SAM E54 Platform » Chola Turbo

refer => http://5.161.106.25:3000/issues/2953#note-16

03/03/2026, Tuesday
Device powered on, dashboard is updating (the running f/w is Gatewayv2_02.16.1_Re_Design_Cloud.zip)

Firmware updated with 2.47.5 -- 2.48, observed minor issues with 4G, Modbus

Added e-mails in E-REMOS for report. Shared login credentials with customer ( also Jagatheswaran.j@elpisitsolutions.com, Testing123$, https://rms.dashboard.elpisitsolutions.com/dashboard )
Installed 4G extension cable. Signal strength is now 100%

Device re-flashed with Gatewayv2_02.16.1_Re_Design_Cloud.zip, dashboard is updating and kept device powered for the purpose of getting e-mail report

04/03/2026

1. Wireshark debug tried but due to the presence of switcth (ORing IES-C1050 5FE Unmanaged Ethernet Switch) connecting device and PLC, traffic not reaching in the port connected to laptop => Verify in Lab setup

Google :
Wireshark can capture traffic on a network switch , but generally only traffic directed to/from your computer, along with broadcast/multicast packets. Because modern switches send packets directly to the destination port, other devices' traffic not seen without special configurations like port mirroring (SPAN) or using a network tap.
To Capture All Traffic on a Switch:
Port Mirroring (SPAN): Configure your managed switch to mirror (duplicate) traffic from all ports (or a specific port) to the port your computer is connected to.
Network Tap: Install a physical TAP device between the switch and the device you want to monitor.
ARP Poisoning: A less recommended, advanced technique to trick the switch, which can impact network performance.

Key Takeaways:
Without Configuration: You will only see traffic destined for your machine's MAC address.
Promiscuous Mode: While Wireshark can use promiscuous mode, it does not bypass the switch's logic to send traffic only to the specific destination port.
Managed Switches: These are required for port mirroring.

If connected to a hub (rare now),all traffic are seen, but on a switch, will only see traffic intended for computer or broadcast traffic unless port mirroring is configured.

2. Flashed f/w "Gatewayv2_02.49_Chola_IP"
   --More debug status at console
   -- Connecting to modbus, getting config packet, posting data to cloud
   -- Cable disconnect/connet is working, but it requires a waiting of 1-2 minutes for modbus connection.(may be due to network switch)
   -- Dashboard values verified with HMI display except Feedback/Alarm/Trip and some descrepancies with few parameters mentioned in #3 onwards
   -- Modbus fails with sometimes with cable reconnect
   -- Modbus is not connecting to PLC with some power cycles
   -- check device status LED as in the photo => https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772629356420?context=%7B%22contextType%22%3A%22chat%22%7D
   -- More number of modbus timeout observed after 6.30pm. Check is it due to new parameter list. Refer logs#69 onwards

3. Verify all dashboard parameter mapping, naming as per modbus address doc => https://elpisit-my.sharepoint.com/:b:/g/personal/satish_sl_elpisitsolutions_com/IQBmDb5XBJKDSIMusD4FaDHAAfIsNaUZWmtUfJ21Od3GDy4?e=JFhniX
   -- PRDS PCV (% opening) is missing in dashboard => https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772624554486?context=%7B%22contextType%22%3A%22chat%22%7D
   -- Seems PCV-2 Output in place of PCV-2(% opening) => check https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772624708666?context=%7B%22contextType%22%3A%22chat%22%7D
   -- PCV 1&2 PID Setpoint is showing zero but configured in PLC as 4. check => https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772624986157?context=%7B%22contextType%22%3A%22chat%22%7D
   -- Turbine Running hours in dashboard is wrongly shown as Turbine Closing Hours
   -- ACB Closing Hours cannot be zero => https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772625522499?context=%7B%22contextType%22%3A%22chat%22%7D

3a. Verify parameter units as per in the customer supplied report format => https://elpisit-my.sharepoint.com/:x:/g/personal/satish_sl_elpisitsolutions_com/IQCmeN_Fw4jyR7PGka-cKFx8AXbDm02Z7pZ0Cb2hN3CsJuk?e=i9OWKH

--- Reg 40007/008 as Current Avg. Change to "Steam Totalised reading(TONS)" This not mentioned in modbus address doc. Alo, Steam Totalised reading(TONS)", is to be in Turbine Parameters screen
--- Use KWh for energy units => https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772622663254?context=%7B%22contextType%22%3A%22chat%22%7D
--- Steam Flow Totaliser . Unit TONS. It is a cumulative value. It will rollover once it reaches the PLC modbus register max value
--- Pressure, PCV unit => KG/CM^2

4. Verify daily report is as per the the report format (no. of pages, order of parameters, units)

5. Limit voltage, current values to one decimal point

6. Dashboard need only seven screens as specified in modbus address doc => https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772623745726?context=%7B%22contextType%22%3A%22chat%22%7D
   --Move all graphs from other screen to Trends screen

7. Feedback, Alarm, Trips not updating in dashboard => https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772625859560?context=%7B%22contextType%22%3A%22chat%22%7D
   --- Once it is updating in dashboard, Chola will generate trigger condition and corresponding status can be verified in dasboard

8. 4G signal strength is not updating in dashboard

Issues with Trend Graph

1. The graph is plotted as a sample series but required as many parameters vs one parameter => https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772728990940?context=%7B%22contextType%22%3A%22chat%22%7D
2. The graph canvas area is very small
3. The graph title to be decided

7. Feedback, Alarm, Trips not updating in dashboard => https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772625859560?context=%7B%22contextType%22%3A%22chat%22%7D
   --- Once it is updating in dashboard, Chola will generate trigger condition and corresponding status can be verified in dasboard

Issue and Resolution => https://elpisit-my.sharepoint.com/:w:/g/personal/satish_sl_elpisitsolutions_com/IQBI2SZIEMGXQpjB66JPw5KbAUiUVwcxI2DFF5ZFXwMbQUo?e=z0pYhx

8. 4G signal strength is not updating in dashboard

This is not enabled in the current version.

Regarding LED/Dashboard

What is the indication when modbus TCP fail (TCP connection or read timeout)
What is the indication for a successful Modbus read
What is the indication when data is posting
What is the indication when 4G connect fails

Also if some modbus register face timeout/read error, how does the dashboard reflect this (currently zero is displaying)

10/03/2026

Summary of changes and status
4G status => Enabled and tested
Device status => not enabled in new release (currently it is working in device and live dashboard)
GPS => not enabled
Device type => '3' tested
USB Config => USB Tool is not working , not tested
status of Modbus TCP fail/timeout => to decide and implement in new release
LED status indications => tested (except USB)
Alarms/trips/feedback => tested

9. Trend screen-1 => In progress https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772796510935?context=%7B%22contextType%22%3A%22chat%22%7D

10. Additional Trend Screens => to add https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772796598792?context=%7B%22contextType%22%3A%22chat%22%7D

11. Decimal point configuration not reflecting dshboard => https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1772708451327?context=%7B%22contextType%22%3A%22chat%22%7D

10/03/2026

Visited Mane Kancor

1. Flashed new firmware => Gatewayv2_02.54
2. getting dashboard as expected
3. observed a wrong modbus command packet => https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1773133667641?context=%7B%22contextType%22%3A%22chat%22%7D
4. bug fixed f/w => Gatewayv2_02.54.05
5. last signal id not reflected in modbus read
6. increased max tags, new f/w => Gatewayv2_02.55
7. bit flags needed int type instead of float => https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1773143188179?context=%7B%22contextType%22%3A%22chat%22%7D

Two issues

A. Device stopped posting and after some time all LEDs turned off automatically
B. Multiple power cycle required for the device to start working with LED sequence

The hot-swap controller is present at the power entry, protecting against inrush, overcurrent, undervoltage, rev polarity
Device is powered from a UPS

The possibilities are

1. cable loose connection at the ext. connector (GND of power sharing with RS232)
2. corrupted program flash
   a. ( As customer mentioned "It is switching off automatically.......... " )
   b. https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1773742910557?context=%7B%22contextType%22%3A%22chat%22%7D
   c. https://teams.microsoft.com/l/message/19:meeting_ZDEyMGJkNzEtMTkxZC00N2UyLWI1ZTUtOWViMjg4NGIyYTY2@thread.v2/1773725537625?context=%7B%22contextType%22%3A%22chat%22%7D
3. improper Power-On reset ( This we will check in the lab )
4. Any EMC/EMI issue - need a detailed study
5. EMI through antenna mounted on panel (mounted on 03/03/2026)
   a. Test with antenna directly mount on device and check signal with door closed

Suggest @Channamallikarjuna Mattihalli to do as follows(26/03/2026)

1. Power off device
2. check cable loose contact and correct
3. Power cycle multiple times and observe
4. Still not resolved, then
5. Reflash the program and capture log
6. disconnect RS232 and programming cable
7. Power cycle multiple times

@VenuMadhav S : improper Power-On reset ( This we need to check in the lab by measuring using scope 3.3v rail and MCU reset during power off and power on)