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Sensia 103381133 Installation, Operation & Maintenance Manual

Instruct lift control systems, instruct esp gateway card
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Lift Control Systems
INSTRUCT LIFT CONTROL SYSTEMS
INSTRUCT ESP Gateway Card
Installation, Operation & Maintenance Manual
MODEL:
103381133
Manual No. LCS-ENG-M0021, (InTouch ref # 7745571), Rev. 05

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Summary of Contents for Sensia 103381133

  • Page 1 Lift Control Systems INSTRUCT LIFT CONTROL SYSTEMS INSTRUCT ESP Gateway Card Installation, Operation & Maintenance Manual MODEL: 103381133 Manual No. LCS-ENG-M0021, (InTouch ref # 7745571), Rev. 05...
  • Page 2 Sensia and may not be copied, imitated, or used, in whole or in part, without the express prior written permission of Sensia. INSTRUCT* is mark of Sensia. An asterisk (*) is used in this document to designate other marks of Sensia.
  • Page 3 Indique des informations supplémentaires sur des conditions ou des circonstances spécifiques pouvant affecter le fonctionnement de l'instrument. Revision History Revision Description of Change Sensia Issuer Date Initial release Lift Control Systems 30-June-2021 Add InTouch reference number Lift Control Systems 20-Feb-2023 Change internal document number to LCS-ENG-M0021 SIM Card APN change to sensia02.com.attz...

  • Page 4: Table Of Contents

    INSTRUCT ESP Gateway Card Table of Contents Section 1: Product Description..............8 1.1 Overview ............................... 8 1.2 End-to-End Diagram ..........................9 Section 2: Specifications ................10 2.1 Hardware Specifications ........................10 2.2 Hardware Overview ..........................10 Section 3: Installation and Operation ............12 3.1 MultiTech Cellular Modem Preparation and Configuration ..............
  • Page 5 INSTRUCT ESP Gateway Card Appendix A: Parts, Spares, Tools, and Supplies ........52 Appendix B: Terminal Emulators .............. 53 Appendix C: References ................55 Appendix D: INSTRUCT ESP Gateway Card Support Resources ..56 Product Documentation ..........................56 Guides and Release Notes ........................56 Technical Support .............................
  • Page 6 INSTRUCT ESP Gateway Card List of Figures Figure 1-1: INSTRUCT ESP Gateway card....................... 8 Figure 1-2: End-to-End Diagram ........................9 Figure 2-1: Front Connections ......................... 10 Figure 3-1: Controller slot configuration for INSTRUCT ESP Gateway Card ..........32 Figure 4-1: COM2 RS485 port ......................... 33 Figure 4-2: COM2 Connector ..........................
  • Page 7 INSTRUCT ESP Gateway Card WARNING! To avoid the risk of electric shock and fire, the following safety instructions must be observed and the guidelines followed. The specifications must not be exceeded, and the device must only be applied as described in the following. Prior to the installation and commissioning of the unit, the installation guide must be GENERAL examined carefully.

  • Page 8: Section 1: Product Description

    INSTRUCT ESP Gateway Card Section 1: Product Description Section 1: Product Description 1.1 OVERVIEW The INSTRUCT ESP Gateway Card is a standalone INSTRUCT SCB3 CPU card, which can be used inside INSTRUCT ESP Intelligent Controller to enable advanced real-time services. The Gateway Card, with external cellular modem, can be used to connect wellsite equipment to the real-time infrastructure servers and allows for remote monitoring, control, and surveillance of the reservoir, pump, motor, and surface equipment.

  • Page 9: End-To-End Diagram

    INSTRUCT ESP Gateway Card Section 1: Product Description 1.2 END-TO-END DIAGRAM Figure 1-2: End-to-End Diagram...

  • Page 10: Section 2: Specifications

    INSTRUCT ESP Gateway Card Section 2: Specifications Section 2: Specifications 2.1 HARDWARE SPECIFICATIONS Part Numbers 103381133 Description INSTRUCT ESP Gateway card PCB Size: 100mm x 160mm Board Size Eurocard 3U compliant (IEC 60297-3) Power Supply DC (Input) 24VDC +/-10%, 300mA...
  • Page 11 INSTRUCT ESP Gateway Card Section 2: Specifications Port Functional Description COM 3 RS-485 Port Default Modbus Acquisition port for communication with INSTRUCT ESP (gateway card Backplane Intelligent Controller Connector)

  • Page 12: Section 3: Installation And Operation

    Note: 3.1.1.1 Hardware Item Description Quantity Details Router, Cellular, LTE CAT M1+NB-IOT Sensia PN: 50369243 (For NA kit 50376574, the router PN is 50376572) Modem Power Cable Sensia PN: 50369242 MultiTech Modem Mounting Bracket Sensia PN: 50369241 (Not included in NA kit 50376574)
  • Page 13 Section 3: Installation and Operation Item Description Quantity Details AT&T SIM Card Power Supply Module Sensia PN: 50369248 (For NA kit 50376574, the Power Supply PN is 50376572) Cat5E Ethernet Cable, 3 ft Sensia PN: 50369237 Mag-Mount Antenna Sensia PN: 77025191...

  • Page 14: Multitech Modem Configuration

    Section 3: Installation and Operation Item Description Quantity Details GLAND, CABLE, NYLON, 3/4 in NPT Sensia PN: 77024442 PSU and Modem Mounting Plate Kit Sensia PN: 50371409 (For NA kit 50376574, Adhesive tape PN: 77027803 is used instead of mounting plate)
  • Page 15 INSTRUCT ESP Gateway Card Section 3: Installation and Operation Instructions Illustrations 1.1. Obtain Power Supply Module (50369248), MultiTech Modem (50369243), MultiTech Power Supply Cable (50369242), Antenna (77025191), and Ethernet Cable (50369237). 1.2. Attach Ethernet cable from MultiTech Modem to PC. 1.3.
  • Page 16 INSTRUCT ESP Gateway Card Section 3: Installation and Operation Instructions Illustrations...
  • Page 17 INSTRUCT ESP Gateway Card Section 3: Installation and Operation Instructions Illustrations 2.4. Update Modem FW to 5.3.6s-s1 Check whether the modem version is at least 5.1.3. If lower than 5.1.3, isolate the modem and contact LCS Custom Service at: liftcontrolsystems@sensiaglo bal.com If the modem already has 5.3.6s-s1 then no need to...
  • Page 18 Go to the Administration option and select Save/Restore. 2.7. Click Browse and then select the configuration file available at InTouch 7745571 or the file downloaded from Sensia Technical Document Library (config_MTR- LEU7_5_3_6s-s1_02_05_20.tar). 2.8. For Zedi Firmware use (config_MTR- MNG2_5_3_6s- s1_FOR_ZEDI_MAY2024tar.gz) Note:...
  • Page 19 INSTRUCT ESP Gateway Card Section 3: Installation and Operation Instructions Illustrations Password: admin 2.9. 2.10. Select Restore. 2.11. The modem will reboot. It will take approximately 10 min for the modem to reboot. Note: Normally restoring the configuration file should take 10 minutes at most. If the modem hangs, or get stuck, then power cycle the modem.

  • Page 20: Components Installation Inside Vsd

    INSTRUCT ESP Gateway Card Section 3: Installation and Operation Instructions Illustrations 2.12. After the MultiTech Modem has completed rebooting, log into the MultiTech website at 192.168.2.1 again. On the login page, enter the following credentials: Username: admin Password: admin It may take a couple of minutes for the modem to finish the booting process.
  • Page 21 Instructions Illustrations 1. INSTRUCT ESP Gateway card Installation. Install INSTRUCT ESP Gateway card (PN: 103381133) into the expansion slot of the INSTRUCT ESP Intelligent Controller inside the VSD drive. 2. Modem and Power Supply Module Installation (For NA kit 50376574, use adhesive tape...

  • Page 22: Instruct Esp Gateway Card Configuration And Commissioning

    3.3 INSTRUCT ESP GATEWAY CARD CONFIGURATION AND COMMISSIONING The INSTRUCT ESP Gateway Card (103381133) is factory loaded with FW 2120901 or later. It is ready to be used directly inside the INSTRUCT ESP Intelligent Controller with the modem. Note that the FW must be started with 212xxxx: that is, the specific FW for the gateway card to be used inside the controller.
  • Page 23 INSTRUCT ESP Gateway Card Section 3: Installation and Operation Item Description Illustrations USB to RS232 serial converter (not provided in the kit) RS232 (DB9 female) to gateway card RS232 COM1 Connector (not provided in the kit) Download Terminal User Interface (TUI) Download URL: –...

  • Page 24: Instruct Esp Gateway Card Configuration Check And Commissioning

    INSTRUCT ESP Gateway Card Section 3: Installation and Operation 3.3.2 INSTRUCT ESP GATEWAY CARD CONFIGURATION CHECK AND COMMISSIONING This section outlines the software configuration required for the gateway card to communicate with the MultiTech Cellular Modem. Instructions Illustrations 1. Connect the USB to RS232 serial converter to the gateway card RS232 Serial Port COM1.
  • Page 25 Avalon: 0948-AVL-G LiftIQ: 0947-LIQ-G Zedi: 43007 If not, refer to section 4.2.5 for the firmware upload process. The latest firmware available in Sensia Technical Document Library or InTouch 6117586 covers support for the gateway Cellular Modem. Note: The picture is for illustration only, please refer to the left...
  • Page 26 INSTRUCT ESP Gateway Card Section 3: Installation and Operation Instructions Illustrations 7. If it is a new gateway card from the factory, wait 10 to15 minutes. The modem status should become Online, and the IP address should be 10.242.xxx.xx or 10.243.xxx.xx. Once the above is verified, skip to the commissioning task in step 11.
  • Page 27 INSTRUCT ESP Gateway Card Section 3: Installation and Operation Instructions Illustrations 8.4. The gateway card will reboot and restart with the factory reset defaults. 9. After the gateway card reboots, enter the admin screen again following the instruction in Step 3. Ensure the firmware version is correct and the I/Os have been erased to 0/0.
  • Page 28 INSTRUCT ESP Gateway Card Section 3: Installation and Operation Instructions Illustrations 11. Commissioning: Note: Before proceeding to the commissioning steps, you should have already obtained a token from the Proser Team. In case you don’t have the token, you need to contact the Proser team (proser@sensiaglobal.com) and provide them the IP address in the form of 10.242.xxx.xxx or 10.243.xxx.xx.
  • Page 29 INSTRUCT ESP Gateway Card Section 3: Installation and Operation Instructions Illustrations 11.5. For Zedi: Not applicable Back up one level to go back to the Commissioning menu. 11.6. Under the Commissioning menu, choose 1. Status/Initiate commissioning. 11.7. Press c to initiate commissioning, and enter the token number obtained from the Proser Team.
  • Page 30 INSTRUCT ESP Gateway Card Section 3: Installation and Operation Instructions Illustrations 11.8. If commissioning is done successfully, the commissioning status should show: Commissioned with the Device The Network Status will be changed to Connected and the modem status will show Online. Check Signal Strength is between 15- Received Strength Signal Indicator (RSSI):...
  • Page 31 INSTRUCT ESP Gateway Card Section 3: Installation and Operation Instructions Illustrations 12. Gateway Card COM3 Configuration: Change the COM3 setting of the Gateway Card and make sure it is same to below: Baud Rate: 9600 Parity: None Type: RS485 (4-Wire) Pre Keying (ms): 2 Post Keying (ms): 2...

  • Page 32: Instruct Esp Intelligent Controller Configuration

    INSTRUCT ESP Gateway Card Section 3: Installation and Operation 3.4 INSTRUCT ESP INTELLIGENT CONTROLLER CONFIGURATION Configure the INSTRUCT ESP Intelligent Controller Slot that contains the gateway card to the setting shown below. The following setting matches the gateway card Serial Port Com3 default setting. It ensures good communication between the controller and the card.

  • Page 33: Section 4: Modbus And Tui Functions

    INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions Section 4: Modbus and TUI Functions 4.1 SECONDARY MODBUS RS-485 CONNECTION (COM2) The secondary Modbus RS-485 data acquisition port is COM2. This communication port shares the same connector as COM1, the Engineering port used to communicate with the CPU board inside the INSTRUCT ESP Gateway Card.

  • Page 34: Configuring Rtu Slaves

    INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions Select the appropriate COM port to be configured (Option 1 or 2). Figure 4-3: Modbus Port Configuration Select each of the configuration parameters one at a time and enter the required values to match the controller.

  • Page 35: Monitoring Communications

    INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions Select an RTU to be configured from among the options provided or add a new RTU. Figure 4-5: RTU Configuration Enter an RTU ID, name, and communication port (COM2 or COM3). Modify other configuration parameters and ensure they match the controller parameters.

  • Page 36: Configuring Test Commands

    INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions Select the 1. I/O Viewer. The I/O viewer permits the technician to check the polling in real time on the serial port and see the status of all the RTUs simultaneously. Figure 4-7: I/O Viewer From the I/O and Acquisition menu, select option 3.

  • Page 37: Issuing Test Commands And Confirmation On Traffic Viewer

    INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions Select option 4. Modbus Test Commands. Figure 4-9: Modbus Test Commands Select option 9. Configure Modbus Test Commands. Figure 4-10: Configure Modbus Test Commands Select a test command and configure the parameters as required. 4.2.5 ISSUING TEST COMMANDS AND CONFIRMATION ON TRAFFIC VIEWER Issuing test commands permits the technician to check the response of the controller and ensure communications.

  • Page 38: Advanced Settings

    INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions Select option 7. Modbus Traffic Viewer. The transmitted and received code will be printed to the screen. Figure 4-11: Modbus Traffic Viewer Verify data received. If no data are received, it would indicate a problem with the connection or the controller. Check the •...

  • Page 39: Site Settings

    INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions 4.3.1 SITE SETTINGS Site Settings allows you to modify the name (SCB3 by default). Figure 4-13: Site Setting 4.3.2 ACTIONS, DIAGNOSTICS AND LOGS The Actions, Diagnostics and Logs option allows you to perform a factory reset that will restore the original configuration of the running firmware version.

  • Page 40: Figure 4-15: Factory Reset

    INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions To perform a factory reset, select 4. Factory Reset (including Network Settings). Figure 4-15: Factory Reset When this option is selected, you must type the reason for the factory reset. Then press Enter and the factory reset will take place.

  • Page 41: Reboot Board

    INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions 4.3.3 REBOOT BOARD The Reboot board option performs a card reset. Figure 4-17: Reboot Board 4.4 UPGRADING THE INSTRUCT ESP GATEWAY CARD FIRMWARE The following steps outline the process to manually upgrade the gateway card firmware. While the firmware may be remotely upgraded over the network, there may be occasions where the installer may perform a local upgrade.

  • Page 42: Figure 4-19: Com2 Connection

    INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions Connect to the gateway card Engineering port (COM2), using the serial cable. To Computer Figure 4-19: COM2 Connection Open a terminal program (PuTTY is recommended) and connect to the gateway card, using serial port COMx with the COM port settings below: Baud Rate: 38,400 •...

  • Page 43: Figure 4-21: Log In

    INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions Power up the INSTRUCT ESP Intelligent Controller and wait for the system to fully boot up. Log in to the administrator interface using “admin” for both username and password. Figure 4-21: Log In Check the existing firmware version.

  • Page 44: Figure 4-24: Upgrade Complete

    INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions Potential Severity: Light Potential Loss: Assets Hazard Category: Electrical, Machinery equipment hand tools Do not type anything on the administrator interface during the upgrading process, or the autoboot process will stop. Wait until the login prompt returns. Go to the administrator interface (i.e., PuTTY) and wait for the gateway card to reboot.
  • Page 45 INSTRUCT ESP Gateway Card Section 4: Modbus and TUI Functions Note: The USB flash drive can be connected to the PC again and inspected for the presence of a “SUCESS” file. USB flash drive 1) When the USB flash drive is plugged into the computer,.ran should appear at the end of the firmware file name.

  • Page 46: Section 5: Maintenance

    INSTRUCT ESP Gateway Card Section 5: Maintenance Section 5: Maintenance 5.1 DEVICE MAINTENANCE 5.1.1 DEVICE CLEANING Use only a damp cloth to clean the instrument to avoid static electricity. 5.1.2 DEVICE REPAIR CAUTION! There are no user-serviceable parts within this product. Any attempt to repair the device may invalidate the warranty.

  • Page 47: Figure 5-1: Tui Main Menu

    INSTRUCT ESP Gateway Card Section 5: Maintenance Select option 4. Advanced Configuration. Figure 5-1: TUI Main Menu Select option 4, Create Full T-Log. Figure 5-2: Create Full T-Log...

  • Page 48: Figure 5-3: Entering A T-Log Reason

    INSTRUCT ESP Gateway Card Section 5: Maintenance Enter the reason for creating the T-Log. Figure 5-3: Entering a T-Log Reason Select 1. Run!. Figure 5-4: Running the T-Log...

  • Page 49: Serial Communication Troubleshooting

    INSTRUCT ESP Gateway Card Section 5: Maintenance Wait until the unit provides confirmation that the T-Log action has been completed. This can take several minutes if there is a significant amount of log data to be collected. Figure 5-5: T-Log Complete Once the T-Log process is complete, wait 20s and then remove the USB drive from the gateway card.
  • Page 50 INSTRUCT ESP Gateway Card Section 5: Maintenance To set the communication between the host controller and card, the COM3 with correct RS485 mode should be used. If RTUs other than host controller are connected, COM2 should be used. The RS-485 wiring is incorrect. Make sure the (+) wires are connected to other (+) wires, and vice versa for (-).

  • Page 51: Service

    5.3.2 REPACKING FOR SHIPMENT When shipping the device to Sensia for service or repair, we recommend the box-in-box technique. Place the instrument in all its original packaging, and then place this box inside a strong outer box, with about 60 to 100 mm internal cushioning material, closed and sealed by H-taping with pressure sensitive tape.

  • Page 52: Appendix A: Parts, Spares, Tools, And Supplies

    INSTRUCT ESP Gateway Card Appendix A: Parts, Spares, Tools, and Supplies Appendix A: Parts, Spares, Tools, and Supplies A.1 Ordering Part Numbers Part Number Description 103381133 INSTRUCT ESP Gateway card 50370539 INSTRUCT ESP Gateway Cellular Modem Kit (Global)

  • Page 53: Appendix B: Terminal Emulators

    INSTRUCT ESP Gateway Card Appendix B: Terminal Emulators Appendix B: Terminal Emulators A terminal emulator is required to interact with the gateway card firmware and perform the initial configuration and setup of the card. The Text User Interface was specifically designed to be flexible and agnostic to the terminal emulation program used, so users may experiment with terminal emulators until they find one they prefer.
  • Page 54 INSTRUCT ESP Gateway Card Appendix B: Terminal Emulators Click Open to log into the terminal. TUI Login...

  • Page 55: Appendix C: References

    INSTRUCT ESP Gateway Card Appendix C: References Appendix C: References Manual, INSTRUCT ESP Intelligent Controller (InTouch ID 6128576): Refer to INSTRUCT ESP Intelligent Controller User Manual for controller related installation and troubleshooting.

  • Page 56: Appendix D: Instruct Esp Gateway Card Support Resources

    Well Production System – ALS-ESP • Surface Electrical helpdesk. HOW TO REACH US You can find more information about Sensia and about the INSTRUCT ESP Gateway Card information here: Sensia Home Page: https://www.sensiaglobal.com/ Sensia Lift Control Solutions Page: https://www.sensiaglobal.com/Sensia-Lift-Control-Systems...
  • Page 57 Add intelligent action to your oil & gas solutions © Sensia LLC 2024. All rights reserved.

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