Level 4 Tier 1 Electrical Submersible Pumping Systems Artificial Lift 907140 Rev. F Effective Date: 01 Nov 2015 Electrospeed Advantage Variable Speed Drive Installation and Operations Manual 2000 / 4000 / 8000 Series Drives 6-, 12-, and 24- Pulse ESP (6-Step) and FPWM NEMA 1 & 4 Enclosure Electrospeed Advantage™ Variable Speed Drive Installation and Operations Manual Revision History Rev. ECM Amendment Detail Reviewer Approver Approval Date A C110273 Release J. Hillshafer B. Haapanen 12 Jan 2011 B J. Hillshafer B. Haapanen 9 Feb 2012 C110627 Updated PS Fuse values, Cable Charts and Flash Card Section C J. Hillshafer B. Haapanen 20 Mar 2013 D C111854 Updated to Release 12 Software; Added 24P Drive J. Hillshafer B. Haapanen 31 Oct 2013 E C112619 Updated to Add Nema 1 Drive J. Hillshafer R. Dubuc 29 May 2014 Updated Electrospeed Input Electrical Filter support, User configured F C113981 R. Dubuc S. Plitt 19 Oct 2015 datalogging, Current Unbalance, EtherNet & Sealed drive drawings Contact your local Baker Hughes representative for current information regarding this product 1 Electrospeed Advantage™ Variable Speed Drive Installation and Operations Manual Table of Contents Table Of Figures ............................................................................................................... 8 Introduction ...................................................................................................................... 9 Features/Functions Benefits .............................................................................. 10 Commissioning Checklist ............................................................................................. 11 Safety and Installation ................................................................................................... 12 Safety Recommendation ............................................................................................ 12 Personal Protective Equipment (PPE) ..................................................................................12 Drive-specific Configuration ..................................................................................................12 Electrical Disconnect Handle with Interlock and Override .....................................................12 Safety Procedures ................................................................................................................13 Shipping and Handling ..........................................................................................................13 Storage .................................................................................................................................13 Installation ...................................................................................................................... 14 Location ................................................................................................................................14 Initial Checks ........................................................................................................................14 Power and Customer Interface Wiring...................................................................................14 Emergency Stop (Category Zero) Option Wiring ...................................................................15 Motor Temperature Sensing .................................................................................................15 IEEE Compliant Systems ......................................................................................................15 System Control Circuit Boards ..............................................................................................15 Graphic Display Basics .............................................................................................. 17 Keypad Switches ..................................................................................................................17 Keypad LEDs ........................................................................................................................18 Capacitive Keypad ................................................................................................................18 Key Pad Lockout Switch ............................................................................................ 19 Weatherproof Design ............................................................................................................19 Display LEDs and Panel Lights .............................................................................................19 Green, Amber and Red Display LEDs ...................................................................................19 Optional External Red, Amber and Green Panel Lights ........................................................20 External Lights ............................................................................................................ 21 External Light Mode: Vortex ..................................................................................................22 External Light Mode: Kratos ..................................................................................................22 External Light Mode: ICS EM ................................................................................................22 Start/Stop Display Unit Switches .............................................................................. 22 Internal Hand/Internal Auto Mode Selection ..........................................................................23 Hand/Off/Auto and Start Panel Mounted Switches (External HOA) .......................................24 Manual Keypad Lockout (Man Kpad Lk) ...............................................................................25 Displaying a Menu, Reading or Setpoint .................................................................. 26 Advantage Drive Display Conventions ..................................................................... 27 2 Electrospeed Advantage™ Variable Speed Drive Installation and Operations Manual Editing a Reading or Setpoint ...............................................................................................28 Auxiliary Restarts Parameter Enable ........................................................................ 29 Alarm and Shutdown Indication ................................................................................ 30 Lockout Condition ...................................................................................................... 30 System Security .......................................................................................................... 30 System Time Clock ..................................................................................................... 31 Backlight Adjust (Brightness)/Software Revs ........................................................................31 Pick Color Scheme ...............................................................................................................32 Citibus Diagnostics ...............................................................................................................32 Utility Menu ................................................................................................................. 33 Add Parm to Status ...............................................................................................................33 Add to Custom User ..............................................................................................................33 Screen Capture .....................................................................................................................33 Rename This Parameter .......................................................................................................34 Log This Parameter ..............................................................................................................34 Active Alarm Screen ................................................................................................... 35 Recording and Restoring a Drive's Configuration ..................................................................35 EasyStart Setup ............................................................................................................. 36 Set Time ...............................................................................................................................36 Set Language and Units .......................................................................................................36 System Setup .......................................................................................................................37 Autograph_PC Setup .................................................................................................. 37 EasyStart Setup Summary ......................................................................................... 37 Transformer Parameters .......................................................................................................38 EasyStart Final Summary .....................................................................................................38 Complete EasyStart ..............................................................................................................38 Easy Start Setup ...................................................................................................................39 Site Information .....................................................................................................................39 Application Type ...................................................................................................................39 Power System Voltage ..........................................................................................................40 Motor Parameters .................................................................................................................40 Cable Parameters .................................................................................................................40 Frequency Parameters .........................................................................................................41 EasyStart Setup Summary ....................................................................................................41 Transformer parameters .......................................................................................................41 Complete EasyStart ..............................................................................................................42 View Legacy Menus .................................................................................................... 42 Easy I/O Setup ................................................................................................................ 42 Easy I/O Setup ......................................................................................................................43 Onboard Digital I/O ..................................................................................................... 47 Onboard Digital Inputs ..........................................................................................................47 Onboard Digital Outputs .......................................................................................................47 3 Electrospeed Advantage™ Variable Speed Drive Installation and Operations Manual Onboard Analog Inputs .........................................................................................................48 The Advantage Drive Menus ......................................................................................... 49 Overview of Menu Structure ...................................................................................... 49 Status Screen .............................................................................................................. 50 Basic Setup ................................................................................................................. 51 Drive Setup .................................................................................................................. 51 Pwm Fltr Cfg .........................................................................................................................56 Filter Currents .......................................................................................................................57 Advanced Setup ......................................................................................................... 58 Load Setup .................................................................................................................. 60 Site Setup .................................................................................................................... 63 Input Filter Setup ........................................................................................................ 64 Features ....................................................................................................................... 66 Starts ........................................................................................................................... 69 Datalog and History ....................................................................................................... 72 Shutdown History ....................................................................................................... 72 Shutdown Detail.......................................................................................................... 72 Event Records ............................................................................................................ 73 Run History ................................................................................................................. 73 Compact Flash Card Datalogging ............................................................................. 76 Datalog Setup ............................................................................................................. 77 Save Historical Data ................................................................................................... 78 Save/Load System Setups ......................................................................................... 79 Save Setup to PC Card .........................................................................................................79 Load Setup From PC Card....................................................................................................80 Directory/File Functions ........................................................................................................82 Advanced Information ...........................................................................................................82 USB Features .............................................................................................................. 83 Get History .................................................................................................................. 84 Load Software Update ................................................................................................ 85 Load Autograph PC File ............................................................................................. 87 Load Configuration File ............................................................................................. 89 Directory and File Functions .................................................................................................90 Site Information .......................................................................................................... 91 4 Electrospeed Advantage™ Variable Speed Drive Installation and Operations Manual Graphing ...................................................................................................................... 91 Ø B Amp Chart .....................................................................................................................92 Faults and Alarms .......................................................................................................... 94 Overload ...................................................................................................................... 94 Underload .................................................................................................................... 97 Current Unbalance.................................................................................................... 101 Aux Rstart Parm ....................................................................................................... 102 Input Ovrvlt ............................................................................................................... 103 Input Undvlt ............................................................................................................... 104 Input Vunbal .............................................................................................................. 106 Low Speed Trip ......................................................................................................... 107 Temp Sensors ........................................................................................................... 108 Heatsink 1 ........................................................................................................................... 109 Heatsink 2 ........................................................................................................................... 109 Heatsink 3 ........................................................................................................................... 110 Heatsink 4 ........................................................................................................................... 110 Inductor Temp ..................................................................................................................... 110 Ambient Temp .................................................................................................................... 111 Auxiliary Temp .................................................................................................................... 111 Telemetry Fail ........................................................................................................... 111 Alarm Setup .............................................................................................................. 114 User Config Function .................................................................................................. 115 Config Function Setup ............................................................................................. 115 Output Frequency Control ....................................................................................... 115 Frequency Setpoint Mode ................................................................................................... 116 Analog Follower Mode ........................................................................................................ 117 Proportional/ Integral/ Derivative Mode ............................................................................... 118 MaxPointTM Control Mode ................................................................................................... 123 MaxRateTM Gas Mitigation Software .................................................................................... 125 User Prog Block ........................................................................................................ 129 Edit Prog Block ................................................................................................................... 129 Edit User Point .................................................................................................................... 131 User Defined Alarms ................................................................................................ 133 User Alarm 1 ....................................................................................................................... 133 User Alarm 2 Through 8 ...................................................................................................... 135 Digital Output Control .............................................................................................. 135 Digital Output Setup (Alarms) ............................................................................................. 136 Select Alarms ...................................................................................................................... 136 Digital Output Setup (Shutdowns) ....................................................................................... 136 5 Electrospeed Advantage™ Variable Speed Drive Installation and Operations Manual Select Shutdowns ............................................................................................................... 137 Digital Output Setup (List) ................................................................................................... 137 Digital Output Setup (View List) .......................................................................................... 137 Digital Output Setup (Reset) ............................................................................................... 138 Analog Output Control ............................................................................................. 138 Analog Out Setup ............................................................................................................... 138 Custom Modbus Maps ............................................................................................. 140 Custom Input Status ........................................................................................................... 140 Custom Input Status Configuration ..................................................................................... 140 Custom Output Status Configuration ................................................................................... 141 Custom Input Registers ...................................................................................................... 141 Custom Output Registers .................................................................................................... 142 User PID Setup .......................................................................................................... 142 Custom User Screen .................................................................................................... 145 Custom User Menu ................................................................................................... 145 SCADA and Security and System ............................................................................... 146 System ....................................................................................................................... 146 Software Rev Num .................................................................................................... 148 SCADA Setup ............................................................................................................ 150 RS 232 Setup ............................................................................................................. 150 RS 232 Com Stats .............................................................................................................. 153 RS 485 Setup ............................................................................................................. 153 RS 485 Terminations and Fail Safe Biasing ........................................................................ 155 RS 485 Com Stats .............................................................................................................. 156 Ethernet Setup .......................................................................................................... 156 ENET1 Com Stats .............................................................................................................. 159 Centl Shutdown ........................................................................................................ 159 Security ..................................................................................................................... 159 Set Time ..................................................................................................................... 160 Analog Setup and Display ........................................................................................... 161 Drive Input Current ................................................................................................... 161 Drive Input Volts ....................................................................................................... 162 Drive Input Power ..................................................................................................... 162 Drive Output .............................................................................................................. 163 Transformer/Motor.................................................................................................... 164 Internal and External Modules .................................................................................... 165 6 Electrospeed Advantage™ Variable Speed Drive Installation and Operations Manual Onboard I/O ............................................................................................................... 166 Internal Analog Input 1 ............................................................................................. 166 High Threshold Setup .............................................................................................. 167 Low Threshold Setup ............................................................................................... 168 Internal Analog Input 2 ............................................................................................. 169 Internal Digital Input 1, 2, 3, 4 and 5 ........................................................................ 170 Internal Digital Output 1, 2, 3, 4 and 5 ..................................................................... 171 Auxiliary I/O ............................................................................................................... 171 Expansion I/O Module 1 ........................................................................................... 172 Expansion I/O Module 2 ........................................................................................... 172 Expansion I/O Module 3 ........................................................................................... 172 CITIBus Module Status ............................................................................................. 172 Module Status ........................................................................................................... 173 Modules Status CITIBus Success Rate .................................................................. 173 Appendix A: Specifications and Ratings ................................................................... 174 Appendix B: Installation/Service Record ................................................................... 175 Appendix C: Data Logging Specifications ................................................................. 176 Appendix D: Product Certification ............................................................................. 178 Appendix E: Multiple Converter / 24 Pulse Drives ................................................... 180 Appendix F: Filtered PWM Operation ......................................................................... 182 Appendix G: Model Designation & Variable Torque VSD Ratings ........................... 185 Variable Torque VSD Ratings .................................................................................. 186 Appendix H: Fuse and Cable Sizing ........................................................................... 187 Appendix I: Control Schematic Diagrams.................................................................. 189 Appendix J: Power Schematic Diagrams .................................................................. 203 Appendix K: Outline And Anchor Dimensional Drawings ........................................ 219 7 Electrospeed Advantage™ Variable Speed Drive Installation and Operations Manual TABLE OF FIGURES Figure 1: ADVANTAGE 2000/4000 NEMA 1 6-PULSE, 12-PULSE ALL STANDARD OPTIONS ............................. 189 Figure 2: ADVANTAGE 2000/4000 NEMA-1 6&12-PULSE CATEGORY 0 SHUT DOWN & INPUT POWER MONITORING ............................................................................................................................................................... 190 Figure 3: ADVANTAGE 2000/4000 NEMA 1 6-PULSE, 12-PULSE CENTINEL AND WELL LIFT INTERFACE ...... 191 Figure 4: VSD ADVANTAGE SERIES 2000 & 4000 N4 WITH ALL STANDARD OPTIONS ......................................... 192 Figure 5: VSD ADVANTAGE SERIES 4000 HARSH ENVIRONMENT NEMA4 24 PULSE WITH ALL STANDARD OPTIONS ...................................................................................................................................................................... 193 Figure 6: ADVANTAGE SERIES 2000 & 4000 N4 12P CURRENT SHARING ............................................................ 194 Figure 7: VSD ADVANTAGE SERIES 2000 & 4000 N4 CATEGORY ZERO SHUT DOWN OPTION........................... 195 Figure 8: VSD ADVANTAGE SERIES, 2000 & 4000 N4 DOWNHOLE INSTRUMENTATION OPTION ...................... 196 Figure 9: ADVANTAGE SERIES 2000 & 4000 N4 SCH/INTERCONNECT, PWM FILTER TO DRIVE ......................... 197 Figure 10: ADVANTAGE VSD 8N4 6/12 & 24P, 4N4 24P ONLY WITH ALL STANDARD OPTIONS ........................... 198 Figure 11: ADVANTAGE 4000-24 PULSE AND SERIES 8000 6/12P, 24 PULSE - CONVERTERS AND CONTROL . 199 Figure 12: ADVANTAGE 4000-24P & 8000 6/12/24 P CATEGORY ‘0’ SHUTDOWN & POWER MONITORING OPTION ......................................................................................................................................................................... 200 Figure 13: ADVANTAGE 4000-24P & 8000 6/12P, 24P DOWNHOLE INSTRUMENTATION: CENTINEL AND WELL LIFT INTERFACE .......................................................................................................................................................... 201 Figure 14: ADVANTAGE 4000-24P AND SERIES 8000 6/12P, 24 P FILTERED PWM OPTION ............................... 202 Figure 15: ADVANTAGE 2000/4000 NEMA1 6/12PULSE CONVERTER, CONTROL BOARD, POWER SUPPLY, COOLING FANS, INVERTER ....................................................................................................................................... 203 Figure 16: ADVANTAGE 2000/4000 NEMA 1 DETAIL: 12-PULSE CONVERTER, 6/12 INPUT MONITORING, IGBT, SCR DIODE DC BUS .................................................................................................................................................... 204 Figure 17: ADVANTAGE 2000/4000 NEMA 4 - 6/12PULSE CONVERTER, CONTROL BOARD, POWER SUPPLY, COOLING FANS, INVERTER ....................................................................................................................................... 205 Figure 18: ADVANTAGE 2000/4000 NEMA4 DETAIL: 12 PULSE CONVERTER, 6 PULSE INPUT MONITORING, IGBT, SCR, DIODE, DC BUS ........................................................................................................................................ 206 Figure 19: ADVANTAGE 8000 NEMA4 6/12 PULSE DETAIL: CONVERTER 1 AND INVERTER 1 ........................... 207 Figure 20: ADVANTAGE 8000 NEMA4 6/12 PULSE DETAIL: CONVERTER 2 AND INVERTER 2 .......................... 208 Figure 21: ADVANTAGE 8000 NEMA4 6/12 PULSE DETAIL: CONTROL BOARD, POWER SUPPLY, COOLING FANS ............................................................................................................................................................................. 209 Figure 22: ADVANTAGE 8000 NEMA4 6/12 PULSE DETAIL: INVERTER BOARD CONNECTIONS ....................... 210 Figure 23: ADVANTAGE 8000 NEMA4 6/12 PULSE DETAIL: CONVERTER BOARD CONNECTIONS .................... 211 Figure 24: ADVANTAGE 8000 NEMA4 6/12 PULSE DETAIL: IGBT, SCR, DIODE, DC BUS .................................... 212 Figure 25 ADVANTAGE 8000 NEMA4 6/12 PULSE DETAIL: CONVERTER 1 & 2 AND INVERTER 1 ...................... 213 Figure 26 : ADVANTAGE 4000/ 8000 NEMA4 6/12 PULSE DETAIL: CONVERTER 3 & 4 AND INVERTER 2 .......... 214 Figure 27: ADVANTAGE 4000/8000 NEMA4 24 PULSE CONTROL BOARD, POWER SUPPLY, COOLING FANS . 215 Figure 28: ADVANTAGE 4000/ 8000 NEMA4 24 PULSE Detail: INVERTER BOARD CONNECTIONS ..................... 216 Figure 29: ADVANTAGE 4000/ 8000 NEMA4 24 PULSE DETAIL: CONVERTER BOARD CONNECTIONS .............. 217 Figure 30: ADVANTAGE 4000/ 8000 NEMA4 24 PULSE DETAIL: IGBT, SCR, DIODE, DC BUS ............................. 218 Figure 31: ADVANTAGE 2000 NEMA 1: OUTLINE & ANCHOR DIMENSIONAL DIAGRAMS .................................... 219 Figure 32: ADVANTAGE 2000 NEMA 1: OUTLINE & ANCHOR DIMENSIONAL DIAGRAMS .................................... 220 Figure 33: ADVANTAGE 2000 NEMA 4: OUTLINE & ANCHOR DIMENSIONAL DIAGRAMS .................................... 221 Figure 34: ADVANTAGE 2000 NEMA 4 SERIES- PWM FILTER OUTLINE & ANCHOR DIMENSIONAL DIAGRAMS 222 Figure 35: ADVANTAGE 4000 NEMA 4 6/12P SERIES OUTLINE & ANCHOR DIMENSIONAL DIAGRAMS ............. 223 Figure 36: ADVANTAGE 4000 NEMA4 24P SERIES HARSH ENVIRONMENT CABINET - OUTLINE & ANCHOR .... 224 Figure 37: ADVANTAGE 4000 NEMA 4 24P SERIES OUTLINE & ANCHOR DIMENSIONAL DIAGRAMS ............... 225 Figure 38: ADVANTAGE 4000 NEMA 4 SERIES-PWM FILTER OUTLINE & ANCHOR DIMENSIONAL DIAGRAMS . 225 Figure 39: ADVANTAGE 8000 NEMA 4 SERIES OUTLINE & ANCHOR DIMENSIONAL DIAGRAMS ....................... 225 Figure 40: ADVANTAGE 8000 NEMA 4 SERIES-PWM FILTER OUTLINE & ANCHOR DIMENSIONAL DIAGRAMS . 225 8 Electrospeed Advantage™ Variable Speed Drive Installation and Operations Manual Electrospeed Advantage™ Variable Speed Drive Installation and Operations Manual INTRODUCTION The Baker Hughes Electrospeed Advantage™ variable speed drive (VSD) is classified as a variable voltage inverter (VVI). It uses a six-pulse silicon controlled rectifier (SCR) front end to convert incoming AC power into variable voltage DC power. This DC power is inverted to variable voltage variable frequency AC power and is used to drive an electrical submersible pump (ESP) or a surface motor. Drives with higher pulse count front ends (converters) identified as 12- or 24-pulse drives can be configured where harmonic reduction is required. An inductor connected in series and capacitors connected in parallel across the DC bus are used to filter the AC ripple. The inverter section uses power insulated gate bipolar transistors (IGBT) to synthesize a 3- phase quasi-sinusoidal output voltage using Baker Hughes’ SelectWaveTM inverter algorithm. This modern AC variable voltage inverter is designed to meet all the requirements of installations requiring a variable frequency source. It operates directly from 380 to 480 VAC 3-phase 50/60 Hertz power. Use of the latest microprocessor technology allows for ease of setup, operation and diagnostics. Microprocessor control also reduces the number of circuit boards required, thus enhancing the reliability and versatility of the drive. The graphical operator interface provides ease of use and programming of special applications. The Advantage drive is programmable for many types of loads such as variable torque, constant torque and constant voltage with extended speed range. The Advantage drive is available in a weatherproof (NEMA 4, IP56) and a general purpose (NEMA1, IP30) enclosure. The weatherproof units use a patented cooling system that eliminates the inefficiencies and reliability problems associated with heat pumps. Currently, three NEMA 4 enclosure sizes referred to as 2000, 4000 and 8000 series are being offered. At this time, the NEMA 1 enclosure is offered in the 2000 series size only. The Advantage drive can communicate with SCADA or telemetry systems, using the included Modbus RTU protocol with the onboard RS-232 and RS-485 hardware interface or via Modbus TCP with either of two included Ethernet ports. The Advantage drive also provides a high-speed interface (CITIBusTM) that simplifies control system expansion and customization. Using the CITIBus interface, input/output expansion modules can be added to the system, thus providing a single point of control and monitoring for a wide range of sensor types. 9