shown in Figure
86: Motor Overload Menu, page 111. This page contains the parameters that are most often changed in
common installations.

Figure 86: Motor Overload Menu

Copyright 2020 Baker Hughes Company. All rights reserved. Page 111 of 277
 Table 25: Motor Overload Menu Common Installations

Parameter Default Description

Motor Overload 0.0 Amps(requiring the user to Nameplate rating of the motor.
set it before running the drive) If the motor current exceeds
the Motor Overload value, the
Overload Bucket will begin to
fill using an algorithm that takes
into account how far above
the overload value the actual
current is (usually referred to
as i2t algorithm). This algorithm
provides shorter trip delays for
severe overloads and longer trip
delays for slight overloads.
OLoadStartDelay 0.0 Seconds Seconds after startup during
which overload is ignored.
The default and recommended
OLoadStartDelay is 0 seconds.
OLoad Delay @ 25% 120 Seconds Time it will take for an empty
overload bucket (0%) to fault
(reach 100%) when the motor
current exceeds the motor
overload by 25%. This setting
does not normally need to be
changed.
Restarts/Allowed 0 Set to non-zero to allow for
automatic restarts after a Motor
Overload fault.
Restart Delay Global Restart Delay between the overload fault
and an automatic restart.
Downhole Amps None Delay between the overload fault
and an automatic restart.
O-Load Bucket None Displays the up to date value of
the Overload Bucket. When the
bucket reaches 100%, the drive
will shut down on overload. This
is a channel and not a parameter.
It need not be changed. It is here
for informational purposes.

Navigate between pages of the menu by pressing the Left Arrow and Right Arrow buttons. The second page
of Overload menu is shown in Figure 87: Overload Menu-Screen 2, page 113.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 112 of 277
 Figure 87: Overload Menu-Screen 2

Table 26: Motor Overload Menu Common Installations Screen 2

Parameter Default Description

OLoad@MinFreq 0.0 Amps Defines an enhanced Overload
function. The overload threshold
is ramped up between this
value (at Min Frequency) to
the Motor Overload setting (at
Max Frequency). The enhanced
overload function is disabled
when the value is set to 0
(overload threshold is the same
at all frequencies).
OLoad Drain 3600 Seconds When motor amps are below
the Overload threshold, the
bucket will be draining. This
value is the time for the
overload bucket to drain from
100% to 0% when motor amps
is 0. This time models the
motor cooling time. Higher
amps result in slower draining.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 113 of 277
 Table 26: Motor Overload Menu Common Installations Screen 2 (cont'd.)

Parameter Default Description

Downhole Amps None This is not a parameter to
be changed. It is a channel
showing the downhole amps for
informational purposes. Note that
the value shows ??? because the
channel is not initialized. In this
case, the downhole transformer
ratio hasn’t been configured.
O-Load Bucket None This is not a parameter to be
changed. It is a channel showing
the overload bucket level. The
drive will shut down on overload
when the bucket reaches 100%.
This is displayed for informational
purposes. Note that the value
shows ??? because the channel
is not initialized. In this case,
O-Load Bucket is a derived
channel and takes Downhole
Amps as one of its inputs. Since
Downhole Amps is not initialized,
O-Load Bucket is not initialized.
Motor OverCurrent None Select to access the Motor
OverCurrent trigger information
screen. The motor overcurrent is
a simple high-limit fault that can
be configured in situations where
the more advanced i2t algorithm is
deemed inappropriate. Using this
trigger, the system will fault if the
motor current exceeds the Motor
Over Current limit for longer than
the trip delay. The amount of the
overload is not considered.

For more information on the Motor Overload protection, see Section 9: Apollo Motor Overload Protection,
page 220 of this manual.

4.8 Configure Motor Underload

Use the Motor Underload menu to configure parameters associated with low current motor protection.
Select Motor Underload from the Main Menu. The first screen of the Motor Underload menu is shown in

Copyright 2020 Baker Hughes Company. All rights reserved. Page 114 of 277
 Figure 88: Motor Underload Menu, page 115. This screen contains the parameters that are most often
changed in common installations.

Figure 88: Motor Underload Menu

Table 27: Motor Underload Menu Common Installations

Parameter Default Description

Motor Underload -9999 Amps Minimum allowable current to the
motor. If the motor goes below
the Motor Underload value, the
controller will start timing down
for a fault. Motor Underload
conditions are most frequently
seen in gassy wells and in wells
that are pumped off. By default,
the Motor Underload is set to
-9999 requiring the user to set it
before running the drive.
Enable Delay 10.0 Seconds Seconds after motor startup
during which underload is
ignored. Best practice is to set
this delay about the same as the
Drive Acceleration Time.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 115 of 277
 Table 27: Motor Underload Menu Common Installations (cont'd.)

Parameter Default Description

Trip Delay 30.0 Seconds Time to tolerate an underload
situation when the drive is
running. Set this time as long
as possible without causing heat
damage to the motor.
Restarts/Allowed 0 Set to non-zero to allow for
automatic restarts on a Motor
Underload fault.
Restart Delay Global Restart Delay between the fault and an
automatic restart.
ULoad@Min Freq 0 Amps Defines an enhanced motor
protection mode in which the
underload limit is ramped up
from the ULoad@Min Freq to
the Motor Underload value at
Max Frequency. Setting this
parameter to 0 Amps (default
value) disables the enhanced
Underload protection mode (the
underload threshold the same at
all frequencies).

Navigate between pages of the menu by pressing the Left Arrow and Right Arrow buttons. The second
screen of menu is shown in Figure 89: Underload Menu-Screen 2, page 117. Changes on this page would
be very rare.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 116 of 277
 Figure 89: Underload Menu-Screen 2

The Apollo underload detection is not a simple threshold/trip delay trigger. It is actually formed by a
combination of the Pre-Trigger and the actual Underload trigger. Apollo shuts down the motor on underload
to prevent motor overheating (low load implies insufficient fluid movement past motor for cooling). A simple
threshold to detect underload would fail to protect the motor in the following condition.

If the load occasionally bumps above the threshold, even for a fraction of a second, the trip delay
timer will be reset. In effect, the motor can be run in an underload condition indefinitely without
stopping-as long as there are occasional bumps above the underload threshold!
In Apollo, the underload pre-trigger is used as the input for the underload trigger. The underload pre-trigger
filters the motor current data to ensure that momentary bumps of the current above the underload threshold
do not cause the underload trip delay timer to restart. Underload Pre-Trigger default operation is as follows:
• The Enable Timer is set for 10 seconds – the underload pre-trigger cannot activate until the drive has
been running for at least 10 seconds.
• The Set Trip Delay is set for 5 seconds – the underload pre-trigger cannot activate until the motor current
has dropped below the motor underload threshold for at least 5 seconds.
• The Clear Delay is set for 10 seconds – here’s where the underload pre-trigger does its magic. The
underload pre-trigger will not clear unless the output current of the drive is above the motor underload
threshold for at least 10 seconds. Thus, the underload trigger does not see short bumps in the drive
output current – only those long enough to allow the underload pre-trigger to clear.
The purpose of the underload pre-trigger is to avoid the problem with a simple threshold.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 117 of 277
 Table 28: Underload Menu #2 Common Installations

Parameter Default Description

U-Load PreTrig None U-Load PreTrig is NOT a setting,
but the state of the Underload
Pre-trigger.
U-Load PreTrig Clear Delay 10 Seconds Time that the motor current must
exceed the underload limit to
clear the underload pre-trigger.
Set this value such that the
trigger filters out short bumps in
the motor current.
Underload None Underload is NOT a setting, but
the state of the Underload trigger.
Underload Limit None This is the underload limit based
on the output frequency and is
presented here for reference only.
To set the Motor Underload value
go to the first page of this menu.

Select any parameter that needs to be changed and make the necessary changes. Press the Save function
button. Acknowledge the confirmation screen by pressing the Yes function button. Press the Exit function
button to return the Motor Overload menu.
When all the necessary changes have been made, press the Exit function button to return to the Main Menu.

4.9 Configure Downhole Limits

Use the Downhole Limits menu to configure parameters associated with downhole tool shutdowns. Select
Downhole Limits from the Main Menu. The first page of the Downhole Limits menu is shown in Figure 90:
Downhole Limits Menu, page 119. This page contains the parameters that are most often changed in
common installations.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 118 of 277
 Figure 90: Downhole Limits Menu

Select a trigger to access its Trigger Info screen. Then adjust the trigger’s limit and make any other
changes needed. By default, all of the triggers are Not In Use. When you set a limit value, the trigger will
be automatically set to In Use.
Example: Selecting Motor Temp High yields the Trigger Info screen shown in Figure 91: Trigger Info Screen
, page 119.

Figure 91: Trigger Info Screen

In this example we select the Limit and change it to 220°F.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 119 of 277
 Figure 92: 220°F Example

Pressing Save yields the Save change? prompt.

Figure 93: Save Change Screen

The trigger is automatically set to In Use. The screenshot below shows the result of the change. Note that
the trigger state indicates the trigger is currently Clear and the trigger limit is set to 220.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 120 of 277
 Figure 94: Downhole Limits Screen

Table 29: Download Limits Common Installations

Parameter Default Description

Motor Temp High Not in Use The motor temperature high
trigger is a Stop->Fault trigger
used to protect the motor. Select
Motor Temp High to set the limit.
Set the Trip Delay and Restart
parameters as desired.
Intake Temp High Not In Use The intake temperature high
trigger is a Stop->Fault trigger
used to protect the motor. Select
Intake Temp High to set the limit.
Set the Trip Delay and Restart
parameters as desired

Copyright 2020 Baker Hughes Company. All rights reserved. Page 121 of 277
 Table 29: Download Limits Common Installations (cont'd.)

Parameter Default Description

IntakePressLow Not In Use The Intake Pressure Low trigger is
a Stop->Fault trigger used to stop
the drive when the intake pressure
drops below a programmed level.
Select IntakePressLow to set
the limit. Set the Trip Delay and
Restart parameters as desired.
Note: The “IntakePressStopStart”
wizard sets up the system to
STOP on low Intake Pressure and
RESTART when Intake Pressure
has recovered.
IntakePressHigh Not In Use The Intake Pressure High trigger
is a Stop->Fault trigger used
to stop the drive if the intake
pressure exceeds a programmed
limit. Select IntakePressHigh
to set the limit. Set the Trip
Delay and Restart parameters as
desired.
D/H VibrationHi Not In Use The Downhole Vibration High
trigger is a Stop->Fault trigger
used to protect the motor. Select
D/H VibrationHi to set the limit.
Set the Trip Delay and Restart
parameters as desired.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 122 of 277
 Table 29: Download Limits Common Installations (cont'd.)

Parameter Default Description

Leakage High Not In Use The Leakage High trigger is
a Stop->Fault trigger used to
protect the motor. Select Leakage
High to set the limit. Set the Trip
Delay and Restart parameters as
desired.
DH Data Invalid DH Data Invalid is a Log Only
trigger used to monitor the validity
of the downhole data. Select DH
Data Invalid to access its Trigger
Info screen. If you wish to shut
down the drive if the downhole
data is invalid, change the Action
to Stop->Fault. After saving the
trigger as Stop->Fault, the restart
parameters will appear and
allow restarts to be configured, if
desired.

Navigate between pages of the menu by pressing the Left Arrow and Right Arrow buttons. The second page
of menu is shown in Figure 90: Downhole Limits Menu, page 119.

Figure 95: Download Limits-Screen 2

Copyright 2020 Baker Hughes Company. All rights reserved. Page 123 of 277
 Table 30: Download Limits #2 Common Installations

Parameter Default Description

Discharge High Not In Use The discharge pressure high
trigger is a Stop->Fault trigger
used to protect the system. Select
Discharge High to set the limit.
Set the Trip Delay and Restart
parameters as desired.
Discharge Low Not In Use The discharge pressure low
trigger is a Stop->Fault trigger
used to protect the system. Select
Discharge Low to set the limit.
Set the Trip Delay and Restart
parameters as desired.
DeltaPressHigh Not In Use The delta pressure high trigger
is a Stop->Fault trigger used
to protect the system. Delta
pressure is the differential
pressure across the pump
(Discharge Pressure – Intake
Pressure). Select DeltaPressHigh
to set the limit. Set the Trip Delay
and Restart parameters as
desired.
DeltaPress Low Not In Use The delta pressure low trigger is a
Stop->Fault trigger used to protect
the system. Delta pressure is
the differential pressure across
the pump (Discharge Pressure
– Intake Pressure). Select
DeltaPress Low to set the limit.
Set the Trip Delay and Restart
parameters as desired.

Select any trigger you wish to adjust and make the necessary changes. Press the Save function button.
Acknowledge the confirmation screen by pressing the Yes function button. Press the Exit function button
to return the Downhole Limits menu.
When all the necessary changes have been made, press the Exit function button to return to the Main Menu.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 124 of 277
 4.10 Enable Autostart

By default, the ManualStartOnly parameter is set to True. The only way to start the drive when
ManualStartOnly is True is by pressing the Start button on the keypad. Change ManualStartOnly to False if
the drive should start under any other conditions. ManualStartOnly should be set to False in most systems.

Figure 96: Selecting ManualStartOnly

Table 31:

Parameter Description
ManualStartOnly Options:
True (default): The drive can only be started by
pressing the Start button on the keypad.
False: The drive can be started from the Start button
on the keypad, a SCADA command, a fault restart,
a power up autostart, or a Start Motor trigger.

Setting ManualStartOnly to false can initiate an automatic start without warning and may
cause equipment damage, injury to personnel or death.

4.11 Adjust Setpoint

The System Setpoint is Drive Mode dependent and is used to adjust the drive output frequency. Access the
Setpoint by pressing the Home function button on the Main Menu screen and then pressing the Settings
function button.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 125 of 277
 In the example shown in Figure 97: Frequency Setpoint Screen, page 126, the drive is in Manual Frequency
mode so the Frequency Setpoint is displayed.

Figure 97: Frequency Setpoint Screen

Use the left and right arrow buttons to select a digit. Use the up and down arrow buttons to change the
selected digit.

The selected digit is just to the right of the insert in the field. By default, the right most digit is
selected.
The basic setup is now complete.

5 Additional Setups
5.1 Add I/O Board

Execute the Add 1st IO board wizard to enable Apollo to use the Apollo I/O board. To execute the wizard,
from the Home Screen select
Settings -> Menu -> Other Initial Setup -> Next Page (Right Arrow) -> Add 1st IO board.
Follow the on-screen directions.
Information needed by the Add 1st IO board wizard:
• Are you connecting PTs or CTs to monitor AC Voltage and current?
– The answer will be no in most VSD applications. If you do wish to add PTs or CTs, you will be prompted
for the ratios.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 126 of 277
 • Are you connecting Backspin probes?
– The answer will be no in most applications.
When the wizard is complete, the I/O board analog inputs (Analog Opt 1 – Analog Opt 8) and digital I/O
(EIO Dig Opt 1 – EIO Dig Opt 12) will appear in the Analogs and Digital IO screens. From the Home
Screen select Data -> Analogs or Digital IO

5.2 Setup a Downhole Tool

The Standard template has an Osiris downhole tool pre-configured. To adjust the Osiris Modbus address,
Communication port, or to select a different downhole tool, navigate to Settings -> Menu -> Other Initial
Setup -> Setup DH Tool.
The DH Tool menu is displayed in Figure 98: DH Tool Menu, page 127.

Figure 98: DH Tool Menu

To change Osiris settings, choose any of the parameters shown in Figure 98: DH Tool Menu, page 127. To
select a different downhole tool, run the Select Down Hole Tool wizard. This wizard is also used to select
different engineering units for downhole pressure and temperature readings. If you have no downhole tool,
this wizard can be used to remove downhole tool channels and screens.
Information needed by the Select Down Hole Tool wizard:
• Tool to use, current choices include Zenith E, Osiris-Smartguard, GRC Scout 3000, Centinel and No
Downhole Tool.
• Units for pressure channels, current choices include PSI, Bar, kPa, MPa.
• Units for temperature channels, current choices include DegF, DegC.
• Surface Panel or I/O board only (Zenith E only)

Copyright 2020 Baker Hughes Company. All rights reserved. Page 127 of 277
 • Communication Port
The Apollo Serial Communication Ports are summarized in Table 32: Apollo Serial Communication Ports,
page 128:

Table 32: Apollo Serial Communication Ports

Comm Port Normal Use Notes

Com2 SCADA Normally RS-232.
Can use as RS-485 with
Expansion Port Module RS-485
(P/N 800638)
Com3 Apollo I/O and Osiris RS-485.
Typically runs at 115KBaud.
Com4 VSD RS-485.
Shared use with other devices is
not recommended.
Com5 Not Used Requires USB to RS-232 Serial
converter (P/N 197349)

Table 33: Sensors

Sensor Communications Notes

Zenith E/Surface Panel RS-232 Com3 (RS-485) recommended if
no I/O board present.
RS-485
Com2 (RS-232) OK if not used
for SCADA.
Com5 (USB to RS-232 converter)
OK.
Zenith E/Interface only (ZIU) RS-232 Com2 (RS-232) recommended if
not used for SCADA.
Com3 (RS-485) with RS-485 to
RS-232 adapter
OK if no I/O board present.
COM5 (USB to RS-232 converter)
Ok.
Osiris/Smartguard RS-232 Always use COM3 at 115KBaud
(even with I/O board present).
RS-485

Copyright 2020 Baker Hughes Company. All rights reserved. Page 128 of 277
 Table 33: Sensors (cont'd.)

Sensor Communications Notes

GRC Scout 3000 RS-485 Com3 (RS-485) recommended if
no I/O board present.
Com2 (RS-485) OK if not used for
SCADA. Requires P/N 800638.
Centinel RS-485 Com3 (RS-485) recommended if
no I/O board present.
Com2 (RS-485) OK if not used
for SCADA.
Requires P/N 800638.

• Low Intake Pressure Limit: A low intake pressure limit may be set. Also note that the trigger action and
restart parameters may also be adjusted as necessary.
• Motor Temperature High Limit: A high motor temperature limit may be set. Also note that the restart
parameters may also be adjusted.
• Intake Temperature High Limit: A high motor temperature limit may be set. Also note that the restart
parameters may also be adjusted.
When the wizard is complete, the Apollo system will reboot.
Data for the downhole tool appears on the Downhole data screen. The navigation path is Home Screen
-> Data -> Downhole Sensor Screen.
To configure limits on the downhole parameters, navigate to Home Screen -> Settings -> Menu -> Downhole
Limits.

5.3 Install RSTi I/O Module

Execute the Install IO Module wizard to enable Apollo to use the RSTi I/O Module. To execute the wizard,
from the Home Screen select.
Settings -> Menu -> Other Initial Setup -> Next Page (Right Arrow) -> Install IO Module.
At this time, only the RSTi 8 RTD setup wizard is available. Contact product support if more than 8 RTD
channels are required.
Follow the on-screen directions.
Information needed by the Install IO Module wizard:
• Units (Degrees F or Degrees C) for the temperature channels.
When the wizard is complete, the RSTi I/O, RSTi temperature channels will appear on a new Data display
screen named Motor Temp.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 129 of 277
 Figure 99: Motor Temp Screen

To set up limits for a channel, use the up/down keys to select the desired channel. Use the left/right arrow
keys for previous/next page if required.

Figure 100: Setting Up Limits for a Channel

You may rename the channel from this screen if necessary.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 130 of 277
 Figure 101: Selecting a Trigger

Each channel has a warning trigger (trigger name has “Hot” appended to the channel name) and a fault
trigger (trigger name has “OH” (Over Heat) appended to the channel name). Warning triggers will keep
the drive from starting but will not stop the drive if it is already running (LOG->NO_START action). Fault
triggers will shut down a running drive (STOP->FAULT action). Select the trigger you wish to set up. By
default, the triggers are Not In Use.

Figure 102: Trigger Info Screen Indicating the Trigger is “Not In

Use”

Copyright 2020 Baker Hughes Company. All rights reserved. Page 131 of 277
 Adjust the limit as needed. The trigger will be set to “In Use” automatically.

Figure 103: Trigger Info Screen Indicating the Trigger with Limit Set to 250°F

5.4 Setup Analog Inputs

Analog inputs are configured using the Channel Info screens for the inputs. The navigation path is Home
Screen -> Data -> Analogs -> the desired analog to configure. Use the left/right arrow keys for previous/next
page.
The Channel Info screen for the first analog input on the drive module is shown in Figure 104: Channel
Information Screen, page 132.

Figure 104: Channel Information Screen

Copyright 2020 Baker Hughes Company. All rights reserved. Page 132 of 277
 Configure the analog input by setting the Offset (Engineering value to be displayed at 0 input) and the
Span (sensor range in Engineering units).
Set the channel’s name and units by pressing the Rename function button.

Figure 105: Edit Name Screen

When saved, Apollo will propose changing the name of any trigger connected to the channel to match the
channel name. Best practice is to allow the trigger names to be changed.

Figure 106: Trigger Name Change Screen

Copyright 2020 Baker Hughes Company. All rights reserved. Page 133 of 277
 The Channel Info screen for the configured analog input is shown in Figure 107: Channel Info Screen For
The Configured Analog Input, page 134.

Figure 107: Channel Info Screen For The Configured Analog Input

If necessary, the channel can also be calibrated. Press the Calibrate function button. The Calibration screen
is shown in Figure 108: Calibration Screen, page 134.

Figure 108: Calibration Screen

Enter the measured value and press the Calibrate function button.

Filtering can also be enabled to smooth out a noisy analog signal.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 134 of 277
 Figure 109: Calibration Screen- Screen 2

Press Exit to return to the Channel Info screen. The Channel Info screen for the configured and calibrated
channel is shown in Figure 110: Channel Info Screen, page 135.

Figure 110: Channel Info Screen

It is very easy to access the Trigger Info screen for any triggers connected to this channel. Simply Highlight
the trigger name and press the Select function button.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 135 of 277
 Figure 111: Highlight the Trigger Name

Figure 112: Trigger Info Screen

Copyright 2020 Baker Hughes Company. All rights reserved. Page 136 of 277
 Change the trigger parameters as needed to fulfill the needs of the application. Note that triggers attached
to analog inputs are “Not In Use” by default. When you change any trigger settings the trigger will be
set to “IN USE” automatically.

Figure 113: Changing the Trigger Parameters

The resulting Trigger Info screen is shown in Figure 114: Resulting Trigger Info Screen, page 137.

Figure 114: Resulting Trigger Info Screen

Copyright 2020 Baker Hughes Company. All rights reserved. Page 137 of 277
 5.5 Setup Digital Inputs

Digital Inputs are configured using the Channel Info screens for the inputs. The navigation path is Home
Screen -> Data -> Digital I/O -> the desired I/O to configure.
The Channel Info screen for the first digital I/O on the Apollo I/O board is shown in Figure 115: Channel Info
Screen for 1st Digital I/O on the Apollo I/O Board, page 138.

Figure 115: Channel Info Screen for 1st Digital I/O on the Apollo I/O Board

Digital Inputs on the drive module (V7Dig In x) are input only. Digital I/O on the Apollo I/O board can be
configured as either inputs or outputs. Note that the correct relay/input module must be installed in the I/O
board. Digital Outputs are configured when they are attached to a trigger. See Section 5.21 Add a Digital
Output to a Trigger, page 182 for discussion on setting up digital outputs.
Digital inputs are Normally Open by default and are connected to a Stop->Fault trigger. This allows Apollo to
run without adding any jumpers across unused digital inputs. Most field sensors are normally closed and
then open to report a fault. Configure the N.O./N.C. as needed and rename the channel (and connected
trigger) as in the Section 5.4 Setup Analog Inputs, page 132.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 138 of 277
 Figure 116: Murphy Switch Trigger-Example 1

Copyright 2020 Baker Hughes Company. All rights reserved. Page 139 of 277
 It is very easy to access the Trigger Info screen for the trigger connected to this channel. Simply Highlight
the trigger name and press the Select function button.

Figure 117: Murphy Switch Trigger-Example #2

Change the trigger parameters as needed to fulfill the needs of the application.

5.6 Setup Drive Mode

Navigate to the Set Drive Mode menu (in the Main Menu). A screenshot is shown in Figure 118: Set Drive
Mode Menu, page 139 . The Drive Mode can be set from this menu or any of the specific mode submenus.
Use the Right and Left Arrow buttons to view both pages of the Set Drive Mode menu.

Figure 118: Set Drive Mode Menu

Copyright 2020 Baker Hughes Company. All rights reserved. Page 140 of 277
 Drive Mode include:

Table 34: Drive Mode Menu

Mode Description
ManualFrequency Manual Frequency Control Mode. Control mode in
which the drive runs at a programmable speed.
CurrentControl Current Control Mode. Control mode in which the
drive speed is automatically varied in an attempt to
provide a fixed output current.
PID Speed Ctrl PID Speed Control Mode. Control mode in which
the drive speed is automatically varied in an attempt
to keep a system parameter (referred to as the
control parameter) at a specified level.
Analog Follower Analog Follower Control Mode. Control mode in
which the drive speed is based on a scaled analog
input.

Figure 119: Drive Mode Menu-Screen 2

Copyright 2020 Baker Hughes Company. All rights reserved. Page 141 of 277
 Table 35: Drive Mode Menu #2

Parameter Description
Rock Start Rock Start is a feature used with hard starting
pumps. If Rock Start is set to On, the motor will
rock back and forth based on the RockStartCycles
and the RockStart Time parameters. This rocking
occurs while the drive is in the Starting state.
After the defined cycles and the output frequency
reaches the Start Frequency, the system enters
Running mode.
RockStartCycles The number of rock cycles to perform. Each cycle
consists of rocking backward and then forward.
RockStart Time The rock start cycle time is the time to complete 1
rock start cycle, including both the backward and
the forward motion.
Rock StartCount Current rock start cycle in progress. This is NOT a
parameter to be edited. It is a channel included on
this screen for information purposes.
Setup Rock Start Enable By default, the drive performs the rock start on
every startup when Rock Start Mode is enabled.
Selecting Setup Rock Start Enable allows the
operator to set the limit of the RockStartEnable
trigger. Rock Start will only occur when this trigger
is set during the Starting state. A default value of
0A ensures that Rock Start occurs on every motor
start. Increasing this limit results in rocking starts
ONLY if the Downhole Amps exceeds the limit
during the Starting State. Note that if Rock Starts
are initiated, the full number of RockStartCycles will
complete even if the downhole amps drops below
the specified limit.
Ramp 1 Speed Frequency Ramps are available only in Manual
Frequency Mode and only after the drive has
reached the Start Frequency and transitioned to
one of the Run Modes. A frequency ramp allows for
a slow fixed rate ramp when the drive frequency
setpoint changes. This ramp is only invoked when
the Ramp 1 Enable trigger is set. Note that the
ramp time is in minutes per Hertz.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 142 of 277
 Table 35: Drive Mode Menu #2 (cont'd.)

Parameter Description
Ramp 1 Enable Trigger to control the Ramp 1 Speed. Edit this
trigger to be active when the ramp should take
effect. By default , the trigger is “Not In Use”, “Active
when Enabled”, and “Enabled only in Run Mode 1”.
To enable the ramp feature, select the Ramp Enable
Trigger and from the Trigger Info screen, press
F3 “On/Off” to activate the trigger. This is all that
is required to enable ramping during every speed
change. More selective enabling of the ramp can
be done by re-configuring the Ramp Enable trigger.
Ramp 2 Speed Frequency Ramps are available only in Manual
Frequency Mode and only after the drive has
reached the Start Frequency and transitioned to
one of the Run Modes. A frequency ramp allows for
a slow fixed rate ramp when the drive frequency
setpoint changes. This ramp is only invoked when
the Ramp 2 Enable trigger is set. Note that the
ramp time is in minutes per Hertz.
Ramp 2 Enable Trigger to control the Ramp 2 Speed. Edit this
trigger to be active when the ramp should take
effect. By default , the trigger is “Not In Use”, “Active
when Enabled”, and “Enabled only in Run Mode 2”.
See Ramp 1 Enable for details on how to enable
the ramp feature.

5.6.1 Manual Frequency Mode

Control mode in which the drive runs at a programmable speed.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 143 of 277
 Figure 120: Frequency Mode Screen

Table 36: Frequency Mode Parameters

Parameter Description
Drive Mode See Table 34: Drive Mode Menu, page 140.
Start Frequency The initial drive frequency setpoint used
when the drive is started. The drive stays in
the Starting state until the start frequency is
achieved, and then transitions to the Running
state and is commanded to the Freq. Setpoint
for the running state. If an enable delay
is configured for a trigger, the delay does
not start until the drive reaches the Start
Frequency.
Freq Setpoint The drive frequency setpoint when the drive
is in the normal Running mode. Note that
triggers can be used to transition the drive
between the normal running mode and the
alternate running modes “Run Mode 2” and
“Run Mode 3”.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 144 of 277
 Table 36: Frequency Mode Parameters (cont'd.)

Parameter Description
Freq Setpoint2 The drive frequency setpoint when the drive
is in the alternate run mode “Run Mode 2”.
Note that triggers can be used to transition
the drive between the normal running mode
and the alternate running modes “Run Mode
2” and “Run Mode 3”.
Freq Setpoint3 The drive frequency setpoint when the drive
is in the alternate run mode “Run Mode 3”.
Note that triggers can be used to transition
the drive between the normal running mode
and the alternate running modes “Run Mode
2” and “Run Mode 3”.

5.6.2 Current Control Mode

Control mode in which the drive speed is varied in an attempt to provide a fixed output current.
Current Control is sometimes used in gassy wells – when a pump encounters a gas pocket, the
load will be reduced, and the output current of the drive will drop. The drive will speed up in an
attempt to clear the gas pocket from the pump. If the gas pocket clears, the load will return, and
the drive speed will slow back to the speed needed to maintain the specified current setpoint.

Figure 121: Current Control Mode Screen

Copyright 2020 Baker Hughes Company. All rights reserved. Page 145 of 277
 Table 37: Current Control Mode Parameters

Parameter Description
Drive Mode See Table 34: Drive Mode Menu, page 140.
iMode Setpoint The desired Amps. The drive speed is varied
to try to keep the Source1 value (Downhole
Amps by default) at this level.
iMode PID ‘P’ The Proportional Gain used by the
Proportional Integral Derivative (PID) control
loop used to control the drive speed. This
parameter can be changed to tune the PID for
optimal performance.
iMode PID ‘I’ The Integral Gain used by the Proportional
Integral Derivative (PID) control loop used
to control the drive speed. This parameter
can be changed to tune the PID for optimal
performance.
iMode PID ROC PID Rate Of Change (ROC) limits how fast
the PID will change. ROC is the amount of
time it takes the PID to ramp from the drive
Min Frequency to the drive Max Frequency.
iMode Rev.Act This should be set to “False” for current
control. This parameter describes the PID’s
output relationship to the control value. A PID
is forward acting if increasing the speed of the
drive increases the control value (i.e. running
the drive faster creates more downhole
current). A PID is reverse acting if increasing
the speed of the drive decreases the control
value (i.e. running the drive faster decreases
the fluid level in a tank that is being pumped
out of).
Change only if you change the Source1
channel to a channel that acts in reverse from
the pump speed.
iModeUpdateRate Run period for the PID loop. Best practice is
to keep at the same rate as the control value
(Source1) is updated. The drive is polled
every 200 ms (and Downhole Amps is derived
from the drive output current). Change only if
the Source1 channel is changed to a device
that is polled at a different rate.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 146 of 277
 Table 37: Current Control Mode Parameters (cont'd.)

Parameter Description
Source1 The channel supplying the current to compare
against the iMode Setpoint. By default, this
is the Downhole Amps and need not be
changed.
Low Clamp Minimum drive speed that the PID control will
output. Leave at the default 0 to use Manual
Param 058 Min Frequency. Note that the
drive speed will never be commanded lower
than 058 Min. Frequency.
High Clamp Maximum drive speed that the PID control will
output. Leave at the default 0 to use Manual
Parameter 059 Max Frequency. Note that the
drive speed will never be commanded higher
than 059 Max Frequency.

5.6.3 PID Speed Control Module

Control mode in which the drive speed is varied in an attempt to keep a system parameter
(referred to as the control parameter) at a specified level.
Common control parameters include:
• Pump Intake Pressure (ESP system)
• Tank Level (SPS system)

Copyright 2020 Baker Hughes Company. All rights reserved. Page 147 of 277
 Figure 122: PID Speed Control Mode-Screen 1

Figure 123: PID Speed Control Mode-Screen 2

Copyright 2020 Baker Hughes Company. All rights reserved. Page 148 of 277
 Figure 124: PID Speed Control Mode-Screen 3

Table 38: PID Speed Control Mode Parameters

Parameter Description
Drive Mode See Table 34: Drive Mode Menu, page 140.
Setpoint The desired value of the control channel
Source1. The drive speed is varied to try
to keep the Source1 value at this level. By
default, Source1 is the downhole tool Intake
Pressure channel.
Setup Pump Speed PID Runs a configuration wizard to walk the user
through setting up a Proportional Integral
Differential (PID) control loop.
Mtr Spd PID ‘P’ The Proportional Gain used by the
Proportional Integral Derivative (PID) control
loop used to control the drive speed. This
parameter can be changed to tune the PID for
optimal performance.
Mtr Spd PID ‘I’ The Integral Gain used by the Proportional
Integral Derivative (PID) control loop used
to control the drive speed. This parameter
can be changed to tune the PID for optimal
performance.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 149 of 277
 Table 38: PID Speed Control Mode Parameters (cont'd.)

Parameter Description
Source1 The channel supplying the current to compare
against the Setpoint. By default, this is the
downhole tool Intake Pressure channel.
Pump Speed Ctrl Speed control output (i.e. drive frequency
commanded by Apollo at this time). It will
reflect the PID output if 055 Drive Mode
is “PID Speed Ctrl” and Trigger 159 “Run
SpdCtrl PID” is SET. This is NOT a
parameter to be edited. It is a channel
(Chan 076 Pump Speed Ctrl) included on
this screen for information purposes.
Run SpdCtrl PID Trigger 159 “Run SpdCtrl PID” is used to
control when the PID should be run if M055
Drive Mode is set to PID. If T159 is CLEAR,
(not SET), the PID will not be run and the
Manual Frequency setting for the current
system mode will be used as the output.
Select this trigger to access its Trigger Info
screen to adjust as needed. By default, the
PID will be run whenever the drive is running
and has reached the Start Frequency.
Low Clamp Minimum drive speed that the PID control will
output. Leave at the default 0 to use the drive
Minimum Frequency.
High Clamp Maximum drive speed that the PID control will
output. Leave at the default 0 to use the drive
Maximum Frequency.
Mtr PID Rev.Act Parameter that describes the PID’s output
relationship to the control value. A PID is
forward acting if increasing the speed of the
drive increases the control value (i.e. running
the drive faster creates more downhole
current). A PID is reverse acting if increasing
the speed of the drive decreases the control
value (i.e. running the drive faster decreases
the fluid level in a tank that is being pumped
out of). Change as needed to match the
relationship between the pump speed and the
Source1 variable.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 150 of 277
 Table 38: PID Speed Control Mode Parameters (cont'd.)

Parameter Description
Mtr PIDUpdate Run period for the PID loop. Best practice
is to keep at the same rate as the control
value (Source1) is updated. The downhole
tool is polled every 5 seconds, and the
Intake Pressure is read from the downhole
tool. Change only if the Source1 channel
is changed to a device that is polled at a
different rate.
Mtr PID ROC PID Rate Of Change (ROC) limits how fast the
PID output will change. ROC is the amount of
time it takes the PID to ramp from 0 Hz to the
drive Max Frequency.
Mtr Spd PID ‘D’ The Derivative Gain used by the Proportional
Integral Derivative (PID) control loop used
to control the drive speed. This parameter
can be changed to tune the PID for optimal
performance. It is usually recommended to
leave the ‘D’ gain at 0.

5.6.4 Analog Follower Mode

Control mode in which the drive speed is based on a scaled analog input. Analog Follower mode
is often used in situations in which another controller, such as a PLC, dictates the speed at which
the drive should run using an analog signal.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 151 of 277
 Figure 125: Analog Follower Mode Screen

Table 39: Analog Follow Mode Parameters

Parameter Description
Drive Mode See Table 34: Drive Mode Menu, page 140.
Follower Src Analog input that the drive speed should
follow.
Setup Analog Follower Mode Runs a configuration wizard to walk the user
through setting up the Analog Follower mode.

The Analog Follower mode frequency is controlled by the Follower Source channel. Select the
Follower Src to access its Channel Info screen. Edit the channel to reflect the drive speed
required. For example, the screenshot below shows V7 Analog 2 set up to run the drive between
45 Hz (at 4mA input) and 70 Hz (at 20mA input). The channel value (57.25 Hz in Figure 126:
Follower Src Channel Info Screen, page 152 ) is the speed command to the drive.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 152 of 277
 Figure 126: Follower Src Channel Info Screen

5.7 Setup Restarts

Auto-restart capability is integral to well control systems. In Apollo, restarts can be enabled/disabled
individually for any trigger. Key elements in Apollo’s support for restarts are described in Table 40: Setup
Restart , page 153.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 153 of 277
 Table 40: Setup Restart

Name Location Description

ManualStartOnly Home Screen -> ManualStartOnly is a global
restart enable.
Settings ->
ManualStartOnly = True
Menu ->
• Drive can only be started by
ManualStartOnly pressing the Start button on the
keypad.
ManualStartOnly = False
• Drive can be started by the
keypad Start button, SCADA
start commands, Autostart on
Power Up, and restarts from
any trigger.
Global Restart Home Screen -> By default, all triggers have their
Restart delay set to the Global
Settings -> Restart Time. Best practice is to
Menu -> set the Global Restart time to the
normal restart time on the drive
Other Initial Setup -> (for an ESP system, this is likely
Global Restart the fluid fallback – backspin time).

Restarts/Allowed Trigger Info Screen Every Stop trigger can be set to

allow restarts. Restarts/Allowed
is shown as x/y on the trigger
info screen. The y is the number
of restarts allowed. X is the
number of restarts that have been
attempted. Setting the allowed
restart to 0 disables restarts for
that trigger.
By default, all triggers have 0
allowed restarts.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 154 of 277
 Table 40: Setup Restart (cont'd.)

Name Location Description

Restart Delay Trigger Info Screen Every Stop trigger has a Restart
Delay. By default, the Restart
Delay is the Global Restart
Delay designated by the G in the
parameter value.
Change the restart value as
required by the application. When
the restart value is changed, the
user will be asked if the global
value should also be changed
or just the restart delay for this
trigger.
Set a trigger’s Restart Delay to 0
to use the Global Restart Timer.
StrtCounterRst Home Screen -> Restart Counter Clear Time.
After the drive has run for the
Settings -> StrtCounterRst time, all triggers’
Menu -> restart counts are reset to 0.

Other Initial Setup -> Default value is 60 minutes.

General Restart Params

ProgRstDelay Home Screen -> Progressive Restart Delay Time.
This time is added to a trigger’s
Settings -> restart delay each time the fault
Menu -> is repeated.

Other Initial Setup -> Default value is 0 minutes.

General Restart Params

Copyright 2020 Baker Hughes Company. All rights reserved. Page 155 of 277
 Table 40: Setup Restart (cont'd.)

Name Location Description

WaitRestrtTimer Home Screen -> When set to true, manual restarts
(after any fault occurs) will be
Settings -> held off until the fault’s restart
Menu -> timer has counted down. If
the ManualStartOnly (M 014)
Other Initial Setup -> parameter is true, pressing the
General Restart Params start button will advance the state
machine to Ready-Manual but the
drive will not start until the start
button is pressed again after the
restart timer has expired. If the
ManualStartOnly parameter is
false, pressing the start button will
clear the lockout and the drive will
enter the Restart Timer state and
will restart after the countdown.
Default value is False.
LocalLokOutClr Home Screen -> Set to True to allow a local lockout
to be cleared by SCADA or
Settings -> Remote.
Menu -> Default Value is True.
Other Initial Setup ->
General Restart Params
RemoteLokoutClr Home Screen -> Set to True to allow a Remote
Lockout to be cleared by local
Settings -> controls.
Menu -> Default Value is True.
Other Initial Setup ->
General Restart Params

5.8 Communication Parameters

Communications parameters determine how the Apollo Well Control System communicates with the other
hardware in the system. Navigate to the Communication Parameters by Home Screen -> Settings -> Menu
-> Right Arrow -> Right Arrow -> Communication Params.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 156 of 277
 Figure 127: Communication Parameters Menu-Screen 1

The second screen of the Communication Parameters menu is shown in Figure 128: Communication
Parameters Menu-Screen 2, page 156.

Figure 128: Communication Parameters Menu-Screen 2

Communication interfaces available are RS-232 and RS-485 Serial ports and Ethernet network ports.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 157 of 277
 Table 41: Serial Communication Ports

Port Standard Use Notes

Com1 Reserved Cannot be assigned.
Com2 RS-232/RS-485 By default, Com2 is RS-232. Can
be used as RS-485 by installing
SCADA P/N 800638, Expansion Port
(Master Port) Module RS-485.
Can be reassigned for use with
another vendor’s downhole tool if
not used for SCADA.
Com3 RS-485 Can be reassigned for use with
another vendor’s downhole tool if
Apollo I/O board and Osiris the Apollo I/O and Osiris are not
Downhole Tool
used in the system.
(Slave Port)
Com4 RS-485 Dedicated for drive
communications. Do not
Drive Communications reassign.
(Slave Port)
Com5 RS-232 Requires USB to RS-232 adapter,
S/N 197349. Can be used for
SCADA or communications with
another vendor’s downhole tool.
Com6 Reserved Please do not assign.

Serial ports are configured as either Master ports or Slave ports based on their function. Slave ports are
used to poll slave devices, like the Apollo I/O board and the Osiris downhole tool. The configuration screen
for a port configured as a Slave port is shown in Figure 129: Port Configured-Screen 1, page 158. This
is the default configuration for Com3.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 158 of 277
 Figure 129: Port Configured-Screen 1

Com3 would need to be configured if the Apollo I/O board and Osiris surface sensor were not used
and another vendor’s downhole tool was being used. Set the communications parameters to match the
downhole tool to be used.

Figure 130: Port Configured-Screen 2

Com2 might need to be configured to connect Apollo to a serial SCADA system. Set the Modbus Address
as specified by the SCADA host. Set the communication parameters to match the SCADA requirements.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 159 of 277
 If the port type (Master/Slave) is changed, the system will need to be power cycled before the
change takes effect. Other changes do not require a restart.
Serial Slaves in the system include the drive, the Apollo I/O board (EIO), the RSTi Expansion I/O Module
and the downhole tool. The Drive Port and the EIO port setups should not be changed. The downhole tool
setup should not be changed unless another vendor’s tool is used.
Modbus Maps
The Apollo Modbus map can be customized using the Install Modbus Map function. Please see the Vector
Plus/Apollo Communication Manual, UM-00014, for more details. This is the default configuration for Com3.
Network Ports
2 network ports are available on the Apollo controller board. The standard wired Ethernet port is configured
using the IP Address, DHCP Enable, and Default Gateway parameters. These parameters should be
configured as necessary for the attached networking equipment. The second interface is a USB to Wireless
connection requiring USB to WIFI Adapter P/N 197350 and is configured using the parameters USB IP
Address and USB DHCP Enable. The USB parameters should not require adjustment.
The wired Ethernet connection is most often used in conjunction with a cellular or satellite modem to provide
SCADA and/or Remote User Interface connections. The WIFI is most often used for on-site monitoring
and control using the Remote User Interface. Please see the Vector Plus/Apollo Communication Manual,
UM-00014, for more details.

5.9 Control Source

The Control Source parameter controls where the Apollo system will accept Start and Speed Control
commands. Navigate to the Control Source by Home Screen -> Settings -> Menu -> Other Initial Setup ->
Right Arrow -> Control Source.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 160 of 277
 Figure 131: Control Source Screen

By default, Apollo will accept Start and speed control commands from both SCADA and the Apollo keypad.
Other options are SCADA Only and Keypad Only.

5.10 Pump Curve Setup

Execute the Pump Curve Setup wizard to configure the pump curve monitoring and control functionality of
Apollo.
Apollo’s Pump Curve Database contains information on hundreds of BH and competitor’s pumps. When
configured, up-thrust and down-thrust limit triggers can shut down the system and provide warnings when
the pump is operated out of or nearly out of the recommended operating range.
Apollo’s Pump Curve tracking also provides:
• Calculated flow.
• Calculated pump head
• Calculated pump power.

The pumping system must provide both Intake and Discharge pressure to Apollo for Pump Curve
monitoring to be used.
To execute the wizard, from the Home Screen select:
Settings -> Menu -> Other Initial Setup -> Next Page -> Pump Curve Setup.
Follow the on-screen directions.

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 Information needed by the Pump Curve Setup wizard:
• Units for Calculated Flow.
– Options are barrels per day (BBL/Day), cubic meters per day (m3/Day), and gallons per minute (GPM).
• Units for the Pump Head channel.
– Options are Feet and Meters
• Units for the Power channel.
– Options are Horsepower (HP) and kilowatts (kW).
• Units for Differential Pressure.
– Options are pounds per square inch (PSI), Bar, kiloPascals (kPa), megaPascals (MPa). These units
MUST MATCH the units used for Intake and Discharge pressure.
• Pump Manufacturer and Model
• Number of pump stages
• Pump Type
– Options are Floater, Compression, and SPS.
• Water Specific Gravity
– If you plan to use Viscosity Compensation, enter the specific gravity of the water in the Oil/Water
mixture being pumped.
– If you do not plan to use Viscosity Compensation, enter the specific gravity of the Oil/Water mixture.
• If Viscosity Compensation is used, you will also have to enter
– Water Cut
– Oil Specific Gravity
– Well fluid viscosity
◆ Options are Viscosity Compensation Disabled, Pump Curve Interpolation Method, Hydraulic Institute
Method.
– Flow Adjustment Factor
When the wizard is complete, the configuration parameters can be adjusted by navigating to Home Screen
-> Settings -> Menu -> Other Initial Setup -> Next Page -> Pump Curve Setup
The Pump Curve and Thrust Limits screens are available by navigating to Home Screen -> Data -> Pump
Curve Screen (or Thrust Limits Graph)
More details about pump curves are available in the Section 11: Pump Curves, page 241 of this manual.

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 5.11 PLC Analog Control

The PLC Analog Control wizard allows an external device to control motor speed with an analog signal
and optionally control motor start/stop using a digital input. Execute the PLC Analog Control wizard to put
Apollo into this “dumbed down” mode.
To execute the wizard, from the Home Screen select:
Settings -> Menu -> Other Initial Setup -> Next Page -> Next Page -> Configuration Wizards -> PLC Analog
Control. Note: If you just need start/stop control and don’t need analog speed control, select the 2-wire
RunStop wizard.
Follow the on-screen directions.
Information needed by the PLC Analog Control wizard:
• Analog Input to use for Speed Control:
– Options are V7 Analog 1, V7 Analog 2, EIO Analog Option 1, EIO Analog Option 2.
• Analog Input Offset (desired pump speed when input is 0V/4mA ).
• Analog Input Span (desired pump speed range,pump speed when input is 10V/20mA minus pump speed
when input is 0V/4mA. For example, (with a 4-20mA input) if the desired pump speed at 4mA is 30Hz and
the desired pump speed at 20mA is 65Hz, set the Offset to 30 Hz and the Span to 35Hz.
• You will be asked if want to use 2-Wire Stop/Start control. If you choose yes, the 2WireRunStop Wizard
will be executed from within the PLC Analog Control Wizard. See information on 2-wire Stop/Start Wizard
below.
This wizard changes the Drive Mode to “Analog Follower”. To restore local frequency control, change the
Drive Mode to “Manual Frequency” or any other Drive Mode. (Settings -> Menu ->Set Drive Mode->Drive
Mode). The Drive Mode setting does not affect operation of the 2-Wire Run/Stop feature.

5.12 2-Wire Run/Stop

2-Wire Run/Stop allows an external controller to control motor start/stop using a digital input. Execute the
2WireRunStop wizard to put Apollo into this “dumbed down” mode.
To execute the wizard, from the Home Screen select:
Settings -> Menu -> Other Initial Setup -> Next Page -> Next Page -> Configuration Wizards ->
2WireRunStop.
Follow the on-screen directions.
Information needed by the 2WireRunStop wizard:
• Digital Input used to Start and Stop the drive. Options are V7 Digital S1, V7 Digital S2, EIO Digital
Option 1, EIO Digital Option 2.
• Digital Input used to enable or disable Start/Stop control (optional). Options are HMI Dig In 1, HMI Dig
In 2, V7 Digital S3, V7 Digital S4, EIO Digital 3 and EIO Digital 4.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 163 of 277
 2 Wire Control is enabled or disabled using either a Manual Parameter or switch connected to another
Digital Input. Either the Manual Parameter or the Digital Input can manually override the 2-wire control so
that the drive can be started even when the Run signal is not present. This override will not affect PLC
Analog speed control.
When you are ready to start the drive under remote 2-wire control:
• Make sure Manual Parameter 014 ManualStartOnly is set to FALSE.
• Make sure the Digital Run/Stop signal is indicating RUN.
• Take the drive out of Locked Out by pressing the Start button 1 time.
• If the system goes to Ready, you must press the Start button again. When the system goes to Restart and
starts counting down, you can either wait for the countdown or press the start button again.
The drive will now start and stop based on the Run/Stop digital input. The procedure above will need to be
repeated If the system is manually stopped or a fault occurs (for which no restarts are programmed).

5.13 Drain Mode

When Drain Mode is active, the drive will run at Frequency Setpoint2 for a fixed amount of time before
transitioning to the standard Frequency Setpoint. The feature was originally intended to allow the drive to
run at a higher frequency for a time to quickly get the intake pressure down in the desired range. However,
the “drain” speed can be faster or slower than the standard setpoint.
To execute the wizard, from the Home Screen select
Settings -> Menu -> Other Initial Setup -> Next Page -> Next Page -> Configuration Wizards -> Next
Page -> DrainMode.
Follow the on-screen directions.
Information needed by the DrainMode wizard:
• Drain speed (Freq Setpoint2)
• Drain Complete Limit (the amount of time to run at Freq Setpoint2)
• Custom name for the drain activity. Note that the standard name is Run Mode 2, but the name can be
changed to better represent the function taking place, such as Draining.
When the wizard is complete, start the drive. The drive will accelerate and run at the Freq Setpoint2
frequency for the drain time with the drive state displaying the custom name and then transition to Running
at the standard frequency setpoint.
To disable Drain Mode, use the Advanced Triggers Config screen and disable the trigger named Drain Start.
To disable a trigger, navigate to the Trigger Info screen and press the On/Off function button.

5.14 PID Speed Control Mode

Control mode in which the drive speed is varied in an attempt to keep a system parameter (referred to as the
control parameter) at a specified level.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 164 of 277
 Common control parameters include:
• Pump Intake Pressure (ESP system)
• Tank Level (SPS system)
Setting up PID Speed Control Mode is aided by the Setup Pump Speed PID wizard. To execute the wizard,
from the Home Screen select
Settings -> Menu -> Set Drive Mode -> PID Control Mode -> Setup Pump Speed PID
Follow the on-screen directions.
Information needed by the Setup Pump Speed PID wizard:
• Control Parameter.
• Custom name for the setpoint.
• Minimum (Low Clamp) and Maximum (High Clamp) frequencies for the PID control. Leaving these
values at 0 will set the low and high clamp frequencies to the drive’s Min Frequency and Max Frequency,
respectively.

The low clamp is set by the “Offset” parameter and the high clamp is set by the “Span” parameter.
• PID Reverse Acting. A reverse acting PID is one in which the control variable with decrease when the
pump speed is increased. Pump Intake Pressure in an ESP system is an example of a reverse acting PID
(pump intake pressure should decrease as pump speed increases). Tank Level while pumping into a tank,
however, would be an example of a forward acting PID (tank level increases as pump speed increases).
• PID Update Time. The control variable is tested against the setpoint and the drive frequency is adjusted
on this time period. A 5 second period is recommended for slow moving signals such as signals from the
downhole sensor. A 1 second period is recommended for faster moving signals.
• Conditionally run the PID? The user can optionally set the PID to run only when specific conditions are
met. To use this option, set up T159 Run SpdCtrlPID trigger to be active when you want the PID to run.
When the trigger is CLEAR, the PID will not run and the motor speed is based on M028 Freq Setpoint. For
example, if you want the drive to run at a fixed speed for 2 minutes before using the PID, set the Trip
Delay for T159 to 120 seconds. At startup, the motor will go to the Start Frequency, then change to the
Manual Frequency for 120 seconds and then start using PID control. If you answer No at this step, the
PID will control motor speed as soon as it reaches the Start Frequency.
• Set system to Pump Speed Control Mode now? The Drive Mode can be changed to PID Speed Control
within the wizard, or it can be changed at any time from Settings -> Menu -> Set Drive Mode.
When the wizard is complete, the PID Control Mode menu will reappear. Set the Setpoint (label will be
based on what you set up in the wizard) to the desired control value.
If the Drive Mode wasn’t changed in the wizard, change it now to PID Speed Cntrl. Start the drive. The drive
speed will vary to try to make the control parameter match the setpoint.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 165 of 277
 Mtr Spd PID ‘P” and Mtr Spd PID “I” are the PID Loop proportional and integral constants. Adjust these
to tune the PID.

5.15 Add a 2nd IO Board

The Apollo Well Control System can support a second Apollo I/O board. A second I/O board system may
be needed in SPS Systems with lots of sensors.

Set Switch S2 position 1 to ON, position 2 to OFF on the second Apollo I/O board.
To execute the wizard, from the Home Screen select:
Settings -> Menu -> Other Initial Setup -> Right Arrow -> Right Arrow -> Configuration Wizards -> 2nd IO
Board
Follow the on-screen directions.
The 2nd IO Board wizard requires no information.
When the wizard is complete, the analog and digital I/O from the added Apollo I/O board will appear in the
Analogs and Digital IO Data Display screens. Analog options are denoted E2 Analog Option 1-8 and
digitals are denoted E2 Dig Opt 1-12.

These new channels can be added to a Data Display screen, if desired.

5.16 Edit a Screen

Apollo Data Display screens can be customized as needed by the application. Figure 132: How to
Customize–Screens 1, page 166 illustrates the process.
1. Log on as level 2 or level 3.
2. Navigate to the screen to be customized. In this example, we’ll customize the Home Screen.
3. Use the Down Arrow button to highlight the screen name.

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 Figure 132: How to Customize–Screens 1

4. Press the Select function button.

Figure 133: How to Customize–Screens 2

The screen in now in Edit mode.

5. Use the Up and Down Arrow buttons to select the field to change. In this example, we’ll replace the
downhole sensor Intake Temperature with the Tubing Pressure that is connected to the drive chassis
analog input 1.

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 Figure 134: How to Customize Screens–Screen 3

6. Press the Select function key to bring up the edit screen. Use the F1 and F5 function buttons to select
the object type or object field. Use the Up and Down Arrows to select the object you wish to display.
In our example, we wish to display the TubingPressure Channel.

Figure 135: How to Customize–Screens 4

7. Press the Save function button to exit back to the Home Screen.

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 Figure 136: How to Customize–Screens 5

8. Press the EndEdit function button to exit the screen edit mode.

Figure 137: How to Customize–Screens 6

The Home Screen has been customized to show the Tubing Pressure. If one needs to display several
channels, he may wish to add them to one of the Custom Screens that are included in the Data Display
screens.

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 5.17 Add a Data Display Screen to the Level 1 Data Screen Rotation

By default, the only Data Display screens in the Level 1 Data rotation are the Downhole Sensor screen, the
Digital I/O screen, the Analogs screen, and the Amp Chart screen. In some cases, it may be desirable for
other screens to be added to the Level 1 Data rotation.
1. Log on as level 2 or level 3.
2. Navigate to the Edit Screens Menu wizard.
a. Home Screen -> Settings -> Menu -> Other Initial Setup -> Right Arrow -> Right Arrow ->
Configuration Wizards -> Set Level1 Screens
3. A list of screens appears with a check mark next to each screen. A check mark indicates that the screen
is in the Level 1 Data Screens rotation. Use the Right and Left Arrow buttons to move between pages.
Use the Up and Down Arrow buttons to highlight the screen you wish to be in the Level 1 Data Screens
rotation. Use the check mark function button (F4) to set or clear the check boxes as desired.

Figure 138: Adding Screens to Level 1 Data Screen

4. In this example, the Custom Screen 1 has been checked so that it will be in the Level 1 Data Screen
rotation. Press Continue to finish the wizard.
The Custom Screen 1 will now appear in the Level 1 Data Screen rotation.

5.18 Add or Delete a Setting in the Settings Rotation

By default, the only Settings in the Level 1 settings rotation are the Speed Setpoint and the Color Scheme.
Level 2 and Level 3 users have access to more settings in the settings rotation. Level 2 and Level 3
users can add or remove parameters Settings rotation and control which are available to Level 1 users
using the Edit Settings wizard.
1. Log on as level 2 or level 3.

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 2. Navigate to the Edit Settings wizard
a. Home Screen -> Settings -> Menu -> Other Initial Setup -> Right Arrow -> Right Arrow ->
Configuration Wizards -> Edit Settings
3. A list of parameters appears. Use the Right and Left Arrow buttons to move between pages. Use the
Up and Down Arrow buttons to highlight a parameter or a blank line. Parameters BEFORE the first
blank line will be available to Level 1 users. Parameters after the first blank line will be available to
Level 2 and Level 3 users.

Figure 139: Edit Mode Screen

4. Only the Setpoint and the Color Scheme are available to Level 1 users by default. In this example, we
will add the motor underload limit to the Level 1 settings rotation. Highlight the FIRST blank line below
the parameters already assigned to the Level 1 rotation.

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 Figure 140: Add the Motor Underload Limit To The Level 1 Settings Rotation

5. Press the Select function button. The Object selection screen appears.

Figure 141: Object Selection Screen

6. The Motor Underload is a Manual Parameter. Use the F1 function button to highlight the leftmost field
on the screen and use the Up and Down Arrow buttons to change the field to Man. Val.

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 Figure 142: Add the Motor Underload Limit To The Level 1 Settings Rotation-Screen 2

7. Use the F5 function button to highlight the right field on the screen and use the Up and Down Arrow
buttons to change the field to Motor Underload.

Figure 143: Add the Motor Underload Limit To The Level 1 Settings Rotation-Screen 3

8. Press the Save function button. The Motor Underload setting now appears with the other parameters in
the Level 1 Settings rotation.

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 Figure 144: Add the Motor Underload Limit To The Level 1 Settings Rotation-Screen 4

9. Press the Continue function button to complete the wizard.

The Motor Underload parameter now appears in the Level 1 Settings rotation.

If you wish to add a parameter to the Settings rotation but have it only available to Level 2 and Level
3 users, use the procedure above but insert the parameter after at least one blank line. Likewise, if
you wish to prevent level 1 users from changing the freq. setpoint, you can delete it from the list.
To delete a setting from the list, use the wizard as described above and select the item to be deleted.
When the screen below is displayed, press F1 to select the selection box on the left and then press the
down-arrow and select “None”.

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 Figure 145: Add the Motor Underload Limit To The Level 1 Settings Rotation-Screen 5

5.19 Change the Drive State Automatic Screens

Automatic screens are displayed without user interaction when the drive changes states. By default, the
automatic screens are:

Table 42: Automatic Screens

Drive State Automatic Screens

Comms (with drive chassis) bad Home Screen
Locked Out Error Mode screen
Fault Error Mode screen
Ready Home Screen
Ready-Manual Home Screen
Restart Error Mode screen (shows countdown)
Prepare2Start Blank-No screen assigned
Starting Home Screen
Running Home Screen
Run Mode 2 Home Screen
Run Mode 3 Home Screen
Stopping Blank-No screen assigned

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 Some configuration wizards will change the automatic screens. For example, the SPS wizard will
change the Prepare2Start automatic screen from blank to a screen that displays the SPS startup
sequencing information.
Level 2 and Level 3 users can change the automatic screens using the Edit Mode Change Screens wizard.
1. Log on as level 2 or level 3.
2. Navigate to the Edit Mode Change Screens wizard.
a. Home Screen -> Settings -> Menu -> Other Initial Setup -> Right Arrow -> Right Arrow ->
Configuration Wizards -> Edit Mode Change Screens.

Figure 146: Edit Mode Change–Screen 1

3. Select the line associated with the drive state shown in the table above. In this example, the Running
automatic screen will be changed to the Pump Curve screen.

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 Figure 147: Pump Curve Screen Change–Screen 1

Figure 148: Select Object–Screen 1

4. Use the Up and Down Arrow buttons to select the desired screen.

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 Figure 149: Select Object–Screen 2

5. Press the Save function button.

Figure 150: Pump Curve Screen Change–Screen 2

6. Press the Continue function button to finish the wizard.

The Pump Curve screen will be displayed automatically when Apollo enters the Running state.

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 5.20 Add a Trigger to a Channel

Channels are real-time information collected and displayed by the system. Often, channels are based on a
system input that is scaled to engineering units. Triggers are used to make decisions based on channel
information. Many channels have triggers attached to them by default. View the triggers attached to a
channel on the Channel Info screen. Figure 151: Osiris Motor Temperature, page 178 is for the Osiris
Motor Temperature.

Figure 151: Osiris Motor Temperature

The pre-attached trigger is the Motor Temp High trigger. If the channel you need to set a limit on does not
have a pre-attached trigger or if you need to add another limit to a Channel. A trigger can be added to
the channel.
1. In this example, a High Temperature Warning trigger will be added to the Motor Temperature Channel
with a limit of 180°F. Use the Up and Down Arrow buttons to highlight the Add a Trigger option.

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 Figure 152: Add a High Temperature Warning Trigger

2. Press the Select function button. A screen appears asking if the limit is a Low Limit or a High Limit.

Figure 153: Low or High Limit Screen

3. In our example, we are creating a Temperature High Warning, so press the YES function button.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 180 of 277
 Figure 154: Temperature High Warning

4. In our example, the trigger is a warning. Use the Rename function to change the name to Motor Temp
High Warning (MtrTempHi Warn).

Figure 155: Final Trigger Info Screen

5. Select the Trigger Action and change it to Log->NoStart. Select the Limit and set it to 180 DegF. The
final Trigger Info screen is shown in Figure 156: Final Channel Info Screen , page 181.

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 Figure 156: Final Channel Info Screen

The final Channel Info screen for the Motor Temp channel is shown in Figure 157: Motor Temperature High
Warning Trigger , page 181.

Figure 157: Motor Temperature High Warning Trigger

The Motor Temp Hi Warning trigger is also displayed on the Channel Info screen.

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 5.21 Add a Digital Output to a Trigger

The Apollo system can be used to control relay activated external devices using digital outputs. This control
is accomplished by attaching the digital output to a trigger. Connecting the digital output to a trigger is
done via the Trigger Info screen.
In our example, we’ll connect the Motor Temperature High Warning trigger we created in Section 5.20 Add a
Trigger to a Channel, page 178 to the drive module digital output 2 (also referred to as M3-M4). The output
will be a Normally Open digital output that closes when the trigger is set. This relay could be used to turn
on an external lamp or trigger a callout.
1. Navigate to the Motor Temperature High Warning Trigger Info screen shown in Figure 158: Motor
Temperature High Warning Trigger–Screen 2, page 182.

Figure 158: Motor Temperature High Warning Trigger–Screen 2

2. Use the Up and Down Arrow buttons to highlight the Drive a Digital Output with this trigger option.

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 Figure 159: Highlight the Drive a Digital Output

3. Press the Select function button. Use the Up and Down Arrow buttons to select the M3-M4 output.

Figure 160: Select the M3–M4 Output

4. Press the Select function button.

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 Figure 161: Digital Output Screen

5. The digital output was specified as Normally Open so press the NO function button. The final trigger info
screen appears in Figure 162: Final Trigger Info Screen, page 184.

Figure 162: Final Trigger Info Screen

The output is shown and has been renamed to include the trigger name.
The digital output will remain open as long as the MtrTempHi Warn trigger is clear. If the motor temperature
exceeds 180 DegF, the trigger will transition to Set and digital output M3-M4 will close.

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 5.22 Load a Template

Select Load a New Template from the second page of the Main Menu. Navigate by Home Screen ->
Settings -> Menu -> Right Arrow.
Use the Up and Down Arrow buttons to highlight the desired template and press the Select function button.
Push the YES function button when prompted to Overwrite Configuration. It is usually a good practice to
clear event and history data, so push the YES function button when prompted. The LEDs will flash for
about a minute and the Apollo system will reboot.
Templates included with the released software are shown in Table 43: Templates, page 185.

Table 43: Templates

Template Use
SWB Use in switchboard and soft-start applications.
Standard Installed by default. Used with Vector VII and Vector
Plus applications.
Analog Use in variable speed drives that Apollo does not
support via a serial (RS-232, RS-485) connection.
A1KBasicIHM Mimics the Vector VII (white screen) user interface.
Note that it also Limits Apollo’s functionality to
that of the Vector VII. Not recommended for new
installations and only when requested by the
customer.

5.23 Miscellaneous Settings

Apollo settings that haven’t already been discussed are included in Table 44: Miscellaneous Settings,
page 186.

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 Table 44: Miscellaneous Settings

Name Location Description

Max Start Time Home Screen -> The maximum acceptable
delay between sending a start
Settings -> command to the drive power
Menu -> Other Initial Setup module and detecting that the
(page 3) drive is running.
If the Max Start Time is exceeded,
Apollo will report a Start Failed.
Default value is 8 seconds.
Pre-Start Delay Home Screen -> The minimum time that Apollo
remains in the Prepare2Start
Settings -> state. Note that Apollo can
Menu -> Other Initial Setup remain in the Prepare2Start state
(page 3) longer if there is an active trigger
with action “Hold in Prestart”. An
example of a “Hold in Prestart”
trigger would be charge pump
minimum pressure trigger in an
SPS system.
The default value is 2 seconds.

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 Table 44: Miscellaneous Settings (cont'd.)

Name Location Description

Screen Timeout Home Screen -> The Apollo LCD display will be
turned off when the keypad is
Settings -> inactive for the Screen Timeout.
Menu -> Other Initial Setup Note that any logged in user will
(page 3) be logged out at the same time
the screen is turned off.
The default value is 10 minutes.
Group Memberships Home Screen -> Group Memberships allow
a SCADA system to send a
Settings -> “Broadcast” group shutdown
Menu -> Other Initial Setup command to all drives on a
(page 3) network. The group shutdown
command will contain a 16 bit
shutdown mask. If a logical AND
of the Group Membership and
the shutdown mask results in a
non-zero value, Apollo will shut
down the drive.
The default value is 32768 (bit 15
set).

5.24 SPS Setup

The most complex applications faced by the Apollo Control System are Surface Pumping System (SPS)
applications.
In the past, complex SPS applications required an expensive Programmable Logic Controller (PLC) to
handle such applications. The Apollo Intelligent Control System can handle the vast majority of such
systems. SPS Specific Functionality built in to Apollo includes:
• Startup Sequencing
• Charge Pump control
• Suction Pressure Monitoring
• Discharge Pressure Monitoring
• Pump Curve Monitoring
• Lube Pump Control
• Lube Oil Pressure/Flow Monitoring

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 • Lube Oil Temperature Monitoring/Control
• Tank Level Monitoring
• Tank Level PID Speed control
• RTD Analog Input Support (motor temperature monitoring)
Configuration of such complex systems can be challenging. Two tools are provided to simplify the
configuration of SPS systems:
• The SPS Setup Wizard is installed in Apollo drive and walks the user through configuring an SPS system.
• The SPS Configuration Utility runs on a PC and creates an SPS configuration wizard with all possible
information pre-configured. The SPS Configuration Utility is available through the GE network.

Both of these tools are described in the Vector Plus Online training course as described in
Section 6: Apollo Simulator, page 190.
To execute the wizard, from the Home Screen select:
Settings -> Menu -> Other Initial Setup -> Next Page (Right Arrow) -> SPS Setup
Proceed through the screens and input the requested information.
Information needed by the SPS Setup wizard:
• Information for the Install I/O board wizard
• Motor Overload
• Information for the Install IO Module wizard
• Oil Pump Control Information
• Thrust Chamber Oil Pressure/Flow Sensor Information
• Oil Heater/Temperature Sensor Information
• Charge Pump Information
• Suction Pressure Transducer Information
• Discharge Pressure Transducer Information
• Information for the Pump Curve Setup wizard
• Tank Level Transducer Information
• Lease Kill Switch Information
• ManualStartOnly setting

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 The SPS Configuration Utility is available on the GE Support Central Drives & Controls Support page
(http://supportcentral.ge.com/products/sup_products.asp?prod_id=264489). Download the latest version.
Unzip. Double-click SPSConfig.exe to run.

Figure 163: SPS Configuration Utility

Proceed through the screens activating the features used in your system. When a feature is activated, the
fields required for that feature appear. On the final screen of the SPS Configuration Utility, press the Build
Wizard button to create the wizard. Copy the wizard file to the \WCS\Shortcuts folder on a USB flash drive.

Proceed through the screens activating the features used in your system. When a feature
is activated, the fields required for that feature appear. On the final screen of the SPS
Configuration Utility press the Build Wizard button to create the wizard. Copy the wizard file to the
\WCS\Shortcuts folder on a USB flash drive.
To install the configuration on an Apollo system, insert the USB flash drive into the Apollo user interface.
Activate the Run Config Wizard function (second page of the USB Menu) and select the wizard file you
created. Note that you will be asked to enter a few values (Motor Overload, Pump Type, ManualStartOnly)
and do any necessary sensor calibrations when the wizard is executed. All other information will be filled
in automatically.

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 6 Apollo Simulator
6.1 Introduction

The Apollo Simulator is the Apollo Control system software cross-compiled to run on a Windows PC. This
software is enhanced by adding the ability to simulate the conditions in the pumping system, including
simulations of the variable speed drive and its inputs, the downhole conditions, and inputs to the Apollo I/O
expansion board.

The installation of Apollo Version 3 simulator will not interfere with the installation of your version
2 simulator. Although both versions can be installed, it is not recommended to run more than
1 simulator at once.

Figure 164: Apollo Simulator

6.2 Installation/ Licensing

The latest release version of the Apollo Simulator is available on the GE Support Central Drives & Controls
Support page (http://supportcentral.ge.com/products/sup_products.asp?prod_id=264489). Download the
latest version and open the zip file. Double-click on the Apollo 3 Simulator.msi file to begin the installation.

If a previous version of the version 3 simulator is already installed on your computer, please use
the Control Panel to remove it before installing a new version. You do not have to uninstall the
Apollo Simulator version 2.

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 Figure 165: Apollo 3 Simulator Setup Wizard

1. Click the Next button to proceed.

Figure 166: Confirm Installation Screen

2. Click the Next button to proceed.

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 Figure 167: Select Installation Folder Screen

3. Change the destination folder if desired. Click the Next button. A Windows confirmation prompt may
appear. Acknowledge it. The installation will take a few seconds.

Figure 168: Installation Complete Screen

4. Click the Close button to Exit.

A Shortcut was installed on the computer desktop during installation.

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 Figure 169: Computer Desktop Shortcut

Double-click the shortcut to start the simulator. A dialog will appear informing you that the license file is
missing. Click the “Self-serve License Site” button and follow the instructions. If you have problems with this,
click the “Send E-mail request for New License” to create an e-mail request for a license. Send the e-mail. If
you cannot send the e-mail from the computer on which the simulator was installed, send the request code
as text to [email protected]. Please do not send a screen shot or image of the request
code.

Figure 170: License Request Code Screen

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 The response for e-mail requests is not automated and will be sent back as soon as possible
during USA Central Time office hours.
Copy and Paste the response code from the website or e-mail into the License Response Code field.

Figure 171: Pasted License Response Code Screen

Click the “Write New License” button. The license will be validated.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 195 of 277
 Figure 172: License Validated Screen

Click the OK button. The simulator will start.

6.3 Simulation Features

The simulator is an Apollo training platform and a platform for Field Service Engineers to set up and test well
configurations before implementing them in an actual pumping system.
Simulation windows are accessed via the View menu. Open the simulation screens as needed. Figure 173:
Simulation Screens, page 196 shows the simulator with the simulation windows open.

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 Figure 173: Simulation Screens

To access simulation windows, click on View on the menu bar and select the device.

6.4 File Operations

• Load Configuration allows for loading configurations from any location on your PC including USB drives.
• Save Configuration allows you to save a configuration to any location including USB drives.
• Save Config as Text provides a text output summary of the most commonly referenced configuration
items. It is not a complete listing of the configuration.
• Run Wizard allows you to run a Configuration Wizard from any location on your PC.

6.5 Online Training

The Vector Plus online training course is available and is accessible through the simulator. The online
training window is accessed in the View menu. Note that you must have access the GE Folders to access
the online training. The simulator and online training window are shown in Figure 174: Simulator and Online
Training Window, page 197.

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 Figure 174: Simulator and Online Training Window

The online training consists of a series of lessons and configuration exercises designed to help you gain
proficiency in the use of Apollo in conjunction with the Vector Plus drive.
Navigation between sections is accomplished using the navigation panel.

Figure 175: Navigation Panel

Navigate between sections of the training using the drop down box. Press the Check Configuration button
as directed in the exercises to check your configuration.

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 6.6 Using the Simulator to Configure a Pumping System

The primary function of the Simulator is to allow field engineers to configure and test a pumping system
before deploying it in the field. This can be accomplished using the following procedure:
1. Configure the Apollo simulator to the pumping system requirements.
2. Use simulator and simulated I/O to test startup sequencing (SPS only).
3. Use simulator and simulated I/O to verify that the drive runs as expected.
4. Use simulator and simulated I/O to test all safety shutdowns.
5. Use simulator and simulated I/O to test any automatic starting conditions.
6. Use the Save Configuration menu option to save the pumping system configuration to a USB Flash
drive. Save to the folder \WCS\CFG\ on the Flash drive. Name the configuration as desired.
7. Insert the USB Flash drive into the Apollo User Interface on the “real” pumping system. Select the “Load
Configuration” option from the USB Menu. Select the desired configuration. Press the YES function
button on the “Overwrite Configuration?” prompt. Best practice is to clear the Events and Data Archives
when a new configuration is loaded and press the YES function button when prompted. The Apollo
system will reboot.
8. The ManualStartOnly parameter is set to True when a new configuration is loaded to ensure the drive
does not start unexpectedly. Navigate to the main menu and set ManualStartOnly to false if the pumping
system utilizes any kind of automatic starts or if it can be started by SCADA.
The simulated configuration is now installed on the Apollo field system.

It is possible to test SCADA using the simulator. Network based SCADA (Modbus/TCP) is
accessible using the host computer’s IP address. Serial SCADA can be tested if COM2, COM5, or
COM6 is available on the computer.

7 Apollo Archive Viewer

7.1 Introduction

The Apollo Archive Viewer is a PC-based Windows program for viewing archive data extracted from Apollo
controllers using the USB function “Get Archive Files”. See Section 12: Appendix A–Full Installation of
Apollo Software, page 258 for information on using the USB menu. Selecting “Get Archive Files” will retrieve
data from the controller and update the archive files on your USB disk. The data can be imported from the
USB disk and saved or updated on your PC. If data is periodically updated from the pumping system, it is
possible to build a continuous log of the system data.

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 7.2 Installation and Learning

The latest release version of the Apollo Archive Viewer is available on the GE Support Central Drives
& Controls Support page (http://supportcentral.ge.com/products/sup_products.asp?prod_id=264489).
Download the latest version.

If a previous version of the archive viewer is already installed on your computer, please use the
Control Panel to remove it before installing a new version. Note that the Archive Viewer works with
all versions of Apollo Software 2.10 or greater.
Double-click on the file Apollo Archive Viewer x.xx then double-click on “Apollo Archive Viewer.msi” to
begin the installation.

Figure 176: Apollo Archive Viewer

Follow the on-screen instructions. When installation is complete, a shortcut will be placed on your desktop.

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 Figure 177: Desktop shortcut for Archive Viewer

Double-click on the icon to start the Archive Viewer. A dialog may appear informing you that the license
file is missing. If so, click the “Self-serve License Site” button and follow the instructions, otherwise skip to
Section 7.3 Importing Apollo Data, page 202. If you have problems with the self-serve site, click the “Send
E-mail request for New License” to create an e-mail request for a license. Send the e-mail. If you cannot
send the e-mail from the computer on which the Archive Viewer was installed, send the request code as text
to [email protected]. Please do not send a screen shot or image of the request code.

Figure 178: License Request Code-Screen 1

Copyright 2020 Baker Hughes Company. All rights reserved. Page 201 of 277
 The response for e-mail requests is not automated and will be sent back as soon as possible
during USA Central Time office hours.
Copy and Paste the response code from the website or e-mail into the License Response Code field.

Figure 179: License Response Code-Screen 2

Click the “Write New License” button. The license will be validated.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 202 of 277
 Figure 180: License Validated Screen

Click OK to continue.

7.3 Importing Apollo Data

To Import new well data, click on “Update or Import New Data”.

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 Figure 181: Importing Apollo Data-Screen 1

Navigate to the folder that contains the data retrieved from the Apollo Controller. If you are getting it directly
from the USB stick inserted in the drive, the files will be located in <Site Name>\<Well Name>. If there is no
Site Name the folder will be the Well Name. Within the data folder, click on the file “<Well Name>.sbc” to
import the data. Every time you retrieve data from the Apollo Controller and then Import the data using the
import function, the new data is merged with the prior data. If the data is retrieved periodically, the Archive
Viewer will attempt to build a continuous log of the Apollo system data.

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 Figure 182: Import Apollo Data-Screen 2

Using the drop-down menus, select the channels you want to view. If you know the date for the data you
want to view, use the drop-down calendar to select it.

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 Figure 183: Import Data-Screen 3

7.4 Displaying the Archive Data

1. Click on the channel labels to bring up a channel menu to change the vertical scaling.
2. Color-coded vertical scales for each channel.
3. “Write Text File” writes a spread-sheet type text file (.csv) of the historical data currently shown on
the graph.
4. Event drop-down window allows you to choose “No Events”, “Faults” or “All Events”.
5. Click on the ARROW buttons to move forward and backwards in time. Double Arrows move a full
page while the Single Arrows move one division.
6. Click on the “+” button to “zoom-in” or the “-“ button to “zoom-out”.
7. Chart Size drop-down allows you to choose the amount of time shown on the horizontal scale. This
can also be accomplished with the zoom buttons.
8. Clicking anywhere on the graph draws a vertical line, prints the time/date and numeric high and low
values for all channels at that point in time.
9. Click on Maximize to increase the size of the graph.
10. Close the graph screen to exit or change the channels you want to view.

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 Figure 184: Graph Screen

If you are viewing the data on a computer that is in the same time-zone as the Apollo system,
the time/date stamps will be the same as the Apollo clock. The Archive Viewer always shows
the time/date as if the data was logged using local time on the computer displaying the data.

7.5 Channel Menu

Click on one of the Channel Labels at the top of the graph to display the channel menu.

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 Figure 185: Channel Menu

Vertical Scaling can be modified on a channel-by-channel basis.

• Manual Scaling allows the user to select the vertical scale for the channel.
• Auto Scale (High & Low) automatically sets the minimum and maximum value so that all the points
on the page fit on the vertical scale.
• Auto High Scale (Low Manual) provides an automatic high scale and a fixed low scale. This is the default
setting with the Min Value set at 0.

The auto scaling works well to position all the traces on the screen but can be deceiving because
the scaling may automatically change when zooming or moving forward and backwards in time.
The “Don’t show this trace” check-box can be used to temporarily hide this channel if you need to simplify
the graph by reducing the number of traces shown.
“Previous” and “Next” changes the Channel Menu to a different channel.
“OK” closes the Channel Menu dialog.

7.6 Changing Displayed Channels

If you want to see different channels, close the graph screen using the X in the upper right corner. Use
the drop-down channel lists to change the channels you want to view.

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 7.7 Displaying Previously Imported Data

Click on “View Existing Well Data” to select data previously imported.

Figure 186: Viewing Previously Imported Data

The Archive Viewer files are saved in “My Documents\Apollo Data”. This set of files is a merged copy of the
imported data which is updated every time you “Update or Import New Data”. If you are importing multiple
data sets from the same controller, make sure you import the oldest set first, followed by the next oldest
and so on. When you view files using the “View Existing” button, the Archive Viewer will have retained
which channels you selected to view.

Figure 187: Selecting Previously Imported Well Data

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 7.8 E-mailing or transferring Apollo Archive Data

To E-mail or otherwise transfer Apollo Archive Data, insert the USB disk (used to extract data) into your
computer and look for a folder named the same as the pumping system’s Site name. Within the Site Name
folder, look for a folder with the same name as the Well Name. If there is no Site Name used, look for
the Well Name in the root of the USB.

Figure 188: Choose the Well Data (on USB Drive)

Select the Well Name folder and right click. Click on “Send to” then on “Compressed (zipped) folder.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 210 of 277
 Figure 189: Creating a Zip File

This will create a zip file containing all the required data for the Archive Viewer. If the zip file is
too big to e-mail (limit is usually 10MB), you can transfer the zip file to the Field Data Folder:
http://supportcentral.ge.com/products/sup_products.asp?prod_id=264489

Copyright 2020 Baker Hughes Company. All rights reserved. Page 211 of 277
 Figure 190: The Field Data Transfer Folder

Click on the Upload button, select “File”, fill out the Upload form and click on “Upload”. Send the above link
to the intended recipient (they must also be a BH employee) and have them click on the file you uploaded
and choose “Save File” to download the zip file to their computer.

This folder is for transfer only and files more than a week old may be deleted.

8 Apollo Applications
8.1 Switchboard Application

8.1.1 Equipment Needed

Table 45: Equipment

Part Part Number

Apollo HMI 197144
Apollo I/O, ESP DSI Panel 197207

8.1.2 Electrical Wiring

For Switchboard Applications refer to Drawing 810624.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 212 of 277
 Not all connections will be made in every application.
General Wiring Table

Table 46: Apollo HMI

From To
Power Supply Line (85-265 Vac) Apollo HMI J21-3
Power Supply Line Neutral (85-265 Vac) Apollo HMI J21-2
Ground Apollo HMI J21-1
Apollo I/O Board J106-6 (+24 Vdc) Apollo HMI J25-6 (+24 Vdc)
Apollo I/O Board J106-5 (GND) Apollo HMI J25-5 (GND)
Cable Shield Apollo HMI J25-4 (SHIELD)
Apollo I/O Board J106-3 (B) Apollo HMI J25-3 (B)
Apollo I/O Board J106-2 (A) Apollo HMI J25-2 (A)

Table 47: Apollo I/O Board

From To
Apollo HMI J25-6 (+24 Vdc) Apollo I/O Board J106-6 (+24 Vdc)
Apollo HMI J25-5 (GND) Apollo I/O Board J106-5 (GND)
Apollo HMI J25-3 (B) Apollo I/O Board J106-3 (B)
Apollo HMI J25-2 (A) Apollo I/O Board J106-2 (A)
Backspin Probe A+ Apollo I/O Board (1) PRB A+
Backspin Probe B+ Apollo I/O Board (2) PRB B+
Backspin Probe C+ Apollo I/O Board (3) PRB C+
Backspin Probe A- Apollo I/O Board (4) PRB A-
Backspin Probe B- Apollo I/O Board (5) PRB B-
Backspin Probe C- Apollo I/O Board (6) PRB C-
Backspin Probe A Shield Apollo I/O Board (7) SHIELD-Jumper (7) to (8)
Backspin Probe B Shield Apollo I/O Board (8) SHIELD-Jumper (7) to (8)
Backspin Probe C Shield Apollo I/O Board (8) SHIELD-Jumper (7) to (8)
Current Transformer CT A+ Apollo I/O Board (9) CT A+
Current Transformer CT A- Apollo I/O Board (10) CT A-

Copyright 2020 Baker Hughes Company. All rights reserved. Page 213 of 277
 Table 47: Apollo I/O Board (cont'd.)

From To
Current Transformer CT B+ Apollo I/O Board (11) CT B+
Current Transformer CT B- Apollo I/O Board (12) CT B-
Current Transformer CT C+ Apollo I/O Board 13) CT C+
Current Transformer CT C - Apollo I/O Board (14) CT C -
PT AC Line Apollo I/O Board (15) PTAC H
PT AB Line Apollo I/O Board (16) PTAB H (Jumper
to (15) for single PT)
PT AC/AB Neutral Apollo I/O Board (17) PTAC N
PT AC/AB Neutral Apollo I/O Board (18) PTAC N
ESP DSI J204-6 (+24 Vdc) Apollo I/O Board J108-6 (+24 Vdc)
ESP DSI J204-5 (GND) Apollo I/O Board J108-5 (GND)
ESP Cable Shield Apollo I/O Board J108-4 (SHIELD)
ESP DSI J204-3 (B) Apollo I/O Board J108-3 (B)
ESP DSI J204-2 (A) Apollo I/O Board J108-2 (A)
Motor Contactor Relay Apollo I/O Board (32) Digital I/O 7
(RUN OUTPUT)
Motor Contactor Relay Neutral Apollo I/O Board (31) Digital I/O 7
(RUN OUTPUT)
(Optional) Run Pilot Light [Green] Apollo I/O Board (32) Digital I/O 7
(RUN OUTPUT)
(Optional) Run Pilot Light Neutral [Green] Apollo I/O Board (31) Digital I/O 7
(RUN OUTPUT)
(Optional) Fault Pilot Light [Red] Apollo I/O Board (34) Digital I/O 8
(FAULT OUTPUT)
(Optional) Fault Pilot Light Neutral [Red] Apollo I/O Board (33) Digital I/O 8
(FAULT OUTPUT)
(Optional) Underload Pilot Light [Amber] Apollo I/O Board (36) Digital I/O 9
(UNDERLOAD OUTPUT)
(Optional) Underload Pilot Light Apollo I/O Board (35) Digital I/O 9
Neutral [Amber] (UNDERLOAD OUTPUT)
(Optional) Hand Switch Apollo I/O Board (20) Digital I/O 1
(HAND INPUT)

Copyright 2020 Baker Hughes Company. All rights reserved. Page 214 of 277
 Table 47: Apollo I/O Board (cont'd.)

From To
(Optional) Hand Switch Neutral Apollo I/O Board (19) Digital I/O 1 Common
(Optional) Auto Switch Apollo I/O Board (22) Digital I/O 2
(AUTO INPUT)
(Optional) Auto Switch Neutral Apollo I/O Board (21) Digital I/O 2 Common
(Optional) Start Switch Apollo I/O Board (24) Digital I/O 3
(START INPUT)
(Optional) Start Switch Neutral Apollo I/O Board (23) Digital I/O 3 Common

Table 48: ESP DSI Board

From To
Apollo I/O Board J108-6 (+24 Vdc) ESP DSI J204-6 (+24 Vdc)
Apollo I/O Board J108-5 (GND) ESP DSI J204-5 (GND)
Apollo I/O Board J108-3 (B) ESP DSI J204-3 (B)
Apollo I/O Board J108-2 (A) ESP DSI J204-2 (A)
Downhole Sensor Choke Panel (Ve+) ESP DSI J206-1 (VE+)
Downhole Sensor Choke Panel (Ve-) ESP DSI J206-2 (VE-)

8.1.3 Configuration

Install the SWB template as described in Section 5.22 Load a Template, page 185. Perform
basic setup sequence as described in Section 4: Basic Setup Sequence, page 85.

The drive specific parameters will not be available in the Switchboard template.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 215 of 277
 8.2 Vector VII / Vector Plus ESP Application

8.2.1 Equipment Needed

Table 49: Vector VII/Vector Plus ESP Application

Part Part Number

Apollo HMI (only if upgrading from old “Blue 810283 (810286 if stainless steel)
Box” HMI)
Apollo I/O, ESP DSI Panel 197207
(if adding full panel with I/O and ESP DSI
boards)
Apollo I/O board 197148
(if adding I/O board to existing panel with ESP
DSI already installed)
Mounting Hardware 4 x 196352 SCREW,PHP M5-0.8X10MM 18-8
4SS
(if adding I/O board to existing panel with ESP
DSI already installed) 4 x 196354 WASHER,LOCK M5 SPLIT 18-8
SS

8.2.2 Electrical Wiring

For Vector VII ESP Standard Applications refer to Drawing 810619.

Not all connections will be made in every application.

General Wiring Table

Table 50: Equipment

From To
Power Supply Line (85-265 Vac) Apollo HMI J21-3
Power Supply Line Neutral (85-265 Vac) Apollo HMI J21-2
Ground Apollo HMI J21-1
Apollo I/O Board J106-6 (+24 Vdc) Apollo HMI J25-6 (+24 Vdc)
Apollo I/O Board J106-5 (GND) Apollo HMI J25-5 (GND)
Cable Shield Apollo HMI J25-4 (SHIELD)

Copyright 2020 Baker Hughes Company. All rights reserved. Page 216 of 277
 Table 50: Equipment (cont'd.)

From To
Apollo I/O Board J106-3 (B) Apollo HMI J25-3 (B)
Apollo I/O Board J106-2 (A) Apollo HMI J25-2 (A)

Table 51: Apollo I/O Board (If Needed)

From To
Apollo HMI J25-6 (+24 Vdc) Apollo I/O Board J106-6 (+24 Vdc)
Apollo HMI J25-5 (GND) Apollo I/O Board J106-5 (GND)
Apollo HMI J25-3 (B) Apollo I/O Board J106-3 (B)
Apollo HMI J25-2 (A) Apollo I/O Board J106-2 (A)
Backspin Probe A+ Apollo I/O Board (1) PRB A+
Backspin Probe B+ Apollo I/O Board (2) PRB B+
Backspin Probe C+ Apollo I/O Board (3) PRB C+
Backspin Probe A- Apollo I/O Board (4) PRB A-
Backspin Probe B- Apollo I/O Board (5) PRB B-
Backspin Probe C- Apollo I/O Board (6) PRB C-
Backspin Probe A Shield Apollo I/O Board (7) SHIELD-Jumper (7) to (8)
Backspin Probe B Shield Apollo I/O Board (8) SHIELD-Jumper (7) to (8)
Backspin Probe C Shield Apollo I/O Board (8) SHIELD-Jumper (7) to (8)
Current Transformer CT A+ Apollo I/O Board (9) CT A+
Current Transformer CT A- Apollo I/O Board (10) CT A-
Current Transformer CT B+ Apollo I/O Board (11) CT B+
Current Transformer CT B- Apollo I/O Board (12) CT B-
Current Transformer CT C+ Apollo I/O Board 13) CT C+
Current Transformer CT C - Apollo I/O Board (14) CT C -
PT AC Line Apollo I/O Board (15) PTAC H
PT AB Line Apollo I/O Board (16) PTAB H (Jumper
to (15) for single PT)
PT AC/AB Neutral Apollo I/O Board (17) PTAC N
PT AC/AB Neutral Apollo I/O Board (18) PTAC N
ESP DSI J204-6 (+24 Vdc) Apollo I/O Board J108-6 (+24 Vdc)

Copyright 2020 Baker Hughes Company. All rights reserved. Page 217 of 277
 Table 51: Apollo I/O Board (If Needed) (cont'd.)

From To
ESP DSI J204-5 (GND) Apollo I/O Board J108-5 (GND)
ESP Cable Shield Apollo I/O Board J108-4 (SHIELD)
ESP DSI J204-3 (B) Apollo I/O Board J108-3 (B)
ESP DSI J204-2 (A) Apollo I/O Board J108-2 (A)

Table 52: ESP DSI

From To
Apollo I/O Board J108-6 (+24 Vdc) ESP DSI J204-6 (+24 Vdc)
Apollo I/O Board J108-5 (GND) ESP DSI J204-5 (GND)
Apollo I/O Board J108-3 (B) ESP DSI J204-3 (B)
Apollo I/O Board J108-2 (A) ESP DSI J204-2 (A)
Downhole Sensor Choke Panel (Ve+) ESP DSI J206-1 (VE+)
Downhole Sensor Choke Panel (Ve-) ESP DSI J206-2 (VE-)

8.2.3 Configuration

Vector VII/Vector Plus applications use the Standard template that is automatically installed
with Apollo. Perform basic setup sequence as described in section 4. If an Apollo Extended
I/O board is included in the system, activate the board as described in Section 3.2.2 Apollo I/O
Board Assembly, page 29.

8.3 Vector VII/Vector Plus SPS Application

8.3.1 Equipment Needed

Table 53: Equipment

Part Part Number

Apollo HMI (only if upgrading from 810283 (810286 if stainless steel)
old “Blue Box” HMI)
Apollo I/O, ESP DSI Panel 197207
(if adding full panel with I/O and ESP
DSI boards)

Copyright 2020 Baker Hughes Company. All rights reserved. Page 218 of 277
 Table 53: Equipment (cont'd.)

Part Part Number

Apollo I/O board 197148
(if adding I/O board to existing panel with
ESP DSI already installed)
Mounting Hardware 4 x 196352 SCREW,PHP M5-0.8X10MM
18-8 4SS
(if adding I/O board to existing panel with
ESP DSI already installed) 4 x 196354 WASHER,LOCK M5
SPLIT 18-8 SS

8.3.2 Electrical Wiring Table

General Wiring Table

Table 54: Apollo HMI

From To
Power Supply Line (85-265 Vac) Apollo HMI J21-3
Power Supply Line Neutral (85-265 Vac) Apollo HMI J21-2
Ground Apollo HMI J21-1
Apollo I/O Board J106-6 (+24 Vdc) Apollo HMI J25-6 (+24 Vdc)
Apollo I/O Board J106-5 (GND) Apollo HMI J25-5 (GND)
Cable Shield Apollo HMI J25-4 (SHIELD)
Apollo I/O Board J106-3 (B) Apollo HMI J25-3 (B)
Apollo I/O Board J106-2 (A) Apollo HMI J25-2 (A)

Table 55: Apollo I/O Board (if needed)

From To
Apollo HMI J25-6 (+24 Vdc) Apollo I/O Board J106-6 (+24 Vdc)
Apollo HMI J25-5 (GND) Apollo I/O Board J106-5 (GND)
Apollo HMI J25-3 (B) Apollo I/O Board J106-3 (B)
Apollo HMI J25-2 (A) Apollo I/O Board J106-2 (A)
Backspin Probe A+ Apollo I/O Board (1) PRB A+
Backspin Probe B+ Apollo I/O Board (2) PRB B+

Copyright 2020 Baker Hughes Company. All rights reserved. Page 219 of 277
 Table 55: Apollo I/O Board (if needed) (cont'd.)

From To
Backspin Probe C+ Apollo I/O Board (3) PRB C+
Backspin Probe A- Apollo I/O Board (4) PRB A-
Backspin Probe B- Apollo I/O Board (5) PRB B-
Backspin Probe C- Apollo I/O Board (6) PRB C-
Backspin Probe A Shield Apollo I/O Board (7) SHIELD-Jumper (7) to (8)
Backspin Probe B Shield Apollo I/O Board (8) SHIELD-Jumper (7) to (8)
Backspin Probe C Shield Apollo I/O Board (8) SHIELD-Jumper (7) to (8)
Current Transformer CT A+ Apollo I/O Board (9) CT A+
Current Transformer CT A- Apollo I/O Board (10) CT A-
Current Transformer CT B+ Apollo I/O Board (11) CT B+
Current Transformer CT B- Apollo I/O Board (12) CT B-
Current Transformer CT C+ Apollo I/O Board 13) CT C+
Current Transformer CT C - Apollo I/O Board (14) CT C -
PT AC Line Apollo I/O Board (15) PTAC H
PT AB Line Apollo I/O Board (16) PTAB H (Jumper
to (15) for single PT)
PT AC/AB Neutral Apollo I/O Board (17) PTAC N
PT AC/AB Neutral Apollo I/O Board (18) PTAC N

Table 56: RSTi I/O Module (if needed)

From To
Apollo I/O Board J108-6 (+24 Vdc) RSTi Power 0, 6
Apollo I/O Board J108-5 (GND) RSTi Power 1, 5
Apollo I/O Board J108-3 (B) RSTi Comms – 2 (Data -)
Apollo I/O Board J108-2 (A) RSTi Comms – 1 (Data +)

8.3.3 Configuration

Vector VII/Vector Plus applications use the Standard template that is automatically installed with
Apollo. Perform setup operations as described in Section 4: Basic Setup Sequence, page 85
and Vector VII/Vector Plus ESP Application for SPS systems, run the SPS Setup wizard (see
Section 5.24 SPS Setup, page 187).

Copyright 2020 Baker Hughes Company. All rights reserved. Page 220 of 277
 9 Apollo Motor Overload Protection
The Apollo Control System provides two types of motor overload protection.
• I2T Motor Overload– The I2T overload algorithm protects the motor from heat damage by modeling the heat
buildup in the motor. The parameters for setting up the I2T overload are shown in Figure 191: Motor Overload
Setup Menu-Screen 1, page 220.

Figure 191: Motor Overload Setup Menu-Screen 1

• Fixed Threshold/Time Delay Overload– The fixed threshold overload algorithm is referred to as Motor
OverCurrent in the Apollo system and protects the motor from heat damage by monitoring motor current using a
simple thresholding algorithm. The parameters for setting up the overcurrent protection are accessible by selecting
Motor OverCurrent in Figure 192: Motor Overload Setup Menu–Screen 2, page 221.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 221 of 277
 Figure 192: Motor Overload Setup Menu–Screen 2

9.1 I2T Motor Overload Algorithm

The purpose of the motor overload algorithm is to protect the motor from heat damage. The I2T algorithm
protects the motor by modeling the heat buildup in the motor.

Figure 193: I2T Motor Overload Algorithm

The graph above shows the time it takes for the system to progress from normal running to an overload as
a function of 2 factors:
• Amount of overload: The higher the overload, the faster the system will shut down.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 222 of 277
 • Overload Time Constant: The longer the time constant, the slower the overload will respond.
For example, a system running at 150% (1.5 on graph) of overload threshold with a 120 second overload
delay will trip in 70 seconds while a system running a 250% will trip in about 20 seconds.
Changing the OL Delay will change the trip time proportionally. For example, doubling the OL Delay will
double the trip time at any overload level.

9.2 Advantages of the I2T Motor Overload Algorithm

An I2T overload algorithm is superior to a fixed threshold/time delay algorithm in several respects.
Advantages include:
• I2T will tolerate light overloads for quite a while. A well tends to pull more current at startup than at steady
state. When using a fixed threshold/time delay algorithm, users tend to artificially raise the overload limit
to accommodate this (for example, by always setting overload to 15% above nameplate), making the
overload less sensitive in steady state conditions. The I2T algorithm can handle the starting current
without compromising protection after the current has stabilized. See Figure 194: Apollo Overload
Simulator, page 223.
• I2T will trip faster on heavy overloads. For example, assume we have a fixed threshold overload with
a delay of 30 seconds. The I2T algorithm will trip faster than the fixed threshold algorithm for loads
greater than about 210%. See screenshots below.
• I2T will not forget about the heat buildup just because the load occasionally drops below the overload
threshold. In a fixed threshold/time delay algorithm, the timer is reset each time the load drops below the
overload value. This could allow a system to run in overload indefinitely and damage the motor. See
Figure 194: Apollo Overload Simulator, page 223.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 223 of 277
 Figure 194: Apollo Overload Simulator

The screenshot above simulates a motor that starts at 110% of the motor overload threshold and then the
load linearly decreases to 95% of the overload threshold in 5 minutes.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 224 of 277
 Figure 195: 125% of Overload Threshold (Left), 250% of Overload Threshold (Right)

Left image illustrates loading at 125% of overload threshold. Right illustrates 250%.
Screenshots of Apollo Overload Simulator showing how overload affects time to overload.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 225 of 277
 Figure 196: How Overload Affects Time To Overload

The screenshot above illustrates how the overload bucket drains off slowly when the current drops below
overload. In this simulation the motor is started at 125% of the overload threshold. The system detects
overload in 2 minutes and stops. The system restarts 2 minutes later with load still at 125%. The system
shuts down almost immediately (as the heat in the motor has not had time to dissipate). The system
is restarted a second time 2 minutes later with loading at 100% of overload. As you can see, at 100%
overload the motor temperature is stable.

10 Trigger Definition
10.1 Trigger Definition

Triggers are used to define events or conditions in the pumping system and to take actions that affect the
state of the motor controller (MC). When the condition is met, the trigger is said to be SET. If the condition is
not met, the trigger is said to be CLEAR. For example, a High Limit trigger tests the value of a channel
against a limit. If the limit is exceeded the trigger is SET and the system state is affected by the ACTION
defined for the particular trigger.
Examples of Triggers:
• Tank Level High Trigger-Starts motor if a tank level exceeds the trigger limit (sometimes referred to as
setpoint or threshold).

Copyright 2020 Baker Hughes Company. All rights reserved. Page 226 of 277
 • Intake Pressure Low Trigger-Stops the motor if the downhole pump intake pressure is less than the
trigger limit.

Figure 197: Rigger Logic Flowchart

10.2 Basic Trigger Settings

Table 57: Basic Trigger Settings

Item Description
Name Name of the trigger. When naming a trigger, use a
name that describes the condition when the trigger
is SET such as Tank Level Hi. Trigger names
cannot exceed 15 characters.
Trigger Type The type of trigger. The Trigger Type determines
the condition that causes the trigger to be activated
(SET). The Trigger Types are described below.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 227 of 277
 Table 57: Basic Trigger Settings (cont'd.)

Item Description
Trigger State The current state of the trigger. Basically, a trigger
is either clear (all conditions specified in the trigger
definition have not been met) or set (all of the
conditions specified in the trigger description have
been met). See Section 10.4 Trigger States, page
228.
Limit The allowed limit that the current value of the
trigger’s input channel is being compared to.
Sometimes referred to as the trigger setpoint or
trigger threshold.
Action The action that is performed when the trigger
transitions to the set state. See Section 10.5 Trigger
Actions (Basic), page 230.
Enable States Motor Control states in which the trigger is enabled.
See Section 10.6 Enable States, page 230.
Enable Delay The time for which the trigger is not checked (and
will not be activated) after the motor control state
transitions from a not enabled state to an enabled
state. Typically, this will be the time the trigger is not
checked after the motor is started.
Trip Delay (Set) Time to tolerate the trigger’s input channel
exceeding the limit before the trigger transitions to
the set state.
Trip Delay (Clear) The time the trigger conditions must remain unmet
before a set trigger will transition to clear.
Restarts/Allowed This field holds 2 numbers. The number of
restarts that have been attempted on this trigger
(automatically generated) and the number of
allowed restarts. Set the number of allowed restarts
to 0 to disable restarts for this trigger.
Restart Delay Delay before attempting to restart the well.
Restart Delay Start Determines the time from which the Restart Delay
begins. Options are Starts when Set (the restart
countdown begins when the trigger transitions to
the set state) and Starts when Clear (the restart
countdown begins when the trigger transitions to
the clear state).

Copyright 2020 Baker Hughes Company. All rights reserved. Page 228 of 277
 10.3 Trigger Types (Basic)

“Basic” Trigger Types are appropriate for at least 90% of the triggers that will need to be field configured.
These types are automatically selected when the user executes the “Add a Trigger” function from the
Channel Info screen. See Trigger Types (full list) below for all trigger types.

Table 58: Trigger Types (basic)

Action Description
(User Level)
Is ON or SET Activates when the Source 1 digital channel is ON.
This type of trigger is added when the user Adds a
(Basic) Trigger to a digital channel from the Channel Info
screen.
Is LESS THAN Activates when the Source 1 value is less than the
limit. This type of trigger can be selected when the
(Basic) user Adds a Trigger to an analog channel from the
Channel Info screen.
Is GREATER THAN Activates when the Source 1 value is greater than
the limit. This type of trigger can be selected when
(Basic) the user Adds a Trigger to an analog channel from
the Channel Info screen.

10.4 Trigger States

Table 59: Trigger States

Trigger State Color Scheme Description

(Text Color)
Clr-Not In Use Gray The trigger is not in use in this
template (or has been disabled
by a user). This trigger will never
affect the motor control state
machine.
Clr-No Init. Gray The trigger has not been
initialized. This indicates that
it depends upon a channel or
another trigger that has not been
initialized. Navigate to the Trigger
Info screen to trace back to the
channel or trigger that is not yet
initialized.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 229 of 277
 Table 59: Trigger States (cont'd.)

Trigger State Color Scheme Description

(Text Color)
Clr-Not Enabled Gray The trigger is not enabled in
the current motor control state.
Triggers that are not enabled
are always considered clear (not
activated). For example, many
triggers associated with a drive
running are not enabled in the
Stopped states.
Clr-Locked Out Red This trigger is now clear – but it
was active and is the trigger that
caused the motor control state to
be locked out.
Clr – TrpDly min:sec Yellow The trigger is now clear, but the
set condition has been met. The
trigger will be activated (set) when
the trip delay has been satisfied.
Clr-Rstrt: min:sec Yellow The trigger is now clear and
is counting down to attempt a
restart. If several of these triggers
are active at the same time,
the well will not start until all of
them have completed their restart
times.
Clear Purple The trigger is enabled (the motor
control is in a state that has been
checked in the “Enable States”)
and the conditions have not been
met to activate (set) the trigger.
Set Yellow All conditions have been met and
the trigger is active (set).

Text colors are only as listed when the Apollo Color Scheme is set to “Color on Black”.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 230 of 277
 10.5 Trigger Actions (Basic)

“Basic” Trigger Actions are appropriate for at least 90% of the triggers that will need to be field configured.
See Trigger Actions (full list) below for all trigger actions.

Table 60: Trigger Actions (basic)

Action Color Scheme Description

(User Level) (background)
Logic Only Brown The trigger has no effect on the
motor control state machine and
(Basic) is not logged. The Logic Only
trigger can be used as an input to
other (derived) triggers.
Log Only Dark Purple The trigger has no effect on the
motor control state machine but is
(Basic) logged in the Event Log.
STOP->FAULT Red The trigger will cause the motor
to stop. On drives, the motor
(Basic) will stop according to the normal
acceleration/deceleration times
or coast as configured. A fault
will be declared. If no restarts
remain on the trigger, the system
will Lock Out.

Text colors are only as listed when the Apollo Color Scheme is set to “Color on Black”.

10.6 Enable States

Enable States can only be selected on the Trigger Edit screen (Advanced Access required).

Copyright 2020 Baker Hughes Company. All rights reserved. Page 231 of 277
 Table 61: Enable States

Enable State Description

STOPPED States Check if you wish the trigger to be enabled when
the drive is stopped. Stopped motor control states
include Initializing, Locked Out, Fault, No Restart,
Hold, and Restart. See Note 1.
Prepare2Start Check if you wish the trigger to be enabled during
the startup sequence. The motor control state
associated with this is Prep to Start (non ESP
templates) or Wait Backspin (ESP templates).
STARTING State Check if you wish the trigger to be enabled during
the STARTING state.
RUN MODE 1 Check if you wish the trigger to be enabled when
the drive is in Running.
Note that you can use the different run modes to
have different active triggers… i.e. you can create
multiple underload triggers and have them enabled
in different run states to better protect your system.
RUN MODE 2 Check if you wish the trigger to be enabled when
the drive is in RUN MODE 2.
RUN MODE 3 Check if you wish the trigger to be enabled when
the drive is in RUN MODE 3.

If a trigger has been enabled in all states AND has an enable delay set, then it will be disabled in
the STOPPED States.

10.7 Trigger Screens

Trigger Info Screen

Shown as logged in at Level 2.
Trigger parameters that can be edited from this screen are:
• Trigger Limit
• Trigger Action
• Enable Delay
• Trip Delay
• Restarts Allowed

Copyright 2020 Baker Hughes Company. All rights reserved. Page 232 of 277
 • Restart Delay
• The trigger can be disabled (Not In Use) or enabled using the On/Off function button.
• The Trigger Name can be edited using the Rename function button.

Figure 198: Trigger Info-Screen 2

Edit Trigger Screen

Only available to Level 3 (Advanced) users.
All trigger parameters can be edited from this screen.
• Trigger Name
• In Use (trigger enabled/disabled)
• Trigger Limit
• Enabled States
• Enable Delay
• Trigger Action
• Restarts Allowed
• No Log on Clear – check this box if you don’t wish for the trigger to be logged when it transitions from
Set to Clear.
• Restart Delay
• Restart Delay Start
• Trip Delay (Set)
• Trip Delay (Clear)

Copyright 2020 Baker Hughes Company. All rights reserved. Page 233 of 277
 • One way to read the Edit Trigger screen is to follow it like a narrative. The Motor Temp High
trigger will be set (activated) if the Motor Temp is greater than 220 degF. The trigger is enabled
in all states and will stop the system when activated.

Figure 199: Edit Trigger-Screen 3

Some triggers are predefined in the Apollo system and cannot be modified. See Section 10.10
Special Triggers, page 238.

10.8 Trigger Types (full list)

“Basic” Trigger Types are appropriate for at least 90% of the triggers that will need to be field configured.
These types are automatically selected when the user executes the “Add a Trigger” function from the
Channel Info screen. “Advanced” Trigger Types should not be used without direction from engineering
or until advanced training courses are completed.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 234 of 277
 Table 62: Trigger Types (full list)

Action (User Level) Description

SET Whenever ENABLED Activates whenever the motor control is in a state
that has been enabled (has a check mark by it).
(Advanced)
Is ON or SET Activates when the Source 1 digital channel is ON.
This type of trigger is added when the user Adds a
(Basic) Trigger to a digital channel from the Channel Info
screen.
Is LESS THAN Activates when the Source 1value is less than the
limit. This type of trigger can be selected when the
(Basic) user Adds a Trigger to an analog channel from the
Channel Info screen.
Is GREATER THAN Activates when the Source 1 value is greater than
the limit. This type of trigger can be selected when
(Basic) the user Adds a Trigger to an analog channel from
the Channel Info screen.
Is EQUAL TO Activates when the Source 1 value is equal to the
limit.
(Advanced)
LESS THAN or = TO Activates when the Source 1 value is less than or
equal to the limit.
(Advanced)
GREATER or = TO Activates when the Source 1 value is greater than
or equal to the limit.
(Advanced)
AND Activates when the logical and of Source 1 and
Source 2 is TRUE. (i.e. both inputs are TRUE)
(Advanced)
OR Activates if the logical or of Source 1 and Source 2
is TRUE. (i.e. either of the inputs are TRUE)
(Advanced)
AND (block from 1 to 2) Activates when the logical and of all the triggers
between Source 1 and Source 2 is TRUE.
(Advanced)
Only use advanced trigger types under direction
from engineering!
OR (block from 1 to 2) Activates when the logical or of all the triggers
between Source 1 and Source 2 is TRUE.
(Advanced)
Only use advanced trigger types under direction
from engineering!

Copyright 2020 Baker Hughes Company. All rights reserved. Page 235 of 277
 Table 62: Trigger Types (full list) (cont'd.)

Action (User Level) Description

Internal Trigger Only use advanced trigger types under direction
from engineering!
(Advanced)
External Trigger Only use advanced trigger types under direction
from engineering!
(Advanced)
Is SET, Cleared on Activates when Source 1 is SET. Clears when
Source 2 is SET.
(Advanced)
Only use advanced trigger types under direction
from engineering!
Is SET or Counting Activates if Source 1 is SET or is counting down
for a restart.
(Advanced)
Only use advanced trigger types under direction
from engineering!

10.9 Trigger Actions (Full List)

“Basic” Trigger Actions are appropriate for at least 90% of the triggers that will need to be field configured.
These actions are automatically selected when the user executes the “Add a Trigger” function from the
Channel Info screen. “Standard” Trigger Actions may be necessary in a small number of situations – like
implementing tank level control from an ESP template. “Advanced” Trigger Actions will rarely be used by
the field engineer.

Table 63: Trigger Actions (full list)

Action (User Level) Color Scheme (background) Description

Logic Only Brown The trigger has no effect on the
motor control state machine and
(Basic) is not logged. The Logic Only
trigger can be used as an input to
other (derived) triggers.
Log Only Dark Purple The trigger has no effect on the
motor control state machine but is
(Basic) logged in the Even Log.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 236 of 277
 Table 63: Trigger Actions (full list) (cont'd.)

Action (User Level) Color Scheme (background) Description

STOP->FAULT Red The trigger will cause the motor
to stop. On drives, the motor
(Basic) will stop according to the normal
acceleration/deceleration times.
A fault will be declared. If no
restarts remain on the trigger, the
system will Lock Out.
STOP->Ready Red The trigger causes the motor
control to stop the motor without
(Standard) issuing a fault or a lockout. In
the hold state, a trigger with the
START Motor action can cause
the motor to start.
STOP->Timer Block Red The trigger causes the motor
control to stop the motor AND
(Advanced) will restart only on that trigger’s
restart timer. The system will not
allow manual starts to override
the timer.
HOLD in Prestart Blue The trigger will cause the motor
control to wait in the Prestart
(Standard) state. The motor control will
remain in the Prestart state until
the trigger is cleared (and then
the motor will be started) or until
another trigger causes a transition
to the fault or lockout state. The
HOLD in Prestart trigger is usually
used as a permissive for running
the system.
START Motor Green The trigger will cause the motor
to start IF the motor control is in
(Standard) the HOLD state.
Go to Run Mode 1 Dark Green The trigger will cause the motor
control to transition to Run Mode
(Advanced) 1.
Go to Run Mode 2 Dark Green The trigger will cause the motor
control to transition to Run Mode
(Advanced) 2.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 237 of 277
 Table 63: Trigger Actions (full list) (cont'd.)

Action (User Level) Color Scheme (background) Description

Go to Run Mode 3 Dark Green The trigger will cause the motor
control to transition to Run Mode
(Advanced) 3.
Clear LockOut Dark Green The trigger will clear any lockout
and allow the motor control to
(Advanced) begin counting down for a restart
(if any trigger have any restarts
remaining).
Save 100ms Trace Dark Green The trigger will activate the
100ms trace function. This
(Advanced) function saves all channels
defined on the Trace Channels
screen at 100 ms intervals from
approximately 3 minutes before
the trigger enters the set state to
3 minutes after the trigger enters
the set state.
Latched Logic Brown The trigger when set will stay set
until a “Clear Latches” trigger is
(Advanced) set. Note that the Latched Logic
trigger has no effect on the motor
control – but can be very used as
an input when creating derived
trigger.
Clear Latches Dark Green The trigger when set will clear all
“Latched Logic” triggers. Note
(Advanced) that the Clear Latches trigger has
no effect on the motor control.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 238 of 277
 Table 63: Trigger Actions (full list) (cont'd.)

Action (User Level) Color Scheme (background) Description

E-STOP->FAULT Red Only for drives.
(Advanced) The trigger will cause control of
the motor to immediately cease,
allowing the motor to coast to a
stop. A fault will be declared. If
no restarts remain on the trigger,
the system will Lock Out.
LOG->NO_START Red This trigger will NOT cause the
motor to stop. It will, however,
(Advanced) prevent the motor from starting
when it is set. Primarily used
to designate warning conditions
that should prevent the motor
from starting. LOG->NO_START
triggers are often used to detect
warning conditions. When any
trigger with LOG->NO_START
action is set, Internal Trigger 228
“Any Warning” will be set. Trigger
228 can be used to indicate that
a warning condition is present.
Note that the Green RUN LED
will blink when a warning trigger
is SET.

10.10 Special Triggers

10.10.1 Internal Triggers

These triggers are set or cleared by logic built in to the software.

Table 64: Internal Triggers

Trigger Number Trigger Name Description

201 EIO 1 Comm Fail Com Failure with IO board
202 SG Comm Fail Com Failure with DH Tool
Surface System
203 Drive Comm Fail Com Failure with Drive Chassis
204 EIO 2 Comm Fail Com Failure with IO board #2

Copyright 2020 Baker Hughes Company. All rights reserved. Page 239 of 277
 Table 64: Internal Triggers (cont'd.)

Trigger Number Trigger Name Description

206 IO Mod ComFail Com Failure with RSTi IO
Module
219 Self-Stop The drive (or motor) has
stopped without being
commanded to do so.
220 Self-Start The drive (or motor) has
started without being
commanded to do so.
221 Remote Start Motor was started by SCADA
or Remote User.
222 Manual Start Motor was started manually.
223 Rst Timer Start Motor was started by
auto-restart timer.
224 Triggered Start Motor was started by a trigger.
225 Start Failed The drive (or motor) failed to
start after being commanded
to do so.
226 Stop Failed The drive (or motor) failed to
stop after being commanded
to do so.
228 Any Warning A Warning (LOG->NO
START) trigger is SET.
229 Group Shutdown Motor was stopped by SCADA
Group Shutdown Command.
230-240 System State See table below.
244 PwrFail SysStop The System was shut down
by power failure.
245 Warm Start The System was restarted
with memory retained.
246 Cold Start The System was restarted
with Event Logs and History
erased.
247 Any Fault A fault caused the motor to
be stopped. Latched until
cleared.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 240 of 277
 Table 64: Internal Triggers (cont'd.)

Trigger Number Trigger Name Description

248 Remote Lockout System Stopped and/or
Locked-Out by SCADA or
Remote User.
249 Local Lockout The System has been
Locked-Out locally (usually by
STOP button).
255 Watchdog Reset The System had to be
restarted due to a hardware
or software failure.

10.10.2 Motor Control State Triggers

At any given time, only one of the following triggers will be set to indicate the current state
of the system.

Table 65: Motor Control State Triggers

Trigger Number Trigger Name Description

230 [No IO Comm] Initial State—Cannot
communicate with
motor-controller. See Note 1.
231 [Locked Out] System is locked out and will
not restart automatically.
232 [Stopped-FAULT] Motor is stopped and will
not restart because a fault is
active.
233 [Ready-Manual] Motor is stopped, no fault is
active, but auto-restarts are
not enabled.
234 [Ready] Motor is stopped, holding for
a start request.
235 [Wait4Restart] Motor is stopped, counting
down to automatically restart.
236 [Prepare2Start] Checking for any “Pre-start
hold” triggers. See Note 2.
237 [Starting] Motor has been commanded
to start.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 241 of 277
 Table 65: Motor Control State Triggers (cont'd.)

Trigger Number Trigger Name Description

238 [Running] Running in Mode 1.
239 [Run Mode 2] Running in Mode 2.
240 [Run Mode 3] Running in Mode 3.
241 [Stopping] Motor has been commanded
to stop.

• Labeled “No IO Comm” in Switchboard applications and “No Drive Comm” in drive
applications.
• Labeled “Prepare2Start” in ESP systems and “StartSequence” in SPS systems.

11 Pump Curves
What is a Pump Curve?
A pump curve is a chart that shows the relationship between pump flow, head, power, and efficiency. Published
curves are for a single stage pump operating at 60 Hz. The pump curve shown below is from page 56 of the GE Oil
& Gas Artificial Lift 2013 Product Catalog.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 242 of 277
 Figure 200: Pump Curve

Pump curves are published for each pump stage sold by Baker Hughes. They are published in the BH Product
Catalog and maintained in Solutions Sizing Software. Applications engineers utilize these pump curves along with
customer production requirements, fluid, and reservoir data to select the proper ESP or Surface Pumping System.
In the Apollo Control System, the pump curve is used in reverse. Apollo assumes the pump curve represents the
pump’s performance. Then, utilizing the real-time operating conditions of the pumping system, Apollo determines
where on the pump curve the pump is operating and uses that information to improve pump protection.

11.1 Pump Curve Terminology

Table 66: Pump Curve Terminology

Term Description
Best Efficiency Point (BEP) The flow rate associated with the pump’s Best
Efficiency Point.
Down Thrust Condition in which the pump is operating at a flow
rate lower than the BEP. Note that some down
thrust is permitted within the operating range.
Efficiency Curve Illustrates the relationship between the fluid flow
through the pump and the efficiency of the pump.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 243 of 277
 Table 66: Pump Curve Terminology (cont'd.)

Term Description
Frequency/Speed The pump speed (in RPM) or frequency (in Hz) for
which the pump curve is valid. Published pump
curves are valid at 60 Hz.
Head Curve Illustrates the relationship between the fluid flow
through the pump and the head (amount of lift)
generated by the pump.
Operating Point The flow rate, head, power, and efficiency at which
the pump is currently operating.
Operating Range The range of flow over which the pump was
designed to run.
Power Curve Illustrates the relationship between the fluid flow
through the pump and the power required by the
pump.
Pump Curve Graph composed of the Head Curve, Power Curve,
and Efficiency Curve plotted against the fluid flow
through the pump.
Up Thrust Condition in which the pump is operating at a flow
rate higher than the BEP. Note that some up thrust
is permitted within the operating range.

11.2 Apollo Pump Curve

The picture Figure 201: Apollo Pump Curve Labeled, page 244 shows the Apollo pump curve with each
part labeled.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 244 of 277
 Figure 201: Apollo Pump Curve Labeled

The Apollo pump curve is recalculated as the drive output frequency changes. The Current Operating Point
is updated as the differential pressure across the pump changes.

The pumping system MUST HAVE both pump intake and pump discharge pressure to use the
Pump curve.
The Pump Curve’s thrust limits can also be seen in the Diff. Press. Meter on the Home Screen. The red
regions are outside the operating range of the pump.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 245 of 277
 Figure 202: Home Screen

11.3 How Apollo Uses the Pump Curve to Protect the Pump

One of the most important functions of a motor control system is to protect the pumping equipment. This
protection is accomplished by monitoring a variety of system parameters in real-time. Such parameters
usually include variable speed drive parameters (output current, output frequency, output voltage), pump
parameters (intake pressure, discharge pressure, fluid temperature), as well as other system parameters
(such as motor temperature, tubing pressure). If one or more of these parameters move outside of
designated safe ranges, the controller will modify the system operations or shut down the system to
protect the equipment.
Integrating the pump curve into Apollo adds another layer of protection for the pump. Centrifugal pumps,
such as those designed and manufactured by BH, are designed to work within a limited operating range.
Operating outside the design criteria will shorten the pump life. Unfortunately, determining if the pump is
operating within its design limits is too complex for simple fixed thresholds, leaving the pump unprotected
from this failure mode. The pump curve allows Apollo to continuously monitor the pump for operation
outside its design limits. Apollo can use this information to adjust the system operations or shut-down the
system as necessary to prevent pump damage.
Protections include:
• Choke Valve Control – If enabled, Apollo uses a Proportional/Integral/Derivative (PID) control loop to
control a proportional choke valve connected to the discharge side of the pump. The PID adjusts the
choke valve to keep the pump in its operational range.
• Up-Thrust Alarm/Fault Detection – Apollo monitors the pump operation for excessive up-thrust. Limits
for both Alarms (creates an Event in the Event Log/can be programmed to signal a digital output) and
Faults (Faults the system) are monitored.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 246 of 277
 • Down-Thrust Alarm/Fault Detection – Apollo monitors the pump operation for excessive down-thrust.
Limits for both Alarms (creates an Event in the Event Log/can be programmed to signal a digital output)
and Faults (Faults the system) are monitored.
In addition to the protections provided by the pump curve, the pump curve also allows Apollo to calculate the
fluid flow rate through the pump.

11.4 Setting up the Pump Curve

From the Home Screen, navigate as follows to the Pump Curve Setup menu.
Home Screen-> Settings-> MENU-> Other Initial Setup-> Right Arrow-> Pump Curve Setup
When you first navigate to the Pump Curve Setup menu, only the “Setup Pump Curve” wizard is shown.
Press the Select function button to walk through the pump curve configuration.
Information needed by the Pump Curve Setup wizard:
• Units for Calculated Flow: Options are barrels per day (BBL/Day), cubic meters per day (m3/Day),
and gallons per minute (GPM).
• Units for the Pump Head channel: Options are Feet and Meters.
• Units for the Power channel: Options are Horsepower (HP) and kilowatts (kW).
• Units for Differential Pressure: Options are pounds per square inch (PSI), Bar, kiloPascals (kPa),
megaPascals (MPa).
• Pump Manufacturer and Model
• Number of pump stages
• Pump Type: Options are Floater, Compression, and SPS.
• Water Specific Gravity:
– If you plan to use Viscosity Compensation, enter the specific gravity of the water in the Oil/Water
mixture being pumped.
– If you do not plan to use Viscosity Compensation, enter the specific gravity of the Oil/Water mixture.
• If Viscosity Compensation is used, you will also have to enter:
– Water Cut
– Oil Specific Gravity
– Well Fluid Viscosity
– Viscosity Method
◆ Options are Viscosity Compensation Disabled, Pump Curve Interpolation Method, Hydraulic Institute
Method.
– Flow Adjustment Factor

Copyright 2020 Baker Hughes Company. All rights reserved. Page 247 of 277
 Figure 203: Setup Pump Curve Wizard

Viscosity compensation using Pump Curve Interpolation (on pumps with viscosity curves available)
and the Hydraulic Institute viscosity compensation calculations can be enabled in the wizard.
Viscosity compensation is in field test at this time and should be considered a “beta” function.
After the Wizard is complete, the Pump Curve Setup menu will appear as shown in Figure 204: Pump
Curve Setup Menu, page 248.
See the wizard information above for details on the parameters.
Pump Thrust Limits are adjusted by selecting the Pump Thrust Limits option on this screen.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 248 of 277
 Figure 204: Pump Curve Setup Menu

Set the parameters in this menu to configure Pump Curve Thrust Limits.
• Upthrust Fault %: Sets the fault level as a % of the range between the pump BEP and the top of the
operational range. Set to 100% to use the operational range as the thrust limit. The default value is 100%.
• Upthrust Alarm %: Sets the alarm level as a % of the range between the pump BEP and the top of
the operational range. The default value is 75%.
• Downthrust Fault % and Downthrust Alarm % are set as a % of the range between the pump BEP and
the bottom of the operational range.
• Each fault/alarm has a trip delay. Set the value to be the time to tolerate the condition before
alarming/faulting.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 249 of 277
 Figure 205: Pump Curve Screen

11.5 Pump Curve Screen

Access the Pump Curve screen by navigating as follows:

Home Screen-> Data -> Pump Curve Screen.

The Pump Curve screen will not appear in the list of data screens until after the Setup Pump
Curve wizard has been executed.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 250 of 277
 Figure 206: Pump Curve Screen

11.6 Pump Thrust Screen

The Pump Thrust Screen graphically illustrates the pump operating position over time. Its capability is
best illustrated in a condition where the pump’s speed is changing. The Red and the Blue curves on
the graph are the Down-Thrust and Up-Thrust fault limits. The Green curve is the differential pressure
measured across the pump.
In the scenario at right, the SPS Setup wizard has been executed. By default, this wizard enables the choke
control PID using Differential Pressure as the feedback (control) value. Apollo uses the pump curve to
determine the Target Pressure (the differential pressure that causes the pump to run at its best efficiency
point or BEP) and controls the choke valve to achieve that pressure.
Notice that the drive starts up and runs for a while at 60 Hz. The frequency setpoint is changed to 40 Hz
and then later to 50 Hz.
As the drive frequency settles, the Valve PID adjusts the (simulated) choke valve to move the pump
performance to the best efficiency point.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 251 of 277
 Figure 207: Pump Thrust Screen

11.7 Updating Pump Database

From time to time, the pump database will be updated. The latest version will
be available on the Support Central Drives & Controls Product Support site
(http://supportcentral.ge.com/products/sup_products.asp?prod_id=264489).

It is currently in the Apollo Wizards drop-down box; look for “Pump Database Upgrade”. Download
the .zip file and copy the 2 files into the root directory of a USB Flash drive.
Insert the USB Flash drive into the Apollo system. The USB Menu will appear. Use the right arrow button to
advance to the second screen of the USB Menu.
Use the up and down arrow buttons to highlight “Update Pump Database” and press the Select function
button.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 252 of 277
 Figure 208: USB Menu

The new pump database will be copied over to the Apollo system.
Power the Apollo system off and back on again to start using the new pump database.

Figure 209: Update Pump Database Screen

11.8 Creating a Custom Pump

The Custom Pump Spreadsheet (CustomPump.xls) allows a user to add a new pump to Apollo’s list of
pumps. Two possible reasons to do this include:

Copyright 2020 Baker Hughes Company. All rights reserved. Page 253 of 277
 • The pump in the system is not in the engineering database.
• The user desires to use the pump curve for the actual pump being used instead of the reference curve.
The Custom Pump spreadsheet is available on the Support Central Drives & Controls Product Support site
(http://supportcentral.ge.com/products/sup_products.asp?prod_id=264489 ).
Every pump is tested to verify its operation to the catalog curve (within an acceptable limit). A pump curve
for that specific pump is created as part of the test. The pump curve information is included on the pump test
sheet provided with each pump. A customer or field engineer can use the Custom Pump spreadsheet to
generate a pump curve file for their pump using the test data. An example is shown in Figure 210: Pump
Test Results for TE-5500 S/N 203F2210P, page 253:

Figure 210: Pump Test Results for TE-5500 S/N 203F2210P

The steps for creating a Custom Pump file for use with Apollo are listed below:
1. Open the CustomPump.xls spreadsheet
2. Click the “Create Custom Pump” button
3. On the resulting dialog, click the “Enter Pump Test Data” button
4. Enter the test data. See Figure 211: Custom Pump Data Entry, page 254.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 254 of 277
 Figure 211: Custom Pump Data Entry

5. Click the OK button. The Custom Pump spreadsheet will perform a regression on the test data to create
the pump curve information.

Figure 212: Custom Pump Screen

6. Make any changes desired. Click the “Update Graph” button and review the pump curve.
7. Click the “Create Pump File”. Enter the name of the file as desired.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 255 of 277
 11.9 Installing/Selecting a Custom Pump on Apollo

Install the custom pump on an Apollo system.

• Copy the .pmp file created by the Custom Pump spreadsheet into the root directory of a USB Flash drive.
• Insert the flash drive into an Apollo system.
• The USB Menu will appear. Press the right arrow button to advance to the second page of the USB Menu.
• Select Install Pump File from the menu.

Figure 213: Install a Pump Curve File from USB Disk Screen

• Select the filename of the new pump.

• Press the Select function button.
Power the Apollo system off and back on again to make the new pump available.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 256 of 277
 Figure 214: Make New Pump Available Screen

Select the new pump.

• Navigate to the Pump Curve Setup menu. Home Screen-> Settings-> Menu-> Other Initial Setup-> Right
Arrow-> Pump Curve Setup
• Highlight Select Pump and press the Select function button.

Figure 215: Selecting New Pump Screen

Copyright 2020 Baker Hughes Company. All rights reserved. Page 257 of 277
 • Highlight Custom and press the Select function button.

That Custom will not appear in the list if no custom pumps have been installed.

Figure 216: Highlight Desired Pump Screen

The Serial number of any custom pumps that have been installed will appear. Highlight the desired pump
and press the Select function button.

Figure 217: Final Custom Pump Screen

The custom pump has been selected.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 258 of 277
 Figure 218: Updated Initial Setup Pump Curve Screen

12 Appendix A–Full Installation of Apollo Software

Use the following procedures to do a full installation of the Apollo Intelligent Control System – over an existing
Apollo system or a Vector VII HMI system.
A full installation is comprised of the following steps:
1. Install Apollo
2. Load a Template (if required)
3. Reset Drive to Defaults (if required)
4. System Setup and Operation

If an Apollo version 2.x drive is being upgraded to version 3.x and you wish to preserve the configuration,
please see Updating a Configuration from Apollo 2.x before beginning this procedure.

12.1 Install Apollo

You will need the Apollo software installed on a USB flash drive to complete this procedure.
1. Power the system off.
2. Insert the USB flash drive containing the Apollo software.
3. Power on the system.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 259 of 277
 4. When the system begins to boot, press and hold the F1 button. Release the F1 key when a white
window appears and files are being copied.
5. When the operation is complete, power off the system. Wait until the screen goes down and then
wait an additional 10 seconds.
6. Power on the system.
The Fault Screen will appear listing parameters that must be set up before running the drive.

Figure 219: Fault Screen

12.2 Load a Template (If Required)

Apollo is pre-loaded with the Standard template that works in Vector VII and Vector Plus applications. If
you are using the Apollo in a Switchboard application or with a different drive, follow the procedure in this
section to install the appropriate template.

Skip this section if Apollo is being used with a Vector VII or Vector Plus drive.
1. Navigate to the second page of the Main Menu. Settings-> Menu-> Right Arrow -> Load a New Template
The Select Template screen appears.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 260 of 277
 Figure 220: Home Screen

2. Select the desired template and press the Select function button. See Section 5.22 Load a Template,
page 185 for additional information.

Figure 221: Select Template Screen

3. Press the YES function button when prompted with “Overwrite Configuration?”.
4. The screen at right appears. Press the YES function button. Wait until the Apollo system reboots.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 261 of 277
 Figure 222: New Configuration Loaded Screen

12.3 Reset Drive To Defaults (If Required)

Please reset the drive to defaults when Apollo is installed on a Vector VII drive. Skip this step if Apollo
is being used with any other system.
When the Apollo software is first loaded onto a Vector VII drive, the drive should be set to defaults. This
procedure will show you how to set the drive to default.

Communications between the Apollo software and the drive chassis must be established before
this procedure is run. Ensure that the drive state in the upper left corner of the Home Screen is
not “No Drive Comm”.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 262 of 277
 Figure 223: Home Screen

1. Navigate to the second page of the Drive Settings screen using the following selections:
a. Settings-> Menu -> Config Drive Settings-> Right Arrow
2. Highlight the RstDrv2Defaults option.
3. Press the Select function button.

Figure 224: Main Menu Drive Settings

4. Use the Right Arrow button to change the value to True.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 263 of 277
 5. Press the Save function button and Confirm the changes. Wait at least 30 seconds. Then power the drive
off and wait until the screen goes dark. Wait an additional 10 seconds and turn the drive power back on.

The procedure is successful if no errors are displayed during the 30 second wait.

Figure 225: 30 Second Cycle Power

12.4 System Setup and Operation

Configure the Apollo system as described in Section 4: Basic Setup Sequence, page 85 of this manual.

12.5 Updating a Configuration from Apollo 2.x

When updating an Apollo system from 2.x to the current release, it is possible to update the configuration.
This procedure is not recommended for simple configurations based on the standard templates. In these
cases, it is recommended to reconfigure the system manually after the software update. However, if the
system used a custom template or a complex configuration in Apollo 2, add the following steps to the
procedure above to update the configuration for Apollo version 3.
1. Prior to beginning the software update:
a. Insert a USB flash drive and select the “Get Configuration Files” option.
b. Note the name of the filename saved.
2. Install the Version 3 Apollo software by inserting the USB flash drive used in Step 1, page 263.
a. Select the “Load Configuration” option… select the configuration saved off earlier.
b. Press F3 Settings and the following will be displayed:

Copyright 2020 Baker Hughes Company. All rights reserved. Page 264 of 277
 Figure 226: On-Screen Instructions

c. Press YES and follow the on-screen instructions.

When the Wizard is complete, you will need to press the Home button to redraw the
Home Screen.

13 Appendix B
13.1 USB Menu

When the Apollo System detects a USB Flash Drive, the following screen is displayed:

Copyright 2020 Baker Hughes Company. All rights reserved. Page 265 of 277
 Figure 227: USB Menu

Copyright 2020 Baker Hughes Company. All rights reserved. Page 266 of 277
 Table 67: USB Menu Options

Option File Description

Get Archive Files 1Site\Well\Archive\*.arc Archive files are binary files that
Site\Well\Event.Log contain the history data for all
channels that are being archived.
3WCS\CFG\date stamp Well.sbc
This function will create the
WCS\CFG\date stamp Well.s01 archive files on the USB Flash
drive if they do not exist there. If
the archive files already exist on
the USB Flash drive, the files will
be updated to include the new
archive data. This is the most
efficient method for collecting
history data – and the preferred
method when using the Archive
Viewer to view the files.
Archive files can be viewed
using the Apollo Archive Viewer
program or using the Apollo Amp
Chart program. These viewer
programs are available on the GE
Drives and Controls Support site.
Note that this function also
saves off the Event Log and
Configuration files, making it the
only function typically needed to
collect Apollo data.
If you need to send files to
OKC for problem solving, ZIP
all of the files and folders in
the Site\Well folder on your
flash drive. Send the ZIP file to
[email protected].

Get Event File Site\Well\Event.Log The Event Log Text file is a text
file containing all event data for a
specified time period. See details
below on how to specify the time
period. The Event Text file can be
viewed using any text editor (like
Notepad or Word).

Copyright 2020 Baker Hughes Company. All rights reserved. Page 266 of 277
 Table 67: USB Menu Options (cont'd.)

Option File Description

4Get Historical Text File 2Site\Well\date
and time The Historical Text file is a text
stamp.csv file containing the archived data
for all archived channels for a
specified period of time at a
specified sample rate. See details
below on how to specify the
historical date and sample rate.
The Historical Data Text file can
be viewed in Excel.
4Get Event Text File Site\Well\Event date and The Event Log Text file is a text
time stamp.txt file containing all event data for a
specified time period. See details
below on how to specify the time
period. The Event Text file can be
viewed using any text editor (like
Notepad or Word).
Get Configuration Files 3WCS\CFG\date stamp Well.sbc The configuration files are binary
and WCS\CFG\date stamp files that define the configuration
Well.s01 of the system. They cannot be
viewed. They can, however,
be loaded back into any Apollo
system to make it a clone of this
system.
Load Configuration WCS\CFG\date stamp Well.sbc The Load Configuration function
allows the user to select a
configuration file and load it
into the Apollo system. The
configuration files should be
placed in the \WCS\CFG\ folder
on the USB flash drive.
Get Default Modbus Map Site\Well\MBDefaultMap.txt The Default Modbus Map file is
a text file that shows the default
Modbus mapping for the system.
The default Modbus map does not
apply if a Custom Modbus map
has been installed or selected.
The Modbus Map file can be
viewed using any text editor (like
Notepad or Word).

Copyright 2020 Baker Hughes Company. All rights reserved. Page 267 of 277
 Table 67: USB Menu Options (cont'd.)

Option File Description

Get Digital IO Report Site\Well\IO Configuration The Digital IO Report file is a text
Report.txt file that contains all of the digital
I/O available in the system. The
report includes the I/O name,
direction (input or output), and
the channel to which the I/O is
connected. The Digital IO Report
file can be viewed using any text
editor (like Notepad or Word).
Get 100ms Trace Files Site\Well\date and time stamp.csv 100ms trace files are files that
contain data on 100ms intervals
for about 3.5 minutes before
to 3.5 minutes after a trigger is
activated. Triggers that activate
100ms trace files to be captured
are defined in the Assign Trace
Channels menu. This function
allows the user to select and save
the 100ms trace files to their USB
Flash drive. 100ms Trace files
can be viewed in Excel.
Get Apollo Manuals ManualName.pdf Various Apollo and Vector Plus
Drive Manuals are stored within
the Apollo filesystem. Select this
function to copy manuals to your
flash drive. The manuals are
copied into the root folder of your
flash drive.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 268 of 277
 Figure 228: USB Menu-Screen 2

Table 68: USB Menu #2 Options

Option File Description

Get Old Config Files Site\Well\date stamp.sbc Backup files are created once
each day if a change has been
made to the Apollo configuration.
These allow the user to revert the
system to a previous configuration
using the System Restore menu.
This function allows the user to
save a backup file onto the USB
Flash drive. The Backup file is a
binary file and cannot be viewed.
Install Modbus Map *.map Modbus remapping files allow the
Apollo to mimic other systems
(root level of the USB Flash drive) when queried by a SCADA host.
The Apollo system includes
remap files for the Vector VII
and the CTI RTU Standard map.
The Install Modbus Map function
allows a user to install a new
Modbus remapping file onto
an Apollo system when one is
needed. Modbus remapping files
are binary and cannot be viewed.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 269 of 277
 Table 68: USB Menu #2 Options (cont'd.)

Option File Description

Install Pump File *.pmp The Apollo system contains
a database containing the
(root level of the USB Flash drive) characterization information for
the current pumps. As new
pumps are created, the Install
Pump File function allows them
to be added to the system.
Pump files are created using the
CustomPump Excel spreadsheet.
Update Pump Database Event.lg1, PumpManfact.txt The database containing the
data for pumps is occasionally
(root level of the USB Flash drive) updated. This function allows
the new database to be loaded
into the Apollo system in the
field. After updating the pump
database, please re-select the
pump you are using to ensure the
latest pump data is being used.
Run Config Wizard \WCS\Shortcuts\*.mac Configuration wizards can be
used to automate many different
configuration tasks. Numerous
wizards are included in the
release software and can be
executed from the Other Initial
Setup menu. New wizards will
be distributed via the Drives &
Controls Product Support page
on Support Central.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 270 of 277
 Table 68: USB Menu #2 Options (cont'd.)

Option File Description

Install DH Tool *.DHT Support for additional downhole
tools will be added over time. This
(root level of the USB Flash drive) function allows the installation
and use of a new tool. Note that
support for Smartguard/Osiris,
Zenith E, and GRC Scout
3000 tools are supported in the
released software and can be
selected using the Setup DH Tool
function in the second page of the
Other Initial Setup menu.
Install IO Module *.IOM Support for additional I/O
modules and/or configurations of
(root level of the USB Flash drive) I/O modules will be added over
time. This function allows the
installation and use of the new
modules or configurations. Note
that support for the RSTi 8 Analog
Input module is supported in the
released software and can be
configured using the Install IO
Module function in the second
page of the Other Initial Setup
menu.

1. Site\Well indicate the Site Name\Well Name. This is the path on the USB Flash Disk. These
names are defined during the quick start procedure.
2. Date and time stamp indicate the start time of the historical log. For example, if the data
begins on November 28, 2010 at 4:46PM, the file name will be 28Nov2010-16h46m.csv.
3. Date stamp is just the date the file was created. For example, 2010-11-30.sbc.
4. Use the Get Historical Text File and Get Event File export routines if you (or a customer) wish
to review the data in standard office format (Excel, Word). Note that both of these functions
require the user to provide additional data as shown in Figure 229: Historical Data Text File
Setup , page 272.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 271 of 277
 13.1.1 Historical Data Text File Setup Screen

Figure 229: Historical Data Text File Setup

• Use the F1 and F5 function buttons to navigate to the various fields on the screen.
• Set the Start Time and Data and the EndTime and Date to match the time period of the data
you wish to export. Set the data interval as desired.
• Set any other fields if necessary.
• Press the Save function button to export the data.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 272 of 277
 13.1.2 Event Log Text File Setup Screen

Figure 230: Event Log Text File Setup

• Use the F1 and F5 function buttons to navigate to the various fields on the screen.
• Set the Start Time and Data and the EndTime and Date to match the time period of the data
you wish to export.
• Set any other fields if necessary.
• Press the Save function button to export the data.
Remove the USB Flash Drive when all necessary functions have been executed. The menu will
be automatically removed.

Copyright 2020 Baker Hughes Company. All rights reserved. Page 273 of 277
Index
129112............................................................... 28 197705 .............................................................. 28
197349 .............................................................. 28 800638 .............................................................. 28
197350 .............................................................. 28 810280 .............................................................. 28
197351 .............................................................. 29