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Datalogger-4200 P/N 066-0207-00 Rev B

Field Installation Guide Page 2 of 49

NOTICE

This manual is intended for private information only, with the understanding that any other use of the subject matter, in whole or in part, by reference or otherwise, shall be only with the prior knowledge and approval of Sercel-GRC Corp, and with the further understanding that this manual is for informational purposes only and that suggestions and recommendations contained herein shall not be understood or construed as a guarantee or warranty of any method, product or device.

Federal copyright law protects the publication. No part of this publication may be copied or distributed, transmitted, transcribed, stored in a retrieval system, or translated into any human or computer language, in any form or by any means, electronic, magnetic, manual or otherwise, or disclosed to third parties without the express written permission of Sercel-GRC Corp.

Any questions concerning the content of this manual, equipment operation, field maintenance, maintenance assistance and operation or maintenance training courses should be directed to:

MODEL: DATALOGGER-4200 FIELD INSTALLATION GUIDE

Sercel-GRC Corp.

6540 East Apache Street, Tulsa, Oklahoma 74115-3616 USA P.O. Box 581570, Tulsa, Oklahoma 74158-1570 USA Telephone: (1) 918-834-9600/ Fax: (1) 918-838-8846

Contact GRC by e-mail at: [email protected] or [email protected] Visit our web page at www.Sercel-GRC.com

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1.0 Gauge Configuration Procedure

The following procedure provides an outline of the necessary steps to perform on the gauges prior to running them into the well. Completing these steps is required to properly configure the downhole gauges attached to a Datalogger 4200 in the field.

1. Identify the types of gauges that are to be attached to the Datalogger 4200.

2. Record the number of data channels that each gauge contains. The Datalogger 4200 can handle up to six data channels. One data channel consists of one of the following:

a. an intake pressure and its associated temperature b. an X-axis vibration and a Y-axis vibration pair

c. a discharge pressure and its associated temperature

3. Assign numbers in the range of 32 through 48 to each data channel of the gauges.

4. Connect only one downhole gauge to the Datalogger 4200 ‘Gauge Sig’ connector (J15) using a relatively short pair of wires. Refer to section 3.0, Datalogger-4200 Power and Gauge Connections for more details on connecting the downhole gauge.

5. Apply power to the Datalogger-4200 and wait for the system to identify and establish communication with the gauge. Valid data from the gauge appears on the screen that should be similar to the data screen shown in Figure 6 - Gauge Readings Screen on page 11.

6. Adjust the gauge FSK address to the number previously defined in step 3 above.

Refer to section 10.10 on page 43 for details on changing the gauge FSK address.

7. Reset the FIC (Figure 34) and repeat steps 4, 5, and 6 for each downhole gauge.

Table 1 - Connector List Connector Description

J2 Analog Inputs – 3 channels (0-15vdc or 4-20mA selectable) J4 Analog Outputs – 2 channels (4-20mA)

J6 Latching Alarm Relay Output #1 (dry contacts 250VAC @ 5A) J7 Latching Alarm Relay Output #2 (dry contacts 250VAC @ 5A) J15 Power and Signal for downhole gauges

J18 COM2 serial port – RS-232 galvanically isolated Modbus slave J21 COM2 serial port – RS-485 galvanically isolated Modbus slave J20 COM1 serial port – RS-232 Modbus slave

J22 COM1 serial port – RS-485 Modbus slave ST1 Earth ground screw for input power

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2.0 Datalogger-4200 Product Description and Specifications

The Datalogger-4200 is a surface interface for FSK downhole gauges. Protection from the environment is provided by a NEMA enclosure. Remote control and data collection communication is via Modbus, RS-232, and RS-485. Data is also recorded internally and can be copied to a USB flash drive for external analysis. Device control is provided to allow Alarm signaling using two high-current, dry-contact relays. External devices may be monitored and controlled using one of the three analog inputs and two analog outputs. USB is provided as an additional interface for data collection and downhole monitoring.

The Datalogger-4200 contains: one FSK downhole gauge interface card, an RTU, and a color touch-screen interface.

Table 2 - Product Specifications Operating Temperature Max +65ºC

Operating Temperature Min -20ºC

DC Operating Voltage +12VDC to +28VDC

AC Operating Voltage 90VAC to 240VAC 50 Hz – 60 Hz Operating Current 300mA @ 24VDC typical

(excluding gauge current)

Status/Fault Indicators Internal LEDs for Power/Comm/Fuse status Display 4.3-inch Color LCD, resolution 480 x 272

User Interface Touch-screen LCD

Enclosure Dimensions 13.56” x 11.43” x 5.21”

344mm x 291mm x 132mm

Analog Inputs x3 0-15VDC or 0-60mA 18-bit resolution Analog Outputs x2 4-20mA 12-bit resolution

Alarm/Relay Outputs x2 SPDT dry contacts 5A @ 240VAC Modbus Communication x2 RS-485 or RS-232 (Modbus slave)

one channel galvanically isolated one channel non-isolated

Removable Data Storage FAT12, FAT16, or FAT32 formatted USB Flash drive with 512-byte sector size

USB One spare port

Ethernet Non-isolated

Front Panel Torque Specification 25 In.lbs

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3.0 Datalogger-4200 Power and Gauge Connections

Figure 1 - Power Supply Connections

To power the Datalogger-4200, connect a 90-240 VAC single-phase power source to the Line and Neutral connections on the DC power supply. The Line and Neutral terminals are located along the bottom side of the DC power supply as shown in Figure 1. An ‘Earth Ground’ screw terminal is provided on the board to the left of the DC power supply.

Figure 2 - Gauge Connection

Connect the gauge Signal and Ground wires to the ‘Gauge Sig’ connector (J15) as shown in Figure 2. Connect the Signal wire to the positive (+) terminal and the Ground wire to the negative (-) terminal.

Line (L) Neutral (N) Ground

Gauge Input

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3.1 Peripheral Connections

The Datalogger-4200 is equipped with two configurable analog outputs, two configurable discrete relay outputs and three analog inputs. The unit also has two Modbus ports; one is galvanically isolated (COM2) and the second one (COM1) is not.

Both ports are capable of RS-485 or RS-232 serial Modbus communications and COM1 may also communicate via USB. See Figure 3 for connection details. Configuration of these two Modbus ports is detailed in Section Configuring Modbus Ports.

Figure 3 - Peripheral Connection Terminals

NOTE: COM1 can communicate via USB, RS-232, or RS-485. Only one of these three protocols may be used at a time. It cannot use two of them at once. The ground on this port is electrically connected to the ground system of the Datalogger 4200. COM2 can communicate via RS-232 or RS-485. COM2 cannot use RS-232 and RS-485 at the same time. The ground system of COM2 is electrically isolated from the ground system of the Datalogger 4200. Isolating the grounds between two connected systems can eliminate communication problems caused by ground loops.

Isolated Modbus connections

Non- Isolated Modbus connections Analog Inputs

Analog Outputs

Alarm Relays (dry closures) Analog Input Configuration

Jumpers J1, J3, and J5

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3.2 Low Voltage Power Switch and Fuses

A power switch (S2) allows disrupting the low voltage (+24VDC) power supply on a temporary basis during installation or maintenance. The switch is located near the fuses as shown in Figure 4. A spare fuse of the proper value is located in the fuse holder immediately above each of the fuses as shown in Figure 4.

Figure 4 - Power Switch and Fuses

3.3 Front Panel Ports

The Datalogger-4200 has two USB ports on the front panel. The ‘USB DRIVE’ port is for transferring logged data to a USB flash memory device and performing system firmware updates while the ‘USB SERIAL’ port handles Modbus serial communication.

Figure 5 - Front Panel Layout

Panel PC

USB Serial Port – COM1 USB Memory

Download Power Switch

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4.0 LED Status Indicators

The chart below provides details of the LED status indicators on the board as well as their purpose.

Indicator Color Usage Purpose

LED1 Red Alarm Relay #1 tripped ON=alarm

LED2 Red Alarm Relay #2 tripped ON=alarm

LED3 Green Fuse OK for Panel PC power ON=fuse good LED4 Green Panel PC power applied ON=power on LED5 Green Fuse OK for +5VDC power ON=fuse good

LED6 Green +5VDC power good ON=power on

LED7 Green Fuse OK for Surface Board power ON=fuse good LED8 Green Surface Board power applied ON=power on LED9 Green Panel PC USB Cable connected ON=USB good LED10 Green Gauge communication activity Flash=data LED11 Green COM2 serial port activity Flash=data LED12 Green COM1 serial port activity Flash=data

LED13 -- Not installed --

LED14 Green Watchdog Timer activity Slow Flash=OK LED15 Yel/Grn I2C communication activity Slow Flash=OK

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5.0 Datalogger-4200 Real Time Display

Once power and gauge connections are complete, the Datalogger is ready to power on.

A splash screen appears after applying power and a status bar shows the progression of the start up process. The touch screen panel PC requires a short time to load the application and establish communication with the gauges. Once the Datalogger is running, the Gauge Readings screen appears which is similar to the one shown in Figure 6. The Gauge Readings screen displays status of the peripherals and the current gauge readings.

NOTE: To wake up the Panel PC from sleep mode press anywhere on the screen.

5.1 Gauge Readings Tab

The Gauge tab displays the gauge alias, current readings, and the Modbus register address for each displayed parameter. Gauge parameters include gauge intake pressure, gauge intake temperature, gauge vibration (if equipped), gauge discharge pressure (if equipped), and gauge discharge temperature (if equipped). The data from a particular gauge is assembled onto its own screen identified by its serial number and a sensor-type letter abbreviation arranged as a series of tabs along the top edge of the screen.

Figure 6 - Gauge Readings Screen

In the example shown in Figure 5, there are two gauges, serial #4 and serial #97125.

Gauge #4 is a PCP-5500 gauge reporting intake pressure (I), discharge pressure (D) and vibration (V). Gauge #97125 is a PCP-4500 reporting discharge pressure (D) and vibration (V). Selecting the Scroll Readings check box allows the displayed data screen to periodically advance from one tab to the next. The Datalogger-4200 can communicate with up to 6 channels of data. Each channel is a gauge parameter such as pressure or vibration (temperature readings are included with each channel).

Scroll Selection Status

Tabs Gauge

Data

Register Address Configuration Menu Access

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5.2 Peripheral Status Tab

The Peripherals tab shows the status of all the Datalogger I/O. It displays current readings for the analog inputs, the analog outputs, and the status of the relay alarm outputs. If a relay alarm has been tripped, it displays the time and date of the alarm in red text as shown in Figure 7.

Figure 7 - Peripherals Status Screen

NOTE: Each tab is displayed for five seconds before advancing to the next tab.

Clearing the ‘Scroll Readings’ checkbox maintains the display on the current tab for up to sixty seconds. The display then returns to advancing to the following tabs at five-second intervals.

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6.0 Accessing Datalogger-4200 Setup/Help Menus

To access the ‘Setup/Help’ menu click the ‘Menu’ button at the bottom right of the

‘Gauge Readings/Peripherals’ screen as shown in Figure 6 and Figure 7. The application protects the configuration settings by requiring entry of the correct password before allowing access to it. The factory default password is ‘ABCD’ and can be changed as described later in this section. A valid password opens the ‘Setup/Help’

menu as shown in Figure 9. The following menu items may be chosen from the

‘Setup/Help’ menu: Memory/Logging (data logging and transfer), Modbus Ports configuration, Peripherals (analog output and relay settings), view the system settings, change the FIC surface board communication settings, and view information regarding troubleshooting and customer service assistance.

Figure 8 - Menu Password for Configuration

NOTE: The factory default password to enter the Setup Menu is ‘ABCD’. This password may be changed in the ‘System Settings Menu’ by choosing ‘Menu Password’ (see Figure 43 - System Settings Menu).

Figure 9 - Setup/Help Menu

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7.0 Memory and Logging Configuration

From the ‘Setup/Help’ menu, access the ‘Memory/Logging’ setup by pressing the

‘Memory/Logging’ button. This opens the ‘Memory Options’ screen shown in Figure 10.

This page allows editing the log data file name and ‘Save Rate’ which configures the interval at which gauge data is written to the Datalogger-4200 internal memory. Several items related to log file status are shown: the current log file name along with its size, the number of log files contained within internal storage, the total size consumed by those log files, and the timestamp of the last sample written to the internal memory.

The Datalogger-4200 creates a new log file whenever the ‘Log Name’ changes. The previous file remains in internal memory until the user chooses to clear the logs.

Figure 10 - Memory Options Screen

7.1 Edit Log Name

To edit the ‘Log Name’, press the ‘Edit’ button to the right of the current log name. This opens the ‘Enter New Log Name’ screen as shown in Figure 11. From here, key in the new log name and press ‘Save’ to create the new file. Exit back to the ‘Memory Options’ screen without saving any pending changes by pressing the ‘Cancel’ button.

Figure 11 - Enter New Log Name

NOTE: Changing ‘Save Rate’ does not affect data acquisition rates of the gauges.

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7.2 Edit ‘Log Save Rate’

Press the ‘Edit’ button next to the ‘Save Rate’ value (Figure 10) to edit the rate at which gauge data from the FSK is requested. This opens the ‘Enter New Log Save Rate’ edit screen as shown in Figure 12. This screen allows incremental changes to the rate at where the permitted logging rate ranges from 1 second to 30 minutes. Double arrows adjust time in 10-second increments and single arrows adjust time in 1-second increments. Press the ‘Save’ button to update the adjusted rate. ‘Cancel’ returns to the previous menu without saving any changes.

Figure 12 - Change Log Data Storage Rate

NOTE: The data storage capacity is dependent upon the ‘Log Save Rate’. The following chart provides a few examples of typical save rates and the time needed to reach several values of record counts. These values are based on 112 bytes per record.

Table 3 – Log Data Save Rates

Save Rate

(seconds) Records

Per Day 250,000

Records 500,000

Records 1,000,000 Records

6 14,400 17.4 days 34.7 days 69.4 days

10 8,640 28.9 days 57.9 days 115.7 days

15 5,760 43.4 days 86.8 days 173.6 days

30 2,880 86.8 days 173.6 days 347.2 days

60 1,440 173.6 days 347.2 days 649.4 days

7.3 Memory Download to USB Drive

To download the stored log file to a USB flash drive, press the ‘Download Logs’ button on the ‘Memory Options’ screen shown in Figure 10. This opens a prompt to insert the USB flash drive into the front panel (Figure 13), wait for the system to recognize it, and press the ‘Yes’ button when the USB flash drive is ready. The update screen shown in Figure 14 displays the progress of the data file download.

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Figure 13 - Insert USB Drive Prompt

NOTE: Typical data transfer rates when writing log data to a USB flash drive varies slightly depending on file size. The following chart details typical transfer times for a few large record count file sizes.

Table 4 – Typical USB Data Transfer Rates

Records File size (bytes)

Minutes Seconds Transfer Rate (bytes/sec)

250,000 25,208,853 1 42 247,146

500,000 50,417,533 3 21 250,833

1,000,000 100,834,893 6 42 250,833

Download status information is displayed as the download operation progresses (see Figure 14). A second screen appears after the download completes requesting if the log files are to be cleared. Press ‘YES’ to clear the internal memory or press ‘Cancel’ to return to the download status screen without clearing the internal memory. A final prompt is provided when it is safe to remove the USB flash drive.

Figure 14 - Successful USB Data Transfer

Return to the ‘Memory Options’ screen by pressing the ‘Back’ button.

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7.4 Clear Logs

The ‘Memory Options’ screen provides a ‘Clear Logs’ button, as shown near the bottom of Figure 10, to clear the internally stored logs without downloading the log data. The screen shown in Figure 15 is the confirmation request to confirm the requested operation is valid. Pressing the ‘Yes’ button permanently erases the log data stored in the Datalogger-4200 internal memory. Pressing the ‘Cancel’ button returns to the

‘Memory Options’ screen without erasing the internal log file data.

Figure 15 - Delete On-Board Log Data Confirmation

NOTE: The Datalogger-4200 does not provide for erasing any files other than log data files from a USB flash drive. This must be done on a standard desktop or laptop computer.

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8.0 Configuring Modbus Ports

The Datalogger-4200 has two Modbus slave ports that can be configured from the

‘Modbus Ports’ option in the ‘Setup/Help’ menu. Press the ‘Modbus Ports’ Button and select the port (COM1 or COM2) by pressing on the port name as shown in Figure 16.

Figure 16 - Select Modbus Port Configuration

After selecting the port to be configured, the ‘Modbus Slave Port’ menu opens. From this menu, the Modbus ‘Slave ID’ and ‘Baud Rate’ for the selected port may be changed. Status information concerning the latest Modbus request is displayed along with the total number of Modbus packets processed are included on this page as shown in Figure 17.

Figure 17 - Modbus Port Configuration Menu

8.1 Edit Slave Address

To edit the Modbus port ‘Slave ID’, press the ‘Edit’ button next to the ‘Slave ID’ shown in Figure 17. The valid Modbus slave ID values are in the range of 1 and 247. Use the arrow keys to increase or decrease the address to the desired value. The double arrows adjust the address by 10 and the single arrows adjust the address by 1 as shown in Figure 18. Press ‘Save’ to accept the changes or ‘Cancel’ to return to the previous screen without saving any changes.

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Figure 18 - Edit Slave ID

8.2 Select Baud Rate

To edit the Modbus port baud rate, press the ‘Edit’ button next to the ‘Baud Rate’ label as shown in Figure 17. This displays the ‘Select Baud Rate’ menu. Valid baud rates are in the range of 1,200 baud to 38,400 baud (see Figure 19). An asterisk identifies the current baud rate selection. Pressing the desired baud rate value highlights the selection and pressing ‘Save’ accepts that change. Pressing ‘Cancel’ returns to the previous screen without saving any changes.

Figure 19 - Select Baud Rate

8.3 Changing the Modbus Word Order

Some Modbus master devices require their data packets in a reversed word order. The Datalogger-4200 allows users to change the Modbus word order by pressing the

‘Modbus Word Order’ text on the ‘Modbus Port Selection Menu’ shown in Figure 16.

The standard word order is ‘High-Low’ (Figure 20). To change the order to ‘Low-High’, press the text to highlight the selection and press ‘Save’ to accept the change. Pressing

‘Cancel’ returns to the previous screen without saving any changes. Configuring the Modbus word order applies that setting to both Modbus ports, COM1 and COM2.

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Figure 20 - Selecting Modbus Word Order

8.4 Modbus Map

The following tables provide a list of Modbus registers and descriptions for the values they contain. All Modbus registers are in the 40000-49999 range of addresses. The registers in Table 5 - Configuration Registers 40000-40056 are read/write registers.

Those in Table 6 - Status Modbus Registers 40200-40223 are read only, and those in Table 7 - Surface Board Modbus Registers 40500-40519 are read only as well. All of the registers contained in section Gauge Data Modbus Registers are also read-only.

Table 5 - Configuration Registers 40000-40056

Name Register Description

COM1 Settings 40000 COM1 serial port configuration COM2 Settings 40001 COM2 serial port configuration

Reserved 40002-40049

DefaultNoGauge 40050 Default value for ‘No Gauge’

DefaultNotAvail 40051 Default value for ‘Not Avail’

DefaultDroppedOut 40052 Default value for ‘Dropped Out’

WordOrderNegHandling 40053 Modbus data word order TemperatureConfig 40054 Temperature multiplier PressureConfig 40055 Pressure multiplier VibrationConfig 40056 Vibration multiplier

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Table 6 - Status Modbus Registers 40200-40223

SoftwareVersion 40200 Datalogger 4200 Revision

Reserved1 40201-40202

RunTime 40203 Cumulative run time high word

RunTimeB 40204 Cumulative run time low word

Reserved2 40205

DLTemperature 40206 Internal temperature

DLVoltageVcc 40207 Main supply voltage

AnalogIn1_V 40208 Analog input voltage #1

AnalogIn1_I 40209 Analog input current #1

AnalogOut1 40214 Analog output current #1

AnalogOut2 40215 Analog output current #2

Relay1Status 40216 Relay #1 status

Relay1TripTime 40217 Relay #1 trip time high word Relay1TripTimeB 40218 Relay #1 trip time low word

Relay2Status 40219 Relay #2 status

Relay2TripTime 40220 Relay #2 trip time high word Relay2TripTimeB 40221 Relay #2 trip time low word SurfaceLastReadTime 40222 Last surface query high word SurfaceLastReadTimeB 40223 Last surface query low word

(23)

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Table 7 - Surface Board Modbus Registers 40500-40519

Flags 40500 Datalogger 4200 Internal flags

LineCOMVolt 40501 Operating COM voltage

SigTarget 40502 Target gauge current

GlobalRate 40503 Gauge query rate

StatusGauges 40504 Gauge scanning status

TenthSec 40505 Cumulative surface board run

time in tenths high word

TenthSecB 40506 Cumulative surface board run

time in tenths low word

Packets 40507 Gauge packet count high word

PacketsB 40508 Gauge packet count low word

ADCLineVolt 40509 Line voltage

ADCMinLineV 40510 Minimum line voltage

ADCMaxLineV 40511 Maximum line voltage

ADCLinemA 40512 Line current in mA

ADCMinLinemA 40513 Minimum line current in mA

ADCMaxLinemA 40514 Maximum current in mA

G12ModbusAddy 40515 Active gauge addresses

ScanCountAddr 40519 FSK gauge scan address

(24)

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8.5 Gauge Data Modbus Registers

# Of Regs Register FSK Address Description Units Applied

1 41001

32

Hi Byte: Gauge Type (1=Qz, 2=Cap, 3=Vibe)

Lo Byte: Gauge Revision

2 41002 Serial Number (int)

1 41004

Serial Number First

Two Non-Numeric Chars (I/D/V)

2 41005 Packet Count

2 41007 Error Count

1 41009

Hi Byte: Signal Current Low (mA) Lo Byte: Signal Current High (mA)

2 41010 Last Packet Time (Seconds x10)

2 41012 Pressure Pressure

2 41014 Temperature Temperature

2 41016 Vibration X Vibration

2 41018 Vibration Y Vibration

1 41028

33

1 41031

Serial Number First

2 41034 Error Count

1 41036

(25)

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1 41055

34

1 41058

Serial Number First

2 41061 Error Count

1 41063

1 41082

35

1 41085

Serial Number First

2 41088 Error Count

1 41090

(26)

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1 41109

36

1 41112

Serial Number First

2 41115 Error Count

1 41117

1 41136

37

1 41139

Serial Number First

2 41142 Error Count

1 41144

(27)

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1 41163

38

1 41166

Serial Number First

2 41169 Error Count

1 41171

1 41190

39

1 41193

Serial Number First

2 41196 Error Count

1 41198

(28)

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1 41217

40

1 41220

Serial Number First

2 41223 Error Count

1 41225

1 41244

41

1 41247

Serial Number First

2 41250 Error Count

1 41252

(29)

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1 41271

42

1 41274

Serial Number First

2 41277 Error Count

1 41279

1 41298

43

1 41301

Serial Number First

2 41304 Error Count

1 41306

(30)

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1 41325

44

1 41328

Serial Number First

2 41331 Error Count

1 41333

1 41352

45

1 41355

Serial Number First

2 41358 Error Count

1 41360

(31)

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1 41379

46

1 41382

Serial Number First

2 41385 Error Count

1 41387

1 41406

47

1 41409

Serial Number First

2 41412 Error Count

1 41414

(32)

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1 41433

48

1 41436

Serial Number First

2 41439 Error Count

1 41441

!"#"$%&&'()*+,,High-Performance Surface Data Acquisition System

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