Summary of Contents for Baker Hughes FusionPro VSD 0130-0260kVA ESP
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Doc Number: 500031032 Rev: A Effective Date: 5 February 2025 FusionPro Operations and Installation Manual Copyright 2025 Baker Hughes Company. All rights reserved.
The information contained in this document is confidential and proprietary property of Baker Hughes and its affiliates. It is to be used only for the benefit of Baker Hughes and may not be distributed, transmitted, reproduced, altered, or used for any purpose without the express written consent of Baker Hughes.
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FusionPro Operations and Installation Manual Revision History Rev. Amendment Detail Author Reviewer/Approver Effective Date Current Revision Rod Smith, Jeremy 105852 Initial Release Gerald Otoide 5 Feb 2025 Hillshafer Three Previous Revisions Copyright 2025 Baker Hughes Company. All rights reserved. Page 3 of 78...
Setup of FusionPro variable speed drives with SWF capability applied on Electrical Submersible Pumps ..66 SWF PWM SYSTEM OVERVIEW ......................................... 66 OPERATION ................................................68 Filter Faults ................................................68 Appendix F: Motor Overload Protection........................69 Appendix G: Schematics ..............................71 Copyright 2025 Baker Hughes Company. All rights reserved. Page 4 of 78...
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Figure 41: 24 VDC Controls (Including E1242-T MOXA) at VSD Customer Interface Panel (Rotated 90° Counterclockwise) ................................46 Figure 42: Moxa Profiles and Physical Dimensions (Characteristics of I/O channel connectors vary per module type) ................................49 Copyright 2025 Baker Hughes Company. All rights reserved. Page 5 of 78...
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Figure 61: Schematic 500030391 Rev A, SHT-7; FusionPro 2N4/4N4 System Control and Power ..77 Figure 62: Schematic 500030391 Rev A, SHT-8; FusionPro 2N4/4N4 System Control and Power ..78 Copyright 2025 Baker Hughes Company. All rights reserved. Page 6 of 78...
FusionPro Operations and Installation Manual Introduction The Baker Hughes FusionPro™ variable speed drive (VSD) is a voltage source inverter (VSI) low voltage VSD that gets its power from the utility supply or generator and uses a six-pulse silicon- controlled rectifier (SCR) front end to convert the incoming AC power into an intermediate DC power.
This drive family implements the foundation to learn the interface only once FusionPro human-machine interface (HMI) that integrates and expands upon the functionality of legacy BH drive HMIs. Copyright 2025 Baker Hughes Company. All rights reserved. Page 8 of 78...
• Ensure Earth ground is properly bonded before making any contact with the drive or attached equipment. See Figure 25. Copyright 2025 Baker Hughes Company. All rights reserved. Page 9 of 78...
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− voiding the product warranty • Baker Hughes is not responsible for any unauthorized use of the equipment; such use may impede physical and software protections provided by the equipment. • This equipment contains a Wi-Fi module (FCC ID: N6C-PMACS and ISED ID: 4908A-PMACS) which operates at 2.4GHz and 5GHz (802.11 a/b/g/n/ac).
CAUTION indicates a hazardous situation which if not avoided, could result in minor or moderate injury. NOTICE indicates instructional information for proper equipment management. Copyright 2025 Baker Hughes Company. All rights reserved. Page 11 of 78...
NFPA 70E or CSA Z462. After installation, another label should be attached by a qualified evaluator indicating the calculated arc-flash risk for the system. Figure 3: Danger Label Arc-Flash Copyright 2025 Baker Hughes Company. All rights reserved. Page 12 of 78...
It also reminds one that the line side of molded case switches or circuit breakers is energized until isolated from source power. Figure 6: Warning Label: “380~480V Input.” Copyright 2025 Baker Hughes Company. All rights reserved. Page 13 of 78...
Ensure a properly rated voltage indicator is used to prove the circuit is dead. Figure 8: Warning Label: “Back-spin Regeneration” Copyright 2025 Baker Hughes Company. All rights reserved. Page 14 of 78...
(input transformer) having a short circuit capacity greater than 65000 Amps. Else, the drive’s circuit protection system may fail to operate as intended. Figure 11: Warning Label: “Short Circuit Current” Copyright 2025 Baker Hughes Company. All rights reserved. Page 15 of 78...
This label is located at the ground bar inside the drive’s J- box. Reference the installation procedures in this manual for more details. Figure 14: Notice Label: “Ground” Copyright 2025 Baker Hughes Company. All rights reserved. Page 16 of 78...
If equipped, this label indicates the drive has been evaluated by the manufacturer and found to be compliant with all the applicable European Union Directives. Figure 19: “Notice Label: “CE Mark” Copyright 2025 Baker Hughes Company. All rights reserved. Page 17 of 78...
PPE must be worn when opening cabinet doors while the drive is energized. High Voltage Shock Death or serious bodily injury • Operate per manufacturer’s specification. Ensure all required PPE is used. • Copyright 2025 Baker Hughes Company. All rights reserved. Page 18 of 78...
NOTICE strap working its way loose during transit. Each strap should have a twist between eyelets to prevent paint damage during transit. Copyright 2025 Baker Hughes Company. All rights reserved. Page 19 of 78...
This equipment must not be installed or operated in potentially explosive atmospheres (outside of Class 1 Div 2 zone). • Ensure adequate clearance from obstructions (see Equipment Placement and Mechanical Installation). Copyright 2025 Baker Hughes Company. All rights reserved. Page 20 of 78...
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All electrical panel doors are equipped with a lockable means and should be secured to prevent unauthorized access. • If this product carries the certified mark by TUV Rheinland, any unauthorized part substitutions or modifications will void this certification. Copyright 2025 Baker Hughes Company. All rights reserved. Page 21 of 78...
The sequence of steps below should be followed when first commissioning a drive. • Steps involving VSD in LOTO state (lock out tag out) Input wire size, quantity, routing, and securement (see Power Wiring Requirements & − Table Copyright 2025 Baker Hughes Company. All rights reserved. Page 22 of 78...
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With the drive’s power output disconnected, perform a No-load test by starting and − running the drive to ensure it reaches the set frequency (tests the converter section). Copyright 2025 Baker Hughes Company. All rights reserved. Page 23 of 78...
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Do not measure the step-up transformer's output voltages unless the proper equipment − is available and medium voltage electrical system training has been completed. − Evaluate the measured motor load to predicted values at the particular operating frequency. Copyright 2025 Baker Hughes Company. All rights reserved. Page 24 of 78...
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Evaluate the measured motor load to predicted values at a particular operating frequency. *** Note that measuring equipment may be inaccurate at frequencies outside of 50/60 Hz *** Copyright 2025 Baker Hughes Company. All rights reserved. Page 25 of 78...
Service access points for low-voltage electrical equipment require 1 meter (3 ft) minimum opening clearance, or as required per local ordinances. Figure 24: Typical Site Equipment Placement Copyright 2025 Baker Hughes Company. All rights reserved. Page 26 of 78...
(per system kVA as deciphered from NEC 250.66) is listed in Table 4, along with the bonding wire size that is included with the recommended armor cable (that can also be used for system bonding). Copyright 2025 Baker Hughes Company. All rights reserved. Page 27 of 78...
Figure 266). Approximate gland plate dimensions and power-connection dimensions are indicated in the Outline and Anchor drawings for 2N4 (PN 500031777) and 4N4 (PN 500031977) in the Appendix. Copyright 2025 Baker Hughes Company. All rights reserved. Page 28 of 78...
J-box. Wire range for related lugs and recommended fastening torques are listed in Table 8 (Appendix). Figure 27: VSD 130-260kVA 6 Pulse J-Box Copyright 2025 Baker Hughes Company. All rights reserved. Page 29 of 78...
Figure 35: VSD 454/520kVA 24 Pulse J-Box Figure 366 represents wiring items detailed in Table 8 (Appendix). These wiring components are recommended for safe and reliable FusionPro installations. Copyright 2025 Baker Hughes Company. All rights reserved. Page 33 of 78...
• Verify that the site is safe prior to removing any LOTO. • Confirm the correct voltage levels are present on the incoming power lines to the drive. Copyright 2025 Baker Hughes Company. All rights reserved. Page 34 of 78...
• All power sources must be isolated and wiring to and from the drive must be proven de-energized before installing this equipment. Always use LOTO. Copyright 2025 Baker Hughes Company. All rights reserved. Page 35 of 78...
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• Optional Surface unit to interface with Zenith down-hole sensors • Control logic for auxiliary equipment. power supply (external 2-amp load capacity) − − Moxa E1242 I/O module Copyright 2025 Baker Hughes Company. All rights reserved. Page 36 of 78...
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Figure 61 in the Appendix section. • Sine wave filter (SWF) option. See Appendix E: Sine-Wave Filter (SWF) PWM Operation. Copyright 2025 Baker Hughes Company. All rights reserved. Page 37 of 78...
Note that terminal blocks are Wago 2202 series with cage clamps for stranded wire from 18 to 14 AWG (1 ~ 2.5 mm ). It is recommended to use ferrules such as Pan-Term® FSD77-10-D when terminating stranded wires. Terminal Block Connector 18AWG Ferrule Copyright 2025 Baker Hughes Company. All rights reserved. Page 38 of 78...
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(RLY21~24, 250V/6A). This provides isolation and increases voltage and current capacity. All Moxa input and output functions are managed through the FusionPro System Controller. Reference this manual for related setup details. Copyright 2025 Baker Hughes Company. All rights reserved. Page 39 of 78...
• Communicate with local network devices. Advantage power module, Moxa, ZIU, and other compatible Modbus devices. − • Communicate with external network devices. RS-232 SCADA (Modbus Serial) − Copyright 2025 Baker Hughes Company. All rights reserved. Page 40 of 78...
Ensure any removed protective covers have been reinstalled. • Verify site is safe prior to removing any LOTO. • Confirm the correct voltage levels are present on the incoming power lines to the drive. Copyright 2025 Baker Hughes Company. All rights reserved. Page 43 of 78...
Connected downhole motor may generate back- • fed voltage. Once all drive incoming power is removed, isolate downhole motor power potential at the vented junction box prior to servicing. Copyright 2025 Baker Hughes Company. All rights reserved. Page 44 of 78...
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“wet contact” I/O modules. Room for additional components will vary depending on whether other options exist. Installation of MOXA modules outside the cabinet should also be possible but has not been thoroughly evaluated. Copyright 2025 Baker Hughes Company. All rights reserved. Page 45 of 78...
0 to 10 Vdc; 0/4~20 mA w/ 120 ohm resistor built 5000006379 E1240-T 8 AIs 2- or 3- wire, 625 k-ohm input impedance, 5000006381 E1260-T 6 RTDs PT1000 (-200 to 350°C), PT50, PT100, PT200, PT500 (-200 to 850°C) Copyright 2025 Baker Hughes Company. All rights reserved. Page 47 of 78...
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Do not touch circuit components inside the • equipment. Use a static-safe workstation, if available. • Store the equipment in appropriate static-safe • packaging when not in use. Copyright 2025 Baker Hughes Company. All rights reserved. Page 48 of 78...
Figure 42: Moxa Profiles and Physical Dimensions (Characteristics of I/O channel connectors vary per module type) Features Ethernet Port Signal TXD+ TXD- RXD+ Signal RXD- Figure 43: Other Moxa Module Details Copyright 2025 Baker Hughes Company. All rights reserved. Page 49 of 78...
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Transmitting or receiving data Port 2 Green Ethernet connection enabled Flashing Transmitting or receiving data Green EXT field power input is connected EXT field power input is disconnected Copyright 2025 Baker Hughes Company. All rights reserved. Page 50 of 78...
However, if additional modules are added and an unshielded ethernet cable is used, the module should be connected to a ground point in the VSD with 16 AWG (1.5 mm ) wire. Copyright 2025 Baker Hughes Company. All rights reserved. Page 51 of 78...
(Suggested Block and open the top cover as near the IO channels. Position the Torque: 3.9 ± 0.4 kg-cm) shown in the diagram. jumper as described below. Copyright 2025 Baker Hughes Company. All rights reserved. Page 52 of 78...
It is also a good practice to avoid running the cable near power wires to avoid electrical noise caused by crosstalk. It is also recommended to place cabling outside of the cabinet in conduit or armored cable to avoid damage. Copyright 2025 Baker Hughes Company. All rights reserved. Page 53 of 78...
Table Phase (typical) Need to account for all input configurations (6P, 12P, & 24P). Frequency 50/60 Hz +/- 2 Hz (stable governing of speed is essential for generators) Copyright 2025 Baker Hughes Company. All rights reserved. Page 54 of 78...
Sea level to 5000 ft (1524 m) without derate Classification Area Non-hazardous Weight and Appendix D: Dimensions and Approximate Weights Dimensions Nameplate VSD Nameplate with general product information 2. VSD physical properties 3. VSD electrical ratings Copyright 2025 Baker Hughes Company. All rights reserved. Page 55 of 78...
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Induction or permanent magnet Manual setpoint Current control PID defined by user. Frequency Control PID + current control Analog follower Hz to PID on the fly ESP Custom Software MaxRate™ GasPrime Copyright 2025 Baker Hughes Company. All rights reserved. Page 56 of 78...
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PS2, 24 VDC @ 2 A, external access per TB23 (-) and TB24 (+) AC Control Power CPT2, 115 VAC @ 2.4 A, external access per TB9 (hot) and TB10 (neutral) Copyright 2025 Baker Hughes Company. All rights reserved. Page 57 of 78...
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The MCCB trip value is factory set to correspond with VSD’s input current rating and rectifier configuration – 6 pulse/12 pulse/24 pulse. :SWF Ratings are for 60 Hz output. Please see Figure 52 for the derating curve for frequencies higher than 60 Hz. Copyright 2025 Baker Hughes Company. All rights reserved. Page 61 of 78...
2-250A 2x82 input, C902159 902169 51145 225/225 (In:2/Out:2) 04FP12ESP (2) output 3/0, (1) per #4 AWG 0200K- 2-250A 2x127 input, C902161 902172 88152 225/225 (In:2/Out:2) 04FP12ESP (2) output Copyright 2025 Baker Hughes Company. All rights reserved. Page 62 of 78...
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500031151 PL GLAND DWG 4N4 AP 500031152 PL GLAND DWG 4N4 AP 500031153 PL GLAND DWG 4N4 AP SS NO PNT 500031154 PL GLAND DWG 4N4 AP BRASS Copyright 2025 Baker Hughes Company. All rights reserved. Page 63 of 78...
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Fuse, 4 amp, 250V 5x20MM time delay C55535 BUSSMAN MDL-4 FU11 & 12 Fuse, 5 amp, 500V Midget time delay C48106 BUSSMAN FNQ-5 FU20 Fuse, 4 amp, 250V 5X20MM time delay C48109 LITTELFUSE 218004 Copyright 2025 Baker Hughes Company. All rights reserved. Page 64 of 78...
Graphics showing the dimensions (D, W, and H) of each drive model can be found in the Outline and Anchor drawings for 2N4 (PN 500031777) and 4N4 (PN 500031977). Copyright 2025 Baker Hughes Company. All rights reserved. Page 65 of 78...
FusionPro SWF PWM drives for frequencies higher than 60Hz. Table 13 shows the percentage load and voltage drop in SWF PWM mode from 10Hz to 200Hz. Figure 52: FusionPro SWF Drive Derate Curve Copyright 2025 Baker Hughes Company. All rights reserved. Page 66 of 78...
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11.3 88.0 12.0 Note: To calculate the output kVA in SWF mode for higher than 60 Hz, please multiply the corresponding percentage load using nominal kVA in Table Copyright 2025 Baker Hughes Company. All rights reserved. Page 67 of 78...
The Status screen of the FusionPro display will show either of the following as the last shutdown: PM Flt Filter Inductor Fault PM Flt Filter Capacitor Fault Figure 53: Filter Fault Display Copyright 2025 Baker Hughes Company. All rights reserved. Page 68 of 78...
It is very important to always refer to the motor specification when adjusting the overload parameters. The graph below represents the overload ratio values and the corresponding trip times. Copyright 2025 Baker Hughes Company. All rights reserved. Page 69 of 78...
500031032 Rev: A Effective Date: 5 Feb 2025 FusionPro Operations and Installation Manual Figure 54: Motor Overload Trip Delay Curve Copyright 2025 Baker Hughes Company. All rights reserved. Page 70 of 78...
500031032 Rev: A Effective Date: 5 Feb 2025 FusionPro Operations and Installation Manual Appendix G: Schematics Figure 55: Schematic 500030391 Rev A, SHT-1; FusionPro 2N4/4N4 System Control and Power Copyright 2025 Baker Hughes Company. All rights reserved. Page 71 of 78...
500031032 Rev: A Effective Date: 5 Feb 2025 FusionPro Operations and Installation Manual Figure 56: Schematic 500030391 Rev A, SHT-2; FusionPro 2N4/4N4 System Control and Power Copyright 2025 Baker Hughes Company. All rights reserved. Page 72 of 78...
500031032 Rev: A Effective Date: 5 Feb 2025 FusionPro Operations and Installation Manual Figure 57: Schematic 500030391 Rev A, SHT-3; FusionPro 2N4/4N4 System Control and Power Copyright 2025 Baker Hughes Company. All rights reserved. Page 73 of 78...
500031032 Rev: A Effective Date: 5 Feb 2025 FusionPro Operations and Installation Manual Figure 58: Schematic 500030391 Rev A, SHT-4; FusionPro 2N4/4N4 System Control and Power Copyright 2025 Baker Hughes Company. All rights reserved. Page 74 of 78...
500031032 Rev: A Effective Date: 5 Feb 2025 FusionPro Operations and Installation Manual Figure 59: Schematic 500030391 Rev A, SHT-5; FusionPro 2N4/4N4 System Control and Power Copyright 2025 Baker Hughes Company. All rights reserved. Page 75 of 78...
500031032 Rev: A Effective Date: 5 Feb 2025 FusionPro Operations and Installation Manual Figure 60: Schematic 500030391 Rev A, SHT-6; FusionPro 2N4/4N4 System Control and Power Copyright 2025 Baker Hughes Company. All rights reserved. Page 76 of 78...
500031032 Rev: A Effective Date: 5 Feb 2025 FusionPro Operations and Installation Manual Figure 61: Schematic 500030391 Rev A, SHT-7; FusionPro 2N4/4N4 System Control and Power Copyright 2025 Baker Hughes Company. All rights reserved. Page 77 of 78...
500031032 Rev: A Effective Date: 5 Feb 2025 FusionPro Operations and Installation Manual Figure 62: Schematic 500030391 Rev A, SHT-8; FusionPro 2N4/4N4 System Control and Power Copyright 2025 Baker Hughes Company. All rights reserved. Page 78 of 78...
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