Task #3239
open
Installation Support
Added by Thomas Joseph 3 months ago. Updated about 1 month ago.
Description
F/W update at customer site
Updated by Thomas Joseph 3 months ago
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#1
Updated by Thomas Joseph 3 months ago
· Edited
Actions
#2
- % Done changed from 0 to 80
Summary (copy of email to SV)
Chola Turbo installed device at Mane in the week of 30/01/2026.
30/01/2026, Friday
We visited Mane Kancor plant and updated the device firmware. Device could get PLC data through Modbus TCP. Also noticed broken Modbus communication
02/02/2026, Monday
Firmware upgraded and device could fetch PLC data continuously . Also data were reflected in E-REMOS dashboard in real-time. The integrity of dashboard data verified by comparing with HMI display installed in the panel(Mane technicians use the data displayed on HMI to generate hourly log report ).
It was noticed that during some power cycle, the device failed to fetch PLC data.
As requested by Mr. Nithin Babu, Manager of Mane Kancor, briefed the progress to him. Mr. Nithin requested to share the report format for them to review. We assured to share the format through Methesh and confirmed that we would make one more visit to update the device firmware to resolve the Modbus connection issue with power cycle.
04/02/2026, Wednesday
Based on our request, Mane technician powered on the device. The device status LEDs were in good indication.
The dashboard values were all zeroes , a symptom of failed Modbus communication with PLC. Even after a power cycle, the device continued posting zero values.
06/02/2026, Friday
Visited Mane Kancor to update the device firmware. Noticed that the device is in power on with posting zero values.
Updated the firmware, still the data from PLC could not be fetched. Then tried with previous firmware which had been fetching PLC data, but could not get Modbus response.
We started troubleshooting with Modbus simulator software and Wireshark.
Checked the behavior of Gateway device by Modbus Server software (to emulate PLC) and confirmed that the device is working as expected.
Upon testing with Modbus Scan( a tool for emulating Gateway device), concluded that the PLC is acknowledging the Modbus TCP request, but not giving the response message(containing holding register value).
Requested Mr. Methesh to check the PLC settings and establish Modbus connectivity by explaining all the troubleshooting results.
Methesh wanted him to install the TIA software (to access PLC) in my Laptop and share the screen using Anydesk for him to access the PLC and verifying the PLC configuration.
The software downloading (approx. 20GB) and installation completed by 07/02/2026, 2.00am
The license key installation failed due to unknown reasons.
07/02/2026, Saturday
Visited Mane Kancor.
Checked with troubleshooting software (Modscan and Wireshark) and observed the continuation of the block in Modbus communication with PLC
Made several try in TIA license key installation, it got failed due to unknown reasons. Tried to contact IT experts (Christy, ....), but all of them were unavailable.
Decided Methesh to visit Mane and check the PLC settings in the week of 09/02/2026. He will share the date of visit after discussing with his Manager.
Updated by Thomas Joseph 3 months ago
Actions
#3
- Due date changed from 30/01/2026 to 04/02/2026
Updated by Thomas Joseph 3 months ago
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#4
- Due date changed from 04/02/2026 to 11/02/2026
Updated by Thomas Joseph 3 months ago
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#5
- Status changed from Analysis Started to In Progress
Updated by Thomas Joseph 2 months ago
· Edited
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#6
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
Updated by Thomas Joseph 2 months ago
· Edited
Actions
#7
04/03/2026
- 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.
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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 -
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
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Verify daily report is as per the the report format (no. of pages, order of parameters, units)
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Limit voltage, current values to one decimal point
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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 -
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 -
4G signal strength is not updating in dashboard
Updated by Thomas Joseph about 2 months ago
Actions
#8
Issues with Trend Graph
- 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
- The graph canvas area is very small
- The graph title to be decided
Updated by Thomas Joseph about 2 months ago
· Edited
Actions
#9
- 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
- 4G signal strength is not updating in dashboard
This is not enabled in the current version.
Updated by Thomas Joseph about 2 months ago
Actions
#10
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)
Updated by Sunder Venugopal about 2 months ago
Actions
#11
- Due date changed from 11/02/2026 to 31/03/2026
Updated by Thomas Joseph about 2 months ago
Actions
#12
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
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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
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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
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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
Updated by Thomas Joseph about 2 months ago
Actions
#13
10/03/2026
Visited Mane Kancor
- Flashed new firmware => Gatewayv2_02.54
- getting dashboard as expected
- 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
- bug fixed f/w => Gatewayv2_02.54.05
- last signal id not reflected in modbus read
- increased max tags, new f/w => Gatewayv2_02.55
- 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
Updated by Thomas Joseph about 1 month ago
· Edited
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#14
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
- cable loose connection at the ext. connector (GND of power sharing with RS232)
- 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 - improper Power-On reset ( This we will check in the lab )
- Any EMC/EMI issue - need a detailed study
- 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)
- Power off device
- check cable loose contact and correct
- Power cycle multiple times and observe
- Still not resolved, then
- Reflash the program and capture log
- disconnect RS232 and programming cable
- 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)