scout-3000

SCOUT-3000ESP Surface Monitoring System

A N Y W H E R E . A N Y T I M E . E V E RY T I M E .

FIELD MANUAL

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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:

Scout-3000 Operations Manual

Copyright 2013 by Sercel-GRC Corp. All rights reserved worldwide.

Document Number: 006-0191-00

Sercel-GRC Corp. 6540 East Apache Street, Tulsa, Oklahoma 74115-3616 USA

P.O. Box 581570 Tulsa, Oklahoma 74158-1570 USA E-Mail: [email protected] or [email protected]

Telephone: (1) 918-834-9600 / Fax: (1) 918-838-8846

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Table of Contents 1.0 Scout-3000 Specifications ................................................................................................. 4 1.1 Accessories and Part Numbers ........................................................................................ 4 1.2 Scout-3000 Surface Readout Instrument Overview ......................................................... 5 2.0 How to Connect the Scout-3000 to a Gauge .................................................................... 6 2.1 Operation of the Scout-3000 .............................................................................................. 7 2.2 Scout-3000 Menu Selection Structure .............................................................................. 7 3.0 Scout-3000 Display Pages and Menus ............................................................................. 8

3.1 Scout-3000 Graph Tab ............................................................................................... 8 3.2 Scout-3000 Long-Term Graph ................................................................................... 9 3.3 Scout-3000 Real-Time Graph ....................................................................................10 3.4 Scout-3000 MENU Tab ..............................................................................................11 3.5 Scout-3000 Display/Sound Setup Menu ..................................................................11 3.6Scout-3000 System Menu ..........................................................................................12 3.7 Scout-3000 Software Version Menu .........................................................................12 3.8 Scout-3000 USB Memory Menu ................................................................................13 3.9 Scout-3000 SPS Menu ...............................................................................................14 3.10 Scout-3000 Ports Menu ...........................................................................................14 3.11 Scout-3000 Modbus Menu ......................................................................................15 3.12 Scout-3000 4-20mA Port Setup Menu ....................................................................16 3.13 Scout-3000 Relay Alarms Setup Ports Menu .........................................................17

4.0 How to Bench Test the Scout-3000 ..................................................................................19 5.0 Viewing Real Time and Historical Data using Memory Tools ........................................20 6.0 Troubleshooting the Scout-3000 ......................................................................................23 Appendix .................................................................................................................................26 I - Scout-3000 Error Codes and Troubleshooting .................................................................26 II - Scout 3000M Memory Download ......................................................................................27 III - Component, Module, and Connection Illustrations ........................................................28 IV - Modbus Slave Address Details ........................................................................................34 V - Scout-3000B (Bulkhead Option) .......................................................................................34 VI- Wiring Analog and Relay Expansion Cards .....................................................................39

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1.0 Scout-3000 Specifications P/N 90D2300 Height 11.5 in (29.2 cm) Width 9.5 in (24.1 cm) Depth 6.25 in (15.9 cm) Weight 6.1lb (2.8 kg) Voltage (Automatic Selection) 115/230 VAC 50/60Hz *see Appendix IV for 12VDC operation Frequency 50/60 Hz Max Current 0.5A Data I/O USB, USB memory stick, Modbus port

Live data on LCD/USB/Modbus RS485/RS422 Isolated Modbus Removable stored data on USB Drive Optional (2) 4-20mA outputs

Display 4.3 Graphic 480x272 pixel color LCD Touch-Screen LCD Simple and Intuitive Menu Selections

Operating Scout-3000 Standard USB -17C to +65C Temperature Scout-3000 Optional USB* -40C to +70C *requires extended temp USB memory stick

Scout-3000M Internal USB -40C to +70C Storage -40C to +70C Temperature Enclosure NEMA-4X Rated Lockable Non-Metallic Front Panel 25 in-lbs (2.8 N-m) Screw Torque

1.1 Accessories and Part Numbers 90D2300 Scout-3000 Surface Readout 90D2300M Scout-3000M Internal Memory Storage 90D2300B Scout-3000 Surface Readout with Bulkhead wiring connector 90B2301 Scout-3000 Portable Option Cable 90B2175 ESP Choke and Surge protection assembly 75A1090-1 Memory Tools Software v18.0 or newer 034-0178-01 USB memory stick replacement 043-0019-00 FUSE, 3 AG 1/10 AMP FAST-ACTING 136-0076-01 USB CABLE A-B FULL RATED 2.09m 034-0187-01 (Optional) USB DRIVE 1GB EXTENDED TEMPERATURE 138-0114-00 Lithium Backup Battery

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1.2 Scout-3000 Surface Readout Instrument Overview The Scout-3000 is an all-inclusive surface readout tool for the Sercel-GRC line of ESP gauges. The system provides power and communication to the ESP gauge through the ESP Choke and Surge protection assembly (p/n 90B2175). The Scout-3000 utilizes an intuitive 4.3 LCD color touch-screen for viewing data, graphing trends and access to the system control settings. The LCD interface displays real time data numerically or graphically and can plot up to 42 days of historical data. A graphic view of the trend data for all sensor outputs is available by selecting the Graph tab on the Scout-3000 LCD display. Graph options include up to 2 sensor parameters on the vertical axis and time on the horizontal axis. The user may select a timeframe from 7 days to 42 days in 7 day increments and the Scout-3000 LCD display will plot the graphs for instant trend viewing. Recorded data is stored on the removable Scout-3000 USB memory stick. Data stored on the USB memory stick may be copied to another PC or memory device and can be converted to CSV format using Memory Tools software. The data on the USB memory stick is times stamped and stored in a unique file based on the serial number of the gauge. The amount of recorded data on the USB memory stick is only limited by the size of the memory stick. The Scout-3000M stores data internally and is retrieved through the USB port on the front panel. An RS-422/485 Isolated Modbus network is provided to allow the Scout-3000 to be polled for Modbus data from any Modbus compatible controller. Single or dual 4-20mA output current loop options and an Alarm Relay may also be easily added to the Scout-3000.

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! CAUTION ! : Lethal Voltages Present inside Enclosure. Remove power anytime the front panel of the Scout-3000 is removed. There are potentially dangerous voltages present!

2.0 How to Connect the Scout-3000 to a Gauge Connect the AC power to power input and gauge signal to the ESP Power output shown in Figure 1. Scout Wiring System Components.

Figure 1. Scout Wiring and System Components

1. AC Power Input: HOT (AC Power +), NEUTRAL(AC Power -), EARTH (AC Ground) 2. ESP Power Output: - (Gauge/Wellhead Ground), + (Gauge Power +) 3. Expansion card header 4. Modbus Slave Port: RS 485 Pin 1 (TR+), Pin 4 (TR-); RS 422 Pin 1 T-, 2 T+, 3 R-, 4 R+ 5. SPS Gauge Communication Module 6. RCM Scout 3000 System Controller 7. Lithium Backup Battery

1

2

1

3

4

5

6

7

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2.1 Operation of the Scout-3000 See Figure 1. Scout Wiring for information on Typical Installation Wiring. After properly installing the ESP gauge and surface components the Scout-3000 is ready to begin receiving data from the ESP gauge. To begin the transmission of data, apply power via the power switch on the front panel. The Scout-3000 logo will momentarily appear followed by the Data-1 display of gauge data. The Scout-3000 will then begin a series of analyzing steps. This indicates that communication with the downhole gauge has begun. Several status messages will follow as communication is established with the gauge and data is received. It will take approximately 3 to 5 minutes before sensor readings will be displayed on the LCD screen. There is a Delay in reading data on the Scout-3000 from the tool caused by the amount of data read from the downhole sensors and the baud rate. All sensors on the downhole module are displayed in real-time. The data rate of the downhole module is approximately 5Hz. The delay for display of downhole module information is normal. The 3 data tabs contain the sensor data being received from the gauge. Select another tab to change which sensors are displayed.

2.2 Scout-3000 Menu Selection Structure

Main Display Data 1

Sensor Data Group1 Data 2

Sensor Data Group2 Data 3

Sensor Data Group3 Graph

Well Data Graph Menu

SPS Menu Ports Menu USB Memory System Display/Sound

About Screen (Enter this menu by touching the GRC Logo)

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3.0 Scout-3000 Display Pages and Menus The Scout-3000 has three tabs that contain the current data from the gauge being read. Up to four parameters are shown on one screen, and the number of parameters displayed depends on the gauge being used. The bottom left footer displays the current date & time, the tool serial number and type, and the elapsed time since the tool was acquired. The bottom center footer shows the current log filename, the status of the USB drive and the last message received from the SPS. If data is being recorded, the data buffer size is displayed to the right of the log filename.

Figure 2. Scout-3000 DATA Page

3.1 Scout-3000 Graph Tab Two different graphing areas are available on the Scout-3000. The first is a long-term graph, which shows up to the last 42 days of data from the devices internal memory. The other option is a real-time graph, which shows data samples live as they are received.

Figure 3. Select Graph Type

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3.2 Scout-3000 Long-Term Graph The Scout-3000 can graph up to the last 42 days of data from two parameters at once. The first graph screen to load is scaled from 0.0; you can zoom in by pressing the graph to decrease the scale. The graph will show a blank gap during the times when the unit is turned off or the gauge is disconnected. Use the Setup button to configure the parameters to graph and the time.

Figure 4. Scout-3000 Graph Page (sample)

Scout-3000 Long-Term Setup Graph Screen The Setup Graph screen lets you select which parameters youd like to graph (up to two on one graph). Past Days To Display is how many days youd like to view at once on the graph, you can select any multiple of 7 days (up to 42 days). The available number of days in graph memory is displayed under Available Days (42 max). If you wish to reset the graph memory, use the Clear Graph Memory button. See Figure 5. Scout-3000 Graphing Parameters Setup.

Figure 5. Scout-3000 Graphing Parameters Setup

A data point from every parameter is saved to graph memory every 2 hours. Graph memory is stored to battery-backed RAM and is saved between power cycles (as long as the internal lithium battery isnt dead). The USB memory operates completely independently of the graph memory, so a USB drive is not required to store graph memory.

Note: The graph memory sampling time depends on the internal real-time clock. If the system time is manually changed more than 1 day ahead/behind the previous time, will reset all graph memory. Connecting a different gauge to the Scout 3000 will also reset the graph memory.

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3.3 Scout-3000 Real-Time Graph The Scout-3000 real-time graph allows you to graph every sample received live for real-time troubleshooting and graphing. The center of the graph is equal to the first point taken, and the scale/span for each parameter is set in the Setup screen. New samples are added to the right hand side of the graph, pushing the oldest samples off the left side (like a strip chart recorder). The screen will show up to 420 samples before old samples are pushed off the end and lost. A green tick mark is placed at the bottom of the screen every 15 minutes as a time reference, and the total samples graphed and latest readings are shown at the bottom of the screen.

Figure 6. Real-Time Graph Screen

Figure 7. Setup Live Graph Screen

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3.4 Scout-3000 MENU Tab The Scout-3000 has a Menu tab that allows the user to set parameters for the general operation of the tool, 4-20 mA controls, alarms, display options, and USB Memory. The options are easily accessed via the touch-screen interface. To edit an option, press the arrow key adjacent to the item. The content of the Menu tab is shown below as Figure 8. Scout-3000 Menu (System Configuration and Setup) below. Note that some changes are not saved permanently until the main menu is exited, so it is possible to lose your changes by disconnecting power before the main menu is excited.

Figure 8. Scout-3000 Menu (System Configuration and Setup)

3.5 Scout-3000 Display/Sound Setup Menu The Display/Sound Setup menu allows you to change the backlight and beep volume level. The current internal temperature of the surface box is displayed under Unit Temperature, and the minimum and maximum surface box temperatures since power up are displayed under Min/Max Temp.

Figure 9. Scout-3000 Display and Sound Configuration Menu

Note: The SPS menu should not be accessed except when troubleshooting problems as outlined under the Troubleshooting section of this manual.

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3.6Scout-3000 System Menu The System Menu allows you to change your units of measurement, real-time clock, and view system information. The voltage of the Lithium battery is shown under Battery Voltage, and you can also view the unit software versions and reset factory defaults under this menu.

Figure 10. Scout-3000 System Configuration Menu

3.7 Scout-3000 Software Version Menu The Software Versions menu displays all the different firmware/ software versions loaded into the unit which might be necessary to communicate to GRC during troubleshooting. It is possible to store debug information to the USB drive by pressing the Debug Info To USB Drive button and confirming (a USB drive must be inserted before attempting this). Information that can help troubleshoot gauge and unit problems is saved in a file called $DEBUG.TXT on the USB drive. This file can be e-mailed to GRC customer support to help troubleshoot common problems.

Figure 11. Scout-3000 Software Versions Menu

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3.8 Scout-3000 USB Memory Menu The USB Memory menu allows you to view information about the USB drive memory. See Figure 12. Scout-3000 USB Data Status Menu. Log Filename is the filename that gauge log data will be stored to. This is saved in the root directory of the USB drive inserted. To start a new log, press the NEW button and type the new name of the log file. If the log exists, you will receive a confirmation if you wish to add onto the log file, press YES, or press NO to cancel the new log. USB Flash Drive contains the name of the USB drive inserted Drive Capacity contains the total size of the drive. Log Size contains the size of the log filename selected. Note: Log memory is written when the Scout-3000 flash drive internal buffer reaches 256 bytes. This means that data is not written to the flash drive with every sample read from the downhole module. When all 256 bytes of data are received from the downhole module, the buffer will be 100% full and data will be written to the flash drive. Then another buffer will start at 0% and continue to fill until another 256 bytes have been received. This process will continue until the flash drive is full. A 1Giga byte USB flash drive can store approximately 1 year of downhole module data under normal operating conditions. Status contains the status of the last write to the USB drive. If the drive is full, not inserted, or if there is a hardware failure this will be reflected here. For a successful write, WRITE OKAY is displayed.

Figure 12. Scout-3000 USB Data Status Menu

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3.9 Scout-3000 SPS Menu The SPS Menu displays information about the Scout Power Supply (or SPS). This power supply (located inside the Scout-3000) is what provides power to the gauge and decodes the data sent from the gauge. See Figure 13. Scout-3000 SPS Menu.

Tool Type shows the tool serial number and type of tool connected.

Leakage Current shows the leakage current between the gauge and surface. This can be a useful tool for looking for cable insulation deterioration and shorts to ground. You can zero the leakage current (to look for relative changes over time) by pressing the Zero button and confirming.

Operation Settings allows you to change the settings for the SPS board. Under normal operation you should not need to change these.

View Control Settings tells you current operating parameters for the SPS board and can be useful for debugging.

Reset SPS Factory Defaults resets the SPS operation settings back to the factory state.

Reboot SPS restarts the SPS board and analyzing steps to find the tool.

Figure 13. Scout-3000 SPS Menu

3.10 Scout-3000 Ports Menu The Ports menu allows configuration of the Modbus slave port, 4-20 mA current loop outputs and the relay alarms. The 4-20mA current loop ports and relay alarms are optional on the Scout-3000. See Figure 14. Scout-3000 Input-Output Ports Setup menu.

Figure 14. Scout-3000 Input-Output Ports Setup menu

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3.11 Scout-3000 Modbus Menu The Modbus menu allows you to change the Modbus address and baud rate of the Scout-3000s built-in Modbus slave port. This port allows a SCADA system or PC to poll the Scout-3000 for well data (see Modbus section Table 2. Modbus Slave Addresses for more information and register mapping). If the slave address or baud rate is changed, you must first exit the menu back to the data screen (to save changes) and cycle power to load the new configuration. For debugging, you can watch the raw traffic (hex format) on the Modbus port by pressing the Watch Traffic button. Received commands (RX), transmitted commands (TX), Modbus addressing mismatches (Not My Address) and CRC errors (Bad CRC) are displayed on this screen.

Figure 15. Scout-3000 Modbus Setup Menu

Figure 16. Scout-3000 Modbus Traffic Monitor Menu

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3.12 Scout-3000 4-20mA Port Setup Menu

The 4-20mA Port Setup menu allows you to configure the optional 4-20mA current output loops. Channel reflects what gauge sensor is controlling the current loop. 4 mA allows you to set the value that 4 mA of current will reflect. In this example, a reading of 0.0 PSI will output 4 mA. 20 mA allows you to set the value that 20 mA of current will reflect. In this example, a reading of 5000.0 PSI will output 20 mA. Alarms: It is possible to set high and low alarm trip points on the 4-20 mA current loop. In this example, a reading under -5.0 PSI or above 5050.0 PSI will both output 12.0 mA. For example, you could setup some SCADA systems to turn the motor off when this current is received. Note: The 4-20 mA current loops can actually output 0 to 24 mA, so this alarm current could be set outside the 4-20 mA range for easy detection. Trim 4.00 mA and Trim 20.00 mA allow you to calibrate the 4-20 mA output with your loop measuring equipment. Select Trim 4.00 mA and adjust the setting until your system reads as close to 4.00 mA as possible. Select Trim 20.00 mA and adjust the setting until your system reads as close to 20.00 mA as possible.

Figure 17. Scout-3000 4-20mA Current Loop Configuration Menu

4-20mA Output Options Passive 4-20mA The passive 4-20mA option is simply a 4-20mA configuration where your host equipment supplies the voltage for the current loop. Active 4-20mA The active 4-20mA option is configured where the Scout provides the voltage for the current loop. See Figure 45 for detailed wiring information. Active Analog 1-5Vdc and Analog 2-10Vdc The analog 1-5Vdc and Analog 2-10Vdc option provides a 1-5Vdc or 2-10Vdc voltage for turning off and on an analog switch. Voltage for the option is provided by the Scout-3000.

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3.13 Scout-3000 Relay Alarms Setup Ports Menu The Relay Alarm Setup menu allows you to set levels for activating the NO/NC relay. If the Scout-3000 was purchased with an optional Relay board, the relay contacts will close when the alarm trips, allowing control of external equipment via the alarms. If you do not have the optional Relay board, you may still use the relay alarms to log events to the USB drive and showing alarms on the Scout-3000 display.

Figure 18. Relay Alarm Setup Screen

Up to 6 different thresholds can be set by pressing the arrow next to the Edit Alarm Thresholds text as shown in Figure 18. You can select the parameter, edit the trip level on this screen and set the trip point to be less than or greater than the trip level. The Alarm Trip Delay value allows you to pick a time to delay before tripping the alarm. The parameter must trip for more than this time before the alarm trips. This is useful if you want to ignore small transients, and only want it to trip if Motor Temperature exceeds 270F for at least 5 minutes (for example). You can also disable the alarms, or set it to trip instantly (no time delay) with this setting. See Figure 19. Select Alarm Trip Delay Screen to see the available options. The current status of all alarm thresholds is displayed on the Relay Alarm Setup screen as well. The threshold setting is shown on the left, and the latest value is shown on the right. A green value means the threshold has not been exceeded. A red value means the trip threshold has been reached. If an alarm trip delay is programmed and the delay time has not been reached, the value with also show DELAYED X min, meaning the threshold has been reached for X minutes (but the time delay has not been reached, so the alarm has not occurred yet).

Figure 19. Select Alarm Trip Delay Screen

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When at least one threshold is reached for at least the Alarm Trip Delay time programmed, the alarm trips. When the alarm trips, the following events occur automatically: If the relay board is installed as an option, the relay contacts close.

A short 5 second alarm is sounded on the Scout-3000 (the volume is the same as is set in the Display/Sound menu).

The event is recorded to the USB thumb drive in a file called ALARMLOG.CSV. The file is appended with one line, in a comma-separated text format, showing the information about the alarm. An example of one trip event in the file is:

"TripTime=Jan 27, 2011 Thu 09:35:00", "Tool= 94351 MultiESP",

"Alarm=Motor Temp > 250.0 F", "LastValue=253.0 F"

All data values on the main Scout-3000 screens turn red and the bottom right corner of the screen flashes ALARM TRIPPED!. Pressing the ALARM TRIPPED! text takes you directly to the Relay Alarm Setup menu screen.

Figure 20. Data Screen with the Alarm Tripped

The Relay Alarm Setup screen changes to show the details of what tripped the alarm.

Figure 21. Relay Alarm Setup with the Alarm Tripped

Cycle power on the Scout-3000 to reset the Alarm and Relay.

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4.0 How to Bench Test the Scout-3000 You can bench the Scout-3000 prior to field implementation using the following procedure. Connect the Scout-3000 Bench Test Cable (90B2301, Scout-3000 Portable Option Cable) to the Scout-3000 connections. See Appendix III for Component and Module connections Connect the red positive alligator clip on the bench test cable to the motor connector pin on the ESP module. Connect the alligator clip on the black ground cable to any part of the ESP housing. See Figure 31 for an illustration. Confirm that the AC Power connections have been wired internally to the Scout-3000. See Figure 1 for the location of the internal connections. Plug the Scout-3000 Bench Test Cable AC plug into a 110 receptacle and turn the switch to on on the front panel of the Scout-3000. Watch the Display screen on the front panel of the Scout. The first item displayed is the GRC Amerada logo followed by Data 1 sensor data information group. Data 1 sensor data will show the analyzing steps that are implemented in detection of the ESP module. The Scout will then go through several sequences to acquire the ESP module. This will continue until Analyze 16 is reached. After going through these 16 analyzing steps, the display will show a couple of SPS Power Off and SPS SncPhs 3 then SPS SncPhs 5 as many as 4 or 5 times. You will then see Rcv Hdr 0 and begin to receive Header data. See Appendix I for a listing of all status messages in chronological order. You will then begin to see the Gauge serial number and Hdr (header) packets. This sequence will take approximately 3-5 minutes. The Scout should show pressure and temperature data for the downhole gauge. The Scout will display the Data 1 page as the startup default. If none of the above data is on the screen upon power up, or if after 10 minutes no tool data is acquired, cycle power and try again. If you are still experiencing difficulty, contact the Sercel GRC customer service department. It is normal for error messages to appear during the analyzing phase of the gauge detection. The analyzing steps will continue, increment, and correct errors seen during the analyzing phase of the automatic configuration of the Scout-3000. If errors continue or analyzing steps do not complete, follow the troubleshooting guide in Appendix I of this manual or contact Sercel GRC Customer Service. If the Scout acquires the data properly from the tool as stated above then disconnect and install in field.

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5.0 Viewing Real Time and Historical Data using Memory Tools

5.1 Connecting the Scout-3000 to a Computer Real Time

In order for your computer to interface with the Scout-3000, a USB type-A male to type-B male cable is required (136-0076-01, USB CABLE A-B FULL RATED 2.09m). Connect one end of the cable to an available USB port on your computer and the other into the Scout-3000 PC Interface USB connector. To display and record real time data, open the Memory Tools software. On the main screen, select Scout-3000 from the dropdown box. Click on Preferences on the menu bar and select Scout-3000 Interface.

Figure 22. Set Memory Tools for Scout-3000

Figure 23. COM Port Setup

Real Time

Read File

Preferences

Tool Select

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Click on Real Time from the menu bar. A new window will open. Click on Start at the bottom, right hand side of the form to begin receiving data from the gauge. You can click on the Text and Chart tabs to switch between text (data table) and graph displays of the gauge data.

Figure 24. Text View Figure 25. Chart View

To end the application, click on the Stop button at the bottom right side of the form. You will have to wait a minute or two before you can close the form. Close form by clicking on the X Cancel on the bottom right corner of the form.

5.2 Reading Scout USB

To read the USB memory from the Scout 3000 remove the USB from the Scout and connect it to the computer. Click the Read button at the top of the Memory Tools home screen and select the file path for the USB memory stick. Select the file from the USB memory and Click Open.

Figure 51. Select USB File

This will open the window to select the storage location on the PC (Figure 52). From this window you can rename the file if required. Click Save and the Header Information window will open. From this window you can add specific details to be saved with the log file. Clicking Save on the Header Information screen (Figure 53) will then open the log file from the Scout.

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Figure 52. Select File Storage Location.

Figure 53. Header Information Window.

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Note: The ESP gauge will not operate if any phase on the motor circuit becomes shorted or open. If a ground fault develops in the motor/cable power circuit and current exceeds 37mA then the LCD will display High Amps. The Scout-3000 should then be shut down and the system checked.

6.0 Troubleshooting the Scout-3000 Before attempting to troubleshoot there are a few general items you should double check:

Check that all connections to the fuse block and three phase choke are correct.

Check the fuse on the fuse block.

Check the fuses in the Scout-3000 (line circuit breaker and gauge signal fuse).

Check for a short circuit in the motor power circuit.

Make sure you have a dedicated ground wire from the Scout-3000 directly to the wellhead ground.

If the Scout is still having trouble establishing communications with the tool after checking the above problems try restoring/rebooting the Scout by going to the SPS Menu and selecting the Restore option, followed by the Reboot option. If this does not work, try to manually set the operating parameters. Turn off the Auto Volt and Auto Analyzer and begin stepping the voltage from 40 V to 80 V to see if that doesnt solve the problem. The SPS is susceptible to faults caused by phase imbalances that can result in AC voltage at the gauge signal connection point. Phase imbalance voltages can result in tool communication problems. In addition, if the voltages at the gauge signal connection is higher than the rated signal fuse, it will result in a blown fuse. If this situation occurs, disconnect the Scout-3000 from the Surface Package and troubleshoot the phase imbalance situation before attempting further communications with the tool. If communications are not established with the tool, the SPS Start voltage may be incorrect for your application. Some of the error messages that may be encountered for this situation are: Low Amps, High Amps and DC-DC Bad. It is normal to see these errors during start-up. If these errors continue over 5 minutes communication settings may need to be changed. Press the Menu tab shown in Error! Reference source not found. to bring up the Scout menu. Select SPS Menu.

Figure 26. Scout-3000 System Menu

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Select Operation Settings.

Figure 27. Scout-3000 SPS Setup Menu

Disable Auto Volt and Auto Analyze. Select Set Voltage to change the SPS voltage.

Figure 28. SPS Operating Settings Menu

After changing the voltage, cycle the Scout 3000 power to begin running with the new settings. If you still are receiving errors then repeat the above process incrementing the voltage by 4 volts. Continue repeating this process until the Scout is reading the gauge data.

Figure 29. SPS Operating Settings Error Status

Select Operation Settings

Select Set Voltage Turn OFF Auto Volt Turn OFF Auto Analyze

Status message will display on this line

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Note: During normal start-up communications with the tool you may see messages of High Amp, Low Amp, DC to DC Bad, Analyze 1 through Analyze 16 as well as other normal messages that are all part of acquiring the tool. After the Scout analyzes the line current from

the tool you will see the message SPS Power OFF a couple of times and then a couple phase Sync packages. The Scout-3000 will then begin to receive header data from the tool.

This is all part of normal operation of the Scout-3000.

The Scout will display other types of error messages if it is not communicating with the tool or the surface package. A list of these errors, potential reasons for the error, and potential resolutions are listed in Table 1. Scout-3000 Error Messages in the Appendix at the end of this document. If the Scout-3000 still does not function properly, note any error messages and contact Customer Service. Collect as much information and data as possible to expedite a solution. Valuable trouble shooting information can be collected by selecting the Software Version Menu. Confirm that a USB Memory stick is plugged into the Scout-3000 and then select Debug Info to USB Drive. Important debug information will be written to the debug file on the USB Memory stick. This information will assist GRC in quickly resolving most problems that may occur.

Note: Many problems with the Scout can be solved with proper grounding techniques. A good ground must be established from the production tubing at the wellhead back to the

ground point at the surface package for proper operation.

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Appendix

I - Scout-3000 Error Codes and Troubleshooting

Error Message Possible Reasons for Error Resolution

"Okay" No error - normal operation

Once the Scout is communicating with the ESP-

1800, the display will show "Okay".

Phase imbalance Check motor drive, ground problems

Short circuit Check surface package, downhole equipment if


Short circuit

Check surface package, downhole equipment if

necessary


Short circuit


necessary


Short circuit


necessary

"High Amps" Short circuit


necessary

All above and/or a fuse is blown

Check and replace fuse in the Scout or in the

Surface Package

Not enough voltage

Try restore/reboot for the Scout to analyze again,

use the SPS menu to do this.

"No Tool" Blown fuse, bad connection most likely Check all fuses and connections

"No Signal" Gauge is potentially not working Check gauge

"Baud Slow" Bad ground, phase imbalance Check motor drive, ground problems

"Baud Fast" Bad ground, phase imbalance Check motor drive, ground problems

"Baud Noisy" Bad ground, phase imbalance Check motor drive, ground problems

"No Sync Break"

Installation problem, locked on something besides

the gauge, bad ground, phase imbalance Check motor drive, ground problems

"HdrPacket XSum" Not correct voltage at the gauge

In manual mode, increase the voltage; in autovolt

mode, try running it manually.

"Header Too Big"

Downhole tool is sending up erroneous header

data; tool might be bad

Try restore/reboot for the Scout to analyze again,

use the SPS menu to do this.

"Reference Err"

If it keeps recurring, the SPS board might be

damaged. Call customer service

"ESP Framing"

Communication problem as the Scout looks for the

optimal voltage to run the gauge.


mode, try running it mannually.

"ESP Overrun"





"ESP StartBit"





"DatPacket XSum"





"SPS EEPROM !!" SPS board is damaged. Replace board.

"SPS FLASH !!" SPS board is damaged. Replace board.

"Analyzing"

Going through analyzing routines trying to find

optimum settings for the gauge. This is normal. Normal operation

"Low Amps"

"DC-DC Bad"

"DC-DC Noisy"

"Line Bad"

"Line Noisy"

Table 1. Scout-3000 Error Messages

Doc. No. 006-0191-00 Rev. D Page 27

II - Scout 3000M Memory Download

Figure 30. Scout 3000M Front Panel

To download memory from The Scout 3000M connect a USB cable from the PC to the USB Memory Download port on the Scout front panel. Following the instructions in section 5.2 of this manual you can read the Scout 3000M log file, copy the file and then delete the file from the internal memory. The Scout 3000M cannot save data to the Internal Memory when the USB cable is connected to the Scout front panel. The Scout display will show by the USB file status until the USB Cable is unplugged. To delete the file connect the USB cable and open My Computer on the PC. The Scout Internal Memory will appear as a USB device in the PC directory as shown in Figure 54. Right Click on the correct file and select Delete from the list of options.

Figure 54. Selecting Log File.

Scout 3000 Memory File

Log Files

Doc. No. 006-0191-00 Rev. D Page 28

III - Component, Module, and Connection Illustrations

Figure 31. Bench Test Gauge Connection

Figure 32. Modbus User Connection (J22)

Gauge (+) Connection

Gauge (-) Connection To Gauge Case

Modbus User Connection (J22)

Doc. No. 006-0191-00 Rev. D Page 29

Figure 33. ESP Gauge User Connection (J10)

Figure 34. Optional 4-20mA Current Loop Module

Optional 4-20mA Current Loop Module

Scout-3000 Gauge Connection Connect these two wires to the Gauge for bench testing as shown in Figure 28 Bench Test Gauge Connection

Doc. No. 006-0191-00 Rev. D Page 30

Figure 35. Earth Ground Connection (to Well Head) Figure 36. AC Power Input Connection

Earth Ground Connections

AC Power Connection for Scout-3000

! Caution ! High Voltages are present.

Disconnect circuit AC power from source before attempting

to wire the Scout-3000

Doc. No. 006-0191-00 Rev. D Page 31

Figure 37. Scout-3000 Internal Subcomponent Identification

SPS Module (Gauge Power Supply)

Gauge Signal Connections

4-20mA/Relay Option Module Connection

AC Power Input Connection

Graphing Memory backup Battery

Earth Ground Connection

Modbus module Connection

Doc. No. 006-0191-00 Rev. D Page 32

Figure 38. Optional 12VDC Power Operation

Figure 39. 4-20mA Current Loop Module Connector

For 12VDC Portable Operation, Cut JUMPER1 and apply power to Terminal T6. Ground to one of the Ground Terminals

Terminal T6 Optional 12VDC power input. JUMPER1 must be cut.

4-20mA Current Loop Module Connection

Doc. No. 006-0191-00 Rev. D Page 33

Figure 40. ESP Gauge Power connection

Figure 41. Scout-3000 User Interface Connection

Gauge Power (+) and Data Connection

Gauge Power (-) and Wellhead

Ground

Gauge Fuse Holder

(replace only with

specified fuse. Other values may

cause gauge damage)

Scout-3000 Power

Protection Circuit

Breaker

USB PC Interface for

LIVE Data display and

charting with Memory

Tools Software

USB Drive: Gauge data is stored to the

USB drive when

inserted.

Doc. No. 006-0191-00 Rev. D Page 34

IV - Modbus Slave Address Details

Table 2. Modbus Slave Addresses

Note: Sensor values may not actually span the entire Range shown. Range is shown for decoding purposes only

V - Scout-3000B (Bulkhead Option)

TAG HEX ADDR

UNITS DESCRIPTION COMMENTS RANGE

40033 0020 Seconds * 10

Packet Time Stamp High 1234 is 123.4s 0.0s 429496729.5s

40034 0021 Packet Time Stamp Low

40035 0022 Count Value

Packet Count High 1234 is 1234 packets

0 4294967295 40036 0023 Packet Count Low

40037 0024 F * 10 Intake Temperature 1234 is 123.4F 0.0F 6553.5F 40038 0025 Psia * 10 Intake Pressure 1234 is 123.4 psia 0.0psia 6553.5psia 40039 0026 F * 10 Discharge Temperature not available

40040 0027 Psia * 10 Discharge Pressure 1234 is 123.4 psia 0.0psia 6553.5psia 40041 0028 F * 10 Motor Temperature 1234 is 123.4F 0.0F 6553.5F 40042 0029 Gs * 10 Vibration X 123 is 12.3 gs 0.0g 6553.5g 40043 002A Bbls/Day * 10 Flow not available

40044 002B Ohms * 10 Conductivity (WaterCut) not available

40045 002C Volts * 10 Line Voltage 123 is 12.3V 0.0V 6553.5V 40046 002D Gs * 10 Vibration Y 123 is 12.3 gs 0.0g 6553.5g 40047 002E Hz * 10 Current leakage 123 is 12.3mA 0.0mA 6553.5mA 40048 002F Hz * 10 Spare 2 not available

Scout-2200 Modbus Registers.

Doc. No. 006-0191-00 Rev. D Page 35

Figure 42. Scout-3000B AC input connection

Figure 43. Scout-3000B Modbus connection

Black and White AC wires from Bulkhead connector

ModBus connection from Bulkhead connector

Doc. No. 006-0191-00 Rev. D Page 36

Figure 44. Scout-3000B Modbus wiring

Figure 45. Scout-3000B Dual 4-20mA connections

4-20mA #2 connection from Bulkhead connector

4-20mA #1 connection from Bulkhead connector

Doc. No. 006-0191-00 Rev. D Page 37

Figure 46. Scout 3000B Dual 4-20 Output Passive Option Wiring

Figure 47. Scout-3000B Single 4-20mA Active Option Wiring

Doc. No. 006-0191-00 Rev. D Page 38

Figure 48. Scout-3000B Single 4-20mA 1-5Volt and 2-10Volt Analog Option Wiring Diagram

Figure 49. Scout-3000B Dual 4-20mA One Active and One Passive Wiring Diagram

Due to the Scout 3000 internal power supply limitations only one 4-20 mA output card can operate in the Active mode. The second 4-20 mA card must be powered from a separate external power supply.

Doc. No. 006-0191-00 Rev. D Page 39

VI- Wiring Analog and Relay Expansion Cards

Figure 55. Connecting 4-20 mA control loop to Scout-3000.

Figure 56. Connecting dual 4-20 mA output option.

Figure 57. Configuring analog board identification switches.

The switches shown in Figure 57 must be set to the positions shown. The Scout 3000 cannot identify board #1 or board #2 if the switches are not set to the corresponding board. Single analog output boards must be set to position 1 for configuration purposes.

Negative 4-20 mA output

Positive 4-20 mA output

4-20 Board #1

4-20 Board #2

Wire as shown above in Figure 55 for each analog board.

4-20 Board #1 4-20 Board #2

Doc. No. 006-0191-00 Rev. D Page 40

Figure 58. Relay output card.

Figure 59. Wiring relay output card.

The Relay Output card contact rating is 8A - 250 VAC or 8A 30 VDC. See details above for wiring contact positions. Section

Normally Closed contact

Common

Normally Open contact

Sercel-GRC Corp.

6540 East Apache

Tulsa, OK 74115-1570 USA

Telephone: +1.918.834.9600

Fax: +1.918.838.8846

Email: [email protected]

www.sercel-grc.com

Printed in the USA. Sercel-GRC Corp. 04-12

Sercel-GRC Corp. is a worldwide leader in downhole data

acquisition and the leader in proprietary technology for

measuring, recording and delivering reliable and accurate

well data with extremely high resolutions.

Sercel-GRC provides gauges and surface readout tools

for permanent, memory, mechanical and artificial lift

applications and is the manufacturer of the Amerada

mechanical gauge used for over 80 years in the oil and

gas industry.

For more information on this product or any of the qual-

ity monitoring and data acqusition solutions Sercel-GRC

offers, contact us.

Ahead of the CurveSM

Anywhere. Anytime. Everytime.

Scout 3000 Manual Rev D Changes Accepted.pdfTable of Contents1.0 Scout-3000 Specifications1.1 Accessories and Part Numbers1.2 Scout-3000 Surface Readout Instrument Overview2.0 How to Connect the Scout-3000 to a Gauge2.1 Operation of the Scout-30002.2 Scout-3000 Menu Selection Structure3.0 Scout-3000 Display Pages and Menus3.1 Scout-3000 Graph Tab3.2 Scout-3000 Long-Term Graph3.3 Scout-3000 Real-Time Graph3.4 Scout-3000 MENU Tab3.5 Scout-3000 Display/Sound Setup Menu3.6Scout-3000 System Menu3.7 Scout-3000 Software Version Menu3.8 Scout-3000 USB Memory Menu3.9 Scout-3000 SPS Menu3.10 Scout-3000 Ports Menu3.11 Scout-3000 Modbus Menu3.12 Scout-3000 4-20mA Port Setup Menu3.13 Scout-3000 Relay Alarms Setup Ports Menu

4.0 How to Bench Test the Scout-30005.0 Viewing Real Time and Historical Data using Memory Tools5.1 Connecting the Scout-3000 to a Computer Real Time5.2 Reading Scout USB

6.0 Troubleshooting the Scout-3000AppendixI - Scout-3000 Error Codes and TroubleshootingII - Scout 3000M Memory DownloadIII - Component, Module, and Connection IllustrationsIV - Modbus Slave Address DetailsV - Scout-3000B (Bulkhead Option)VI- Wiring Analog and Relay Expansion Cards

scout-3000

Documents

system menu

menu tab

e v e ry t i

n y w h e r e

operations manual copyright

field maintenance

approval of sercel

graph tab