User Manual Zenith Sensor Panel

Baker Hughes a GE Company
ZenithTM Production Monitoring & Optimisation Systems
Zenith™ Production Monitoring & Optimisation Systems
ZenithTM down-hole Monitoring System

E Series Sensor and ZSP
ZSP with Removable Media
(Set-up and Configuration)
Rev J
Oct 2016
1
Proprietary Information
Information in this document is subject to change without notice and does not represent a commitment on the
part of Baker Hughes a GE Company, ZenithTM Product Line. The software described in this document is furnished
under a license agreement. The software may be copied only in accordance with the terms agreed in the license.
The purchaser may make one copy of the software for backup purposes. No part of this manual may be
reproduced of transmitted in any form or by any means, electronic or mechanical, including photocopying,
recording or information storage and retrieval systems, for any purpose other than the purchaser's personal use,
without the express written permission of Baker Hughes a GE Company, ZenithTM Product Line
Trademarks
Windows™ is a trademark of Microsoft Corporation.

Modbus is a trademark or registered trademark of Schneider Automation Inc.
All other trademarks acknowledged.
Editions
ZSP Set up and Configuration

User Manual Part B Rev D August 2007
ECN 0330 Rev E September 2008
ECN 0351 Rev F November 2008
ECN 1799 Rev H December 2015
ECN 1882 Rev I June 2016
ECN 1959 Rev J Oct 2016
Baker Hughes, a GE Company

Zenith™ Production Monitoring & Optimisation Systems
Unit 8 Camieston Road,
Inverurie,
Aberdeenshire
UK.
AB51 5GT
Tel: +44 (0)1467 628866

Fax: +44 (0)1467 629857
Email: support@ge.com
2
ELECTRICAL HAZARD!
WARNING! The down-hole sensor system is attached to the
high voltage supply of the ESP.
Only personnel with the correct training should be
allowed to have access to equipment.
ELECTRICAL HAZARD!
WARNING! Remove medium voltage fuses from the surface
choke before commencing any work that might be
required to be carried out on the surface equipment.
This isolates the surface equipment from the
medium voltage side of the drive.
ELECTRICAL HAZARD!
WARNING! ESP drive or variable speed drive must be shut down
and isolated before any work is carried out within
the medium voltage area or on any equipment. This
ensures that the medium voltage cannot be
switched on accidentally by a third party.
And most of all remember
Think Safe!
Work Safe!
3
Section 1 - ZSP Overview.......................................................................................................................................................................................... 5
Modbus Map – ZSP System ........................................................................................................................................................................ 7
ZSP Set up and Configuration ................................................................................................................................................................... 8
ZSP Units – Set up for Metric or Imperial Units ................................................................................................................................ 8
ZKey and SD Card ............................................................................................................................................................................................ 8
Section 2 - ZSP Keypad and Display................................................................................................................................................................ 10
ZSP Keypad 11
ZSP Boot up Sequence 12
ZKey and SD Card 13
ZSP Display 14
Screen 1 – Config Screen .......................................................................................................................................................................... 14
Screen 2 – Data display screen (a) ....................................................................................................................................................... 14
Screen 3 – Trend Screen ........................................................................................................................................................................... 15
Screen 4 – Active Alarms Screen (a) .................................................................................................................................................... 15
Screen 5 – Modbus Table (a to s) .......................................................................................................................................................... 16
Screen 6 - Communications.................................................................................................................................................................... 16
Screen 7 – Data Logging ........................................................................................................................................................................... 17
Section 3- Browser Set Up .................................................................................................................................................................................... 18
ZSP Browser Set Up. 19
PC to ZSP E-Net Connection. ................................................................................................................................................................... 19
PC to ZSP Local Area Connection Set Up ......................................................................................................................................... 20
Confirming a PC Local Area Connection .......................................................................................................................................... 22
Opening the ZSP Browser ......................................................................................................................................................................... 22
Browser Menu Navigation........................................................................................................................................................................ 23
Section 4 - ZSP Set Up and Configuration - Keypad or Browser ...................................................................................................... 26
ZSP Configuration 27
ZSP Configuration Menu 28
Keypad Mode Configuration 29
Browser Mode Configuration 29
ZSP Configuration. 30
Port 1 Menu ...................................................................................................................................................................................................... 30
Port 2 Menu ...................................................................................................................................................................................................... 30
Parameters Menu ......................................................................................................................................................................................... 33
Alarms Menu ................................................................................................................................................................................................... 35
Analogue Menu .............................................................................................................................................................................................. 40
Data Menu ........................................................................................................................................................................................................ 41
ZKey Menu (SD Card Removal and Re-install) ............................................................................................................................... 47
Date / Time Menu ......................................................................................................................................................................................... 49
Screen Menu .................................................................................................................................................................................................... 50
Section 5– Log Download ..................................................................................................................................................................................... 51
Log download via browser ...................................................................................................................................................................... 52
Log download from SD card ................................................................................................................................................................... 53
Clearing Flash Memory Logs .................................................................................................................................................................. 53
Section 6 – Appendix A ........................................................................................................................................................................................... 54
Standard Operating Procedure ......................................................................................................................................................................... 54
SOP : ZSP with ZKey – SD Card Removal, Data log transfer and Card Re-install 55
4
Section 1 - ZSP Overview
5
ZenithTM Surface Panel
This manual should be used in conjunction with the User Manual - Part A which covers the
equipment installation and field wiring arrangements in detail
The ZenithTM Surface Panel (ZSP) provides an interface, via the Zenith Surface Choke, with the
ZenithTM down hole Sensor.
The ZSP provided
Real time monitoring of ZenithTM Sensor data via the LCD screen display
Data and status logging to the on-board Flash Memory
Alarm and Trip set up from any (Logged) parameter
Third party Modbus communications port (RS232 or RS485)
Accept up to an additional eight parameters as Analogue Input (4 – 20mA)
Can provide up to eight parameters as Analogue Output (4 – 20mA) on request
The ZSP is supplied with 24 V PSU, ESP Interface Board, Display Terminal Board, Analogue
Input/Output Board, Alarm and Trip relays and Engineers E-Net port.
The ZSP is supplied pre-wired and ready for field installation

Field wiring requirements consist of
Power supply (110-220VAC) – Cable and ZSP gland provided

Signal cable from ZenithTM Surface Choke – Cable and ZSP gland provided
Alarm and Trip wiring to appropriate field wiring terminal board
Modbus wiring to appropriate DT Board Port 2 connection
Analogue input/output wiring to field wiring terminal board
The ZSP is supplied with two fitted cable glands (Power and signal cable).
An additional four gland holes (0.813” dia) allow for additional cable glands to be fitted.
Blanking plugs are fitted to these holes
The client will supply any additional cabling, glands etc required
Field installation and wiring arrangements are covered in detail in User Manual – Part A
6
Modbus Map – ZSP System
Register ModBus
Description Data Type Units and Scaling
Number Address
Bar * 10 or * 100 (set by register 107)
0 Intake Pressure 40001 Unsigned Integer OR
Psi * 10
Bar * 10 or * 100 (set by register 107)
1 Discharge Pressure 40002 Unsigned Integer OR
Psi * 10
2 Intake Temperature 40003 Unsigned Integer Degrees C * 10 OR F * 10
3 Motor Temperature 40004 Unsigned Integer Degrees C * 10 OR F * 10
4 Vibration X 40005 Unsigned Integer g* 1000
5 Vibration Z 40006 Unsigned Integer g * 1000
6 Tool Current 40007 Unsigned Integer mA * 10
7 Tool Voltage 40008 Unsigned Integer Volts * 10
8 Intake Pressure 40009 Unsigned Integer Psi * 10
9 Discharge Pressure 40010 Unsigned Integer Psi * 10
10 Intake Temperature 40011 Unsigned Integer Degrees F * 10
11 Motor Temperature 40012 Unsigned Integer Degrees F * 10

40013 to
12 to 19 N/A Unsigned Integer
40020
40021 to
20 to 27 Analog inputs A1 to A8 Unsigned Integer
40028
Modbus Map – ZSP
Note:
The ZenithTM system Modbus output operates in MMIC mode (ZSP Port 1 and 2 Mode should both be set
to MMICmode)
In earlier versions of software, parameters 1 to 4 (Pi, Pd, Ti and Tm – Modbus registers 40001 to 40004
output was in metric units (Bar/Deg C with Parameter 9 to 12 (Pi2 Pd2, Ti2 and Tm2 – Modbus registers
40009 to 400012) output is in imperial units (Psi/Deg F)
In later versions software parameters 1 to 4 can be set to metric or imperial units by changing the
“Units” name (Config Parameters Units) – See User Manual Part B – Set up and Configuration –
However Modbus output from registers 40001 to 40004 remains in metric units Except for software
version 1.56.1 which will provide register 40001to 40004 output in imperial units
7
ZSP Set up and Configuration
ZSP configuration can be done from either keypad or by using the web browser
Note however that SD card removal can only be done from Keypad – the safe removal of the SD card
CONNOT be done from the browser interface
ZSP Units – Set up for Metric or Imperial Units

In earliest versions of software, parameters 1 to 4 (Pi, Pd, Ti and Tm ) output was in metric units (Bar/Deg
C)
Parameter 9 to 12 (Pi2 Pd2, Ti2 and Tm2 ) output was in imperial units (Psi/Deg F) – With this early
version software access to port 1 menu was required to allow parameters 1 to 4 to output in imperial
units
In Latest versions software parameters 1 to 4 can be set to metric or imperial units by changing the
“Units” name (Config Parameters Units) – See section 4 – Set up and Configuration
Setting units name for parameters 1 and 2 (Pi and Pd) to Bar will output metric parameter values –
setting units name to Psi will output imperial parameter values
Similarly for parameters 3 and 4 (Ti and Tm) naming units as DegC outputs metric values, DegF outputs
imperial values (See Parameter Units Menu – P32)
Note However even if parameters 1 to 4 display out put is changed to imperial units, modbus register
40001 to 40004 output units remains as metric - To view Modbus in imperial units (psi and deg F)
modbus registers 40009 to 40012 must be polled
Software version 1.56.1 however provides an exception and this version allows for registers 40001 to
40004 to ‘follow’ the displayed units
ZKey and SD Card

Software version 1.56 or above is recommended for use with SD card system
The ZSP ZKey (flash memory) with removable SD card is mounted internally on the back plate of the
display and analogue board
The Zkey is a 4mb flash memory capable of storing around 22 days of data logged at 1 minute intervals.
This ZKey memory DOES NOT overwrite when full and should therefore be cleared (after saving logs) on
a regular basis
Data and status logs from the ZKey is copied to SD card for ease of download (note data is not
transferred directly to SD card – The SD card merely copies the contents of the Flash memory)
The appropriate procedure MUST be followed for removal of SD card from the ZSP
The SD card must be removed via the ZKey menu option – This menu option is available from keypad
Config menu only
On selecting ZKey Remove SD Card data transfer from Flash memory to SD card is updated and
stopped, A message is then displayed when it is safe to remove the SD card
8
When the ZSP restarts without SD card an error message is displayed – This message can be ignored
When the ZSP is started without SD card data will automatically be logged to ZKey memory.
When the SD card is later inserted, the ZSP will detect the card and run through a housekeeping
sequence of updating the card.
The SD card is inserted with the card label facing towards the panel door..
It is recommended that good quality SD cards are used – Cards should be formatted before first use
9
Section 2 - ZSP Keypad and Display
10
ZSP Keypad
The ZSP front plate display section houses the LCD screen along with the 9 soft key pad
The keypad can be split into four distinct sections
Keys 1 and 2
These two keys allow access to various menu options and additional display screens (e.g. Config,
Trend, Fast Log, More etc)
In each case a ‘legend’ on the LCD screen bottom row will indicate the function of the appropriate
key
Keys 3 and 4
These 2 keys allow for scrolling through various display screens (Back/Next)
In each case a ‘legend’ on the LCD screen bottom row will indicate the function of the appropriate
key
Keys 5, 6, 7 and 8
These four keys allow navigation through the various menu screens to scroll up or down, or in the
case of the alphanumeric configuration screens, left or right
Key 9
The Enter (Select) key – This key selects or enters a request, instruction or data to the ZSP
The ZSP offers 7 main display screens – Select Next (Key 4) to scroll through the 7 available main
screens
11
ZSP Boot up Sequence
On power up the ZSP runs through a boot up sequence and automatically cycles through five
screens as shown below.
The first screen (ZSP Surface Panel….) will only be displayed during the boot up sequence if the
Flash Screen option is set to On (from the Configuration Screen menu)
The second screen displayed indicates that the data logging Flash Memory with SD Card (ZKey)
has been detected whilst screens 3 and 4 confirm the presence of the SD card before settling to
data display screen- Screen 2 (a)
Engineers should monitor the panel boot up sequence, noting software version, confirming data
logging medium (RAM, Flash or ZKey) and where applicable confirming the presence of the SD
card
Zenith Surface
Panel
Version 2.08. Flash Memory
Found
Zenith Oilfield Technology Ltd Logging to ZKey
www.zenithoilfield.com
Copying to SD Card SD Card Inserted

Please wait
Well Name 1
28 / 07 / 06 15 : 28 : 00 SCREEN 2 (a)
Parameter Data Display screen – Display
Pi Bar XX 0.0
Pd Bar XX 0.0
defaults to this screen on panel
Ti Deg C XX 0.00 boot up (also and panel re-boot
Tm Deg C XX 0.00 when exiting configuration mode
Vx G XX 0.000
Vz G XX 0.000
Vt V XX 121.3
Ct mA XX 0.00
TREND MORE BACK NEXT
When the ZSP is powered up (or on re-boot as panel exits configuration mode) the display will run
through the boot up sequence and will automatically default to data display screen SCREEN 2 (a)
12
On boot up the first values to be displayed on screen will be Vt (120V approx) and Ct (10mA
approx)
Ct may be seen to hunt 9 – 15mA as communications is established with the Sensor before
settling back to 10mA
It may then take 1 – 2 minutes before a full set of down hole parameters is updated on screen.
If the ZSP is powered up without a Sensor connected then all parameters will display zero with
the exception of the Tool Voltage (VT) (approx 120V)
If Vt shows 0V then link 3-4 on the signal cable terminal block is not in place
ZKey and SD Card

The ZSP ZKey (flash memory) with removable SD card is mounted internally on the back plate of
the display and analogue board
The Zkey is a 4mb flash memory capable of storing around 22 days of data logged at 1 minute
intervals.
This ZKey memory DOES NOT overwrite when full and should therefore be cleared (after saving
logs) on a regular basis
Data and status logs from the ZKey is copied to SD card for ease of download (note data is not
transferred directly to SD card – The SD card merely copies the contents of the Flash memory)
The appropriate procedure MUST be followed for removal of SD card from the ZSP
The SD card must be removed via the ZKey menu option – This menu option is available from
keypad Config menu only
On selecting ZKey Remove SD Card data transfer from Flash memory to SD card is updated
and stopped
A message is then displayed when it is safe to remove the SD card

When the ZSP restarts without SD card an error message is displayed – This message can be
ignored
When the ZSP is started without SD card data will automatically be logged to ZKey memory.
When the SD card is later inserted, the ZSP will detect the card and run through a housekeeping
sequence of updating the card.
The SD card is inserted with the card label facing towards the panel door..
It is recommended that good quality SD cards are used – Cards should be formatted before first
use
13
ZSP Display
The ZSP displays 7 main level screens. – Data Display covers up to four screens (screen 2a to 2d)
to allow all (logged) data to be displayed
Note:
That where logging has been disabled for a specific parameter then that parameter will not be
displayed on screen – Underlying screens (2b, c and d) will only be accessible if a sufficient
number of parameters is being logged
The number of underlying screens accessible will depend on the number of parameters being
logged – For example if only 12 parameters are logged then data display will cover two screens –
If all 32 parameters are logged then data display will cover all four screens (a to d)
Screen 1 – Config Screen

The main screen displays current date and time along with Zenith product contact details
(Address, telephone fax and e mail details)
The contacts screen offers 3 keypad options

• Config
Press key 1 - Allows access to configuration mode
• Back
Press key 3 – Scrolls back one screen
• Next
Press key 4 – Scrolls forward one screen
Screen 2 – Data display screen (a)

The data display screen shows well name on row 1 (see Screens Well Name Menu) along with
current date and time on row 2
Rows 4 to 11 shows the first 8 parameters where logging is currently enabled, displaying
parameter names, values, units and alarm and trip status –
Note:
That only parameters where logging facility has been enabled will be displayed on screen (See
Parameters Logged menu) – Where a specific parameter is not logged then next parameter
will be moved up 1 row
ZSP software (ver 1.57 or later) will allow up to 32 parameters to be displayed over four individual
screens (a to d) – Some of these parameters apply to different applications (PCP Sensor torque
and positioning tools) and do not apply for E series Sensor systems – Logging should be disabled
on all irrelevant parameters – These parameters will not then be shown on the display screen.
Disabling logging on all irrelevant parameters will also save on data logger log space
14
The data display screen offers 4 keypad options
• Trend
Press key 1 – Moves directly to Trend screen (Next serves the same purpose)
• More
Press key 2 – Scrolls to a second level data display screen (b) – Screen b displays next 8
parameters. Use More to scroll through display screens (c) and (d) and back to screen (a)
• Back
• Next
Screen 3 – Trend Screen

The trend screen allows trends to be displayed for any two (logged) parameters
The Trend display screen offers 4 keypad options –
Note:
The Trend screen can also be accessed from Screens (1 or 2)
Note:
If there is no logged data in memory or if the parameter has remained constant over the selected
time frame then a trend will not be displayed and the message No Data will be shown
The Trend screen offers 4 keypad options

• Time Frame
Press key 1 – allows a time frame of 1, 4, 8, 12, 24 or 84hours
• Param
Press key 2 – Allows any two logged parameters to be selected for trending purposes.
Parameters are selected through a sub menu as P1 (parameter one) and P2 (parameter
two)
• Back
• Next
Screen 4 – Active Alarms Screen (a)

The Active Alarms screen displays Lo and Hi trip and alarm status for the (logged) parameters. –
The display shows if alarms and trips are enabled or disabled and if the alarm or trip has been
activated
If the alarm or trip is disabled – or has been set with invalid levels then the appropriate box will
display X
If the alarm or trip has been enabled but has not been activated then the appropriate box will
remain blank
15
If the alarm or trip is enabled and has been activated then the appropriate box will display YES
The Active Alarms screen offers 4 keypad options

• More
Press key 1 – Scrolls through four Active Alarm screens (a to d) allowing alarm and trip
status to be monitored for all active parameters
• Level
Press key 2 – Displays parameter current value along with alarm and trip set points – On
screen message will also advise if invalid levels are set
• Back
• Next
Screen 5 – Modbus Table (a to s)

Modbus table screen displays parameter name, assigned Modbus (address) register and modbus
output value.
Modbus Table covers 19 screens (More key) and covers modbus registers 40001 to 40028, 40101
to 40106, 41001 to 41056 and 41101 to 41156 – Most of these registers are for specific ZenithTM
applications and normally only registers 40001 to 40012 will be of interest to the operator
Note:
Modbus register assignment is fixed and cannot be changed
The Modbus Table screen offers 3 keypad options

• More
Press key 1 – Scrolls through 19 Modbus Table screens (a to s) allowing modbus output to
be monitored – Normally only modbus registers 40001 to 40012 will be of interest to the
operator
• Back
• Next
Screen 6 - Communications
This screen offers a trouble shooting guide tracking ports 1 and 2 communications and errors
The Communications screen offers 2 keypad options

• Back
• Next
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Screen 7 – Data Logging
The data logging screen provides a useful guide to logging status. This screen confirms Logging
to Zkey (Flash) – Also listed is the date and time of last log, the percentage of memory used and
the logging time remaining.
This screen also indicates if the SD card has been detected

It is recommended that engineers use this screen as part of their checks before leaving location
The Data Logging screen offers keypad options

• Back
• Next
Press key 4 – Scrolls forward one screen (Back to screen 1)
Note:
The Zkey incorporates a 4Mb flash memory is capable of holding approximately 22 days of data
with the ZSP logging at 1 minute intervals - Data stored on the Flash is copied to SD card – Data
is not written directly to SD card
The Flash memory does not overwrite when full and must be cleared on a regular basis – If Flash
memory is full then data will be lost - ie WILL NOT be written directly to SD card
17
Section 3- Browser Set Up
18
ZSP Browser Set Up.
Browser configuration is carried out via the ZSP ‘Engineers Port’ 6 pin military style connector
located on the bottom left of the ZSP enclosure (Figure 3.1)
An ‘Engineers Cable’ (14460077000 – Figure 3.2) is supplied with the cable installation pack for
connection from the ZSP to PC.
Figure 3.1 Figure 3.2

Engineers Port. Engineers Port Cable (14460077000)
PC to ZSP E-Net Connection.

The Engineers Port cable (P.No14460077000) connects from the PC network port (RJ45) to the ZSP
‘Engineers Port’ (6 pin military) connector located on the bottom left of the ZSP housing.
The Engineers port is connected internally to the ZSP Display Terminal Board. E-Net port
In the unlikely event that this cable should ever be disconnected then care must be taken when
re-connecting, ensuring the connection is made to the E-Net port
E-Net Port connection MUST NOT be made to the R-Net Port.
The E-Net port is located beneath the 32 way cable ribbon connecting the Display Terminal
Board to the field wiring terminal block.
In order for the ZSP and PC to communicate, the appropriate PC Local Area Connection must first
be set up. In many cases the PC used for ZSP configuration and down load will also be used to
connect to an office LAN.
It will therefore be necessary to set up the Local Area Connection each time a connection to ZSP
is to be made and to reverse these changes after disconnecting from the ZSP. If the set up is not
reversed then it will not then be possible to reconnect to the office LAN
19
PC to ZSP Local Area Connection Set Up
To allow communications with the ZSP the PC network connection must first be configured,
setting the ZSP IP address (See Browser Connection – Figures 3.3 – 3.6)
From the Start Menu
Select - Control Panel

Select - Network connections
Right click - Local Area connection
Select - Properties
Select - Highlight Internet Protocol (TCP/IP)
Select - Properties
Select - Internet Protocol (TCP/IP) Properties screen
Highlight - “Use the following IP address”
Set up the connection IP address as shown below

IP Address 192. 168. 0 . 1
Subnet Mask 255. 255. 255. 0
Default Gateway 192. 168. 0 .100
Select “OK” to save the property changes
Figures E, F, G and H below show the appropriate PC screens for setting the ZSP IP address.
Note:
After disconnecting from the ZSP it will then be necessary to return the PC to default status to
allow connections to other networks (e.g. office LAN)
Repeat the steps above to get to the Internet Protocol (TCP/IP) Properties screen and highlight
Select “Obtain an IP address automatically”

Select “OK” to save the configuration
Failure to reset the Internet Protocol (TCP/IP) properties will mean the PC will be unable to re-
connect to other local networks (e.g. office LAN)
20
Browser Configuration – PC set up
21
Confirming a PC Local Area Connection
Any computer running Windows 2000 or XP should normally show a Local Area Connection icon
on the bottom right taskbar – If the LAN icon is not visible then open the adapter Properties
dialog box (through control panel) and select the option to display the taskbar icon.
With no cable connected a red cross will be displayed over the LAN icon (may also show an error
balloon – “Network cable unplugged”)
• Connect the Engineers Port E-Net cable from PC to ZSP

• Switch on ZSP (if not already on)
• The Local Area Connection icon should now show the Local Area Connection open at
10mbs
If the icon does not show a connection then check the PC set up and Engineers Port cable. If this
does not solve the problem then check that the Engineers port cable is securely plugged into the
correct (E-Net) port on the Display Terminal board.
Opening the ZSP Browser

Open a standard web browser (Internet Explorer, Mozilla Firefox etc)
Enter web address as http://192.168.0.100/
The ZSP login screen (Figure 3.7) will then open

If the Login screen is not displayed then a connection has not been established between the ZSP
and PC.
Check both Local Area Connection Properties and cabling to locate the problem
Figure 3.7 – Browser Log in screen
22
Browser Menu Navigation
A user name and password are required to open the ZSP browser
User Name: zenith (lower case)

Password: AB51 (UPPER case)
Type in the user name and password and select the SUBMIT to enter the configuration mode. –
In browser mode the Submit option serves the same purpose as keying Return in keypad mode
whilst Back (browser) and Exit (keypad) perform the same function
When the ZSP enters the configuration mode, the ZSP stops communication with the down hole
Sensor, the data display disappears from screen and is replaced with an on screen message –
“System halted whilst configuration is modified”
The browser main menu screen (Top Menu) will then be displayed (on PC)
The ‘System halted….’ message remains on (ZSP) screen until the panel is brought out of the edit
(configuration) mode and returned to operational status.
During this period the ZSP does not display data, communicate with or log data from the down
hole Sensor
Selecting the ‘Save Changes’ or ‘Discard Changes’ options will exit the edit mode.
After 5 minutes of inactivity the edit mode is automatically exited – Any changes not saved will be
lost
Figures I and J show the Log-in and Main (Top) Menu PC screens
The SUBMIT button is used to enter data, information or request to the ZSP.
Highlighting Submit may open an underlying menu level or may accept a value level entered
from PC (e.g. an alarm level). In other cases the Submit may return to the previous menu level
Changes are then stored in a buffer memory until either the SAVE CHANGES or DISCARD
CHANGES option (Top Menu screen) is selected
Keying Submit uploads the changes to the ZSP buffer but does not save the changes.
When the SAVE CHANGES option is selected, the ZSP then runs through a re-boot sequence and
updates the (new) configuration before returning to the normal data display screen (screen 2)
If Discard Changes is selected then the ZSP display returns directly to the data screen without
re-boot. In this case no changes are made to the panel configuration.
Only after Save Changes has been accepted is the ZSP configuration updated.
The browser page BACK option will return to the previous (browser) page
Continue to select BACK to return to the Top menu screen where the Save Changes/ Discard
Changes option can then be selected and accepted.
23
In some cases, in some underlying menus, the BACK option may not be available and selecting
an item will return to the previous level.
Note that if the ZSP times out (after 5 minutes of inactivity) and returns to operational mode then
any changes not saved will be lost
Figure 3.7 - ZSP Browser Log in Screen
24
On entering the correct user name and password the browser configuration screen (figure 3.8)
will then be displayed
Figure 3.8 – ZSP Browser Main (Top) Menu Screen
25
Section 4 - ZSP Set Up and

Configuration - Keypad or Browser
26
ZSP Configuration
ZSP configuration and set up can be carried out from either keypad or from PC via the web
browser (Engineers E-Net cable 14460077000 required to interface to ZSP)
Keypad configuration mode is accessed from screen 1 by selecting Config (key 1) option
The menu structures for both keypad and browser configuration are generally very similar.
Note however SD card removal can only be carried out from keypad – this action cannot be
accessed from browser.
The browser option on the other hand offers an option to down load (and upload) ZSP
configuration files to (from) PC – This option is useful where several panels are required to be set
up with exactly the same configuration.
Note:
The configuration menu can only be entered from one option at a time – i.e. If the configuration
menu is entered from the ZSP browser then the keypad will be disabled until the configuration
menu is exited (from browser). - Likewise if the configuration mode is entered from the keypad
then the ZSP browser cannot be opened until the configuration menu is exited (from keypad)
When the ZSP enters configuration mode (by either method) then communications between the
ZSP and Sensor is halted and the screen display is replaced by the message
“System halted whilst configuration is modified”
When the configuration mode is entered from PC via the ZSP browser, the ‘System halted…..’
message will remain on screen until the configuration mode is exited (from browser)
Where the configuration mode was entered from keypad then the ‘System halted…..’ message will
display for approximately 5-10 seconds before being replaced by the Configuration (Main) Menu
There is no password required to enter the configuration mode from the ZSP key pad. However
the password AB51 is required to clear data and/or status logs
There is no special software required for configuration via the ZSP browser. However it is
necessary to establish the PC to ZSP LAN connection via the Engineers Port E-Net cable
Access to the ZSP browser menu requires a user name and password to be entered in the home
page
User Name - zenith (lower case)
Password - AB51 (UPPER CASE)
The password AB51 is also required to clear data and/or status logs
Port 1 menu is no longer accessible to field operators - A password is now required to enter this
menu from both browser and keypad options
27
ZSP Configuration Menu
ZSP menu configuration is very similar from both keypad or browser options and in most cases
differences are merely in screen layout
The main differences are the ZKey option in keypad mode – This option does not exist in the
browser – SD card removal can only be initiated from the keypad
The keypad Analogues menu offers an option – analogue calibration – This is a factory set up
menu and is not required for field operatorions
The Configuration Interface Menu screen provides a selection of 8 menu options plus the save
changes and discard changes options
Port 1 – This menu is factory configured and MUST NOT be altered
A password is required in software ver 1.57 to access this menu
Port 2 – Configures Port 2 for third party comms systems (Modbus)
Parameters – Allows selection of parameters to be logged
This menu also allows for parameter units to be changed
(Parameter Units option)
Alarms - Allows set up of Alarm and trip levels
Analogs - Allows set up of analogue input/outputs
Data - Allows logging rate to be set, logs download and clearing etc
Zkey- Allows SD card removal in approved manner –
This menu option is available in keypad mode only
Date/Time - Allows set up of Date and Time – Uses European Format
Screen - To set up display screen – Well Name is entered from this menu
View Param and Displays Configuration file

Alarm Config- This menu option is available in Browser mode only
Configuration File- Allows for configuration file down load to PC or upload from PC
Save Changes - Saves Changes made in configuration mode
This option is available in Browser mode only
Discard Changes – Discards changes and returns ZSP to previous configuration
This option is available in Browser mode only
ZKey Menu option is available on Keypad configuration mode only

Menu options shown in red are available through browser configuration mode
only
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Keypad Mode Configuration
In keypad mode menus are selected by highlighting the appropriate option and selecting by the
Return key (key 9) – This may select a particular option or may open an underlying menu
Most menu levels include the EXIT option – selecting EXIT will return to previous screen
Where there is no EXIT option then the display will return to previous screen by highlighting the
appropriate option and pressing key 9
On touchpad keyboard screens the Ret option will return to previous screen
On completion the EXIT option should be selected to scroll bay to Save Changes Screen
On the save changes screen highlight YES (or NO) to save the changes (or discard) changes.
All configuration changes are saved in buffer memory until the save changes option is exercised
If NO is selected then all changes are discarded and the ZSP immediately leaves configuration
mode returning directly to screen 2(a)
If YES is selected then the changes are applied to the configuration fileand the ZSP then runs
through a re-boot sequence (see ZSP Boot up sequence – P11) before returning to screen 2a
In many cases selecting a specific option will open a drop down menu listing some but usually
not all parameters – These drop down menus will also include a More and Exit option
The Exit option will return to the previous screen
The More option will list additional parameters
The ZSP by default lists 32 parameters – these parameters are covered by four separate screens
or lists – The More option scrolls through these screens (lists)
Browser Mode Configuration

In Browser mode menus are selected by highlighting the appropriate option or parameter and
keying return or selecting SUBMIT (where available) to move to the next level
Where a value has been entered for a specific parameter then select the SUBMIT option to store
the value in buffer and return to the previous level
Most menu levels include the BACK option – selecting this option will return to previous menu
level
Where there is no BACK option then select SUBMIT to the previous level
When configuration in browser mode is complete select BACK to return to the main menu (ZSP
Configuration Interface screen)
In the ZSP Configuration Interface screen select Save Changes or Discard Changes
As with keypad configuration if discard changes is selected then the ZSP will immediately exit
configuration mode returning to screen 2(a)- data display screen and all changes will be lost
29
If the save changes option is selected then any changes made will be applied to the
configuration file after which the ZSP will run through a re-boot sequence returning to the default
data display screen (see ZSP Boot up sequence – P11)
Note:
Changes made in configuration mode are saved in buffer memory – Changes are not applied to
the configuration file until the Save Changes option has been selected
If the Discard Changes option is selected then any changes made in configuration mode will be
discarded
Note:
If the ZSP browser configuration mode remains inactive for 5 minutes the ZSP will automatically
exit the configuration mode and the display will revert to data display screen 2a – Any changes
made to the configuration prior to the 5 minutes of inactivity will be lost. Changes are only applied
when the Save Changes option is selected
ZSP Configuration.
Port 1 Menu
In older versions software access to port 1 menu was necessary to allow output units to be set.
Output units are now set through Parameters Units menu
Port 1 menu is now restricted to internal communications set up between Interface card and ZSP
display terminal and is no longer required for field purposes
Accesss to Port 1 menu is now restricted Zenith personnel only.
Port 2 Menu
Port 2 is the third party communications port linking between the ZSP and the external system
(e.g. client SCADA, PC running HyperTerminal etc). Configuration will depend on the external
device set up
ZSP system Modbus Map is shown in section 1 – page 7
Port 2 menu offers six second level menu options required to set up manage the
communications link between the ZSP and third party device
• Output Port
• Mode
• Baud Rate
• Data Bits
• Parity
• Modbus
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Output Port
This menu offers two options –
• RS232
• RS485
The ZSP provides for two different Modbus communications levels. However, only one converter
can be used at any one time.
Probably one of the most common causes of Modbus problems is where the output port is set to
one level (e.g. RS232) whilst the Display Terminal Board is wired for the alternative mode (RS485)
For a RS232 connection, Display Terminal Board terminal J10, connections 8, 9 and 12 (Gnd) are
required
For a Half-Duplex RS485 connection, Display Terminal Board terminal J10, connections 10 and 11
are required – Normally a Half-Duplex RS485 would not require the ground connection
See User Manual part 1 for Modbus field wiring connections
Mode
This menu offers 3 second level menu options
• Port 1 Echo
• Modbus Slave
• MMIC
MMIC is the standard mode for third party output interface (e.g. SCADA).
Baud Rate
This menu offers a selection of baud rate options from 1200 to 38400bps
Baud rate should match the third party Modbus Master configuration.
Data Bits
This menu offers an option of 7 or 8 data bits from the drop down menu. (normally 8)
Selection should match third party Modbus Master configuration.
Parity
This menu offers an option of None, Odd or Even parity from the drop down menu (normally
None).
Selection should match third party Modbus Master configuration.
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Modbus
Port 2 Modbus option is used to set the Modbus slave number (address) and can be in the range 0
to 255. The default slave number is 1.
The Modbus slave number must match that set to that to be polled by the third party Modbus
master.
Use the Back (browser) or Exit (Keypad) to return to the save changes screen
32
Parameters Menu
The Parameters menu allows for changing parameter names and units. It also allows the
selection of parameters to be logged to memory
Changing a parameter name does not re-assign a parameter to a different channel
Changing parameter units on pressure and temperature parameters does however change
output value from metric to imperial units (or vice versa) – Pressure values may be expressed in
Bar or Psi and temperature units in Deg C or Deg F –
In older versions software the option to change units used to be done through port 1 menu –
However with version 1.57 or above this is now accessible through this parameters menu
The Parameters menu also now includes an additional three options – Decimal places and Filter
Coeff and Filter passes.
Decimal Places menu is not applicable for ESP E series sensors
Filter Coeff and Filter Passes menus have been introduced to overcome issues related to motor
winding temperature systems
Because motor winding temperature thermocouple is located close to motor windings, this
parameter is very susceptible to noise pick up and can result in ‘spikey data’ being observed.
Traditionally most ESP monitoring systems have handled this issue by incorporating a fixed rate
filter in the down hole sensor.
ZenithTM feel that this approach is somewhat suspect and have opted to incorporate an
adjustable filtering facility in the surface package -
The parameters menu provides six second level menus

• Names
• Units
• Logged
• Decimal Places
• Filter Coeff
• Filter Passes
• Exit
Names
Select the required parameter from the drop down menu and select Return (Submit) to edit the
parameter name
In keypad mode use the touch screen to edit the parameter name – Select RET to exit touch
screen
Note:
This only changes the parameter name – It does not re-assign a parameter from a different
channel
33
Unit
Select the required parameter from the drop down menu and select Return (Submit)to edit the
parameter units
This menu is now used to change between imperial and metric units – Unit names are changed
via the touchpad screen
For pressure enter unit name as Bar or Psi. For temperature units enter name as DegF or DegC
By making the appropriate name changes the ZSP will then output parameter nos 1 to 4 in either
imperial or metric units dependant on units name
Pressures and temperatures are the only parameters where units may be changed (Bar or Psi
and Centigrade or Fahrenheit). –
Default names should remain unchanged for all other parameters

Note:
Changing unit names will not alter the modbus register output
Logged
This menu allows the selection of which parameters to be logged to the Flash Memory (ZKey/SD
card) for data log storage and trending purposes.
It is advised that only relevant parameters are logged - Normally Pi, Pd, Ti, Tm, Vx, Vz, Vt and Ct
with possibly dP, dT and Clp - Note however this is not a definitive list and logged parameters will
depend on client requirements
It is recommended that logging is disabled (off) on all parameters where no data (zeros) is being
returned
Select the required parameter from the drop down menu and select Return (Submit) to edit
which parameters are logged (Yes) or not logged (No)
Note:
Changes to the selection of logged data can only be made after the data log has been cleared
and before a fresh log has started (i.e. before exiting the configuration mode).
Where a parameter is not selected for logging then that parameter WILL NOT be displayed on
the data display screen (screen 2 a to d)
Logging status can also be checked via the Browser – View Parameters ans Alarm Configuration
menu option
Selecting only required parameters for logging purposes will greatly increase logging capacity of
Flash memory or Zkey/SD card
34
Decimal Places
This is a special applications menu and normally should not be altered (1 for pressures,
temperatures and tool voltage – 2 for tool current and 3 for vibrations).
Filter Coeff
This menu allows filtering to be set on motor temperature to compensate for ‘noise’ (spiking) on
motor windings temperature data
Under normal conditions Filter Coefficient is normally set to 150-200
Filter Passes
This menu is used in conjunction with the Filter Coeff menu. The Filter Passes menu allows for
smoothing of motor winding temperature by averaging out the data
Under normal conditions Filter Coefficient is usually set to 2 or 3

Note:
Filter passes option is not available from browser menu
Note:
That in Keypad option, the screens to enter Filter Coeff and Filter Passes values are not touch
screens. – Values are entered using keypad. The RET option is used to return to main menu
Alarms Menu
The Alarms menu allows for configuration and activation of Alarm and Trip facility.
Alarm and Trips can be set on any parameter and the respective relay activated or inhibited.
Wherever a trip value is set, it is recommended that a corresponding alarm level is also set up. It
is also recommended that appropriate levels are set on both Hi and Lo relays
(Low Trip, Lo Alarm, Hi Alarm and Hi Trip).
Values must be chosen appropriately and with care to avoid spurious Trips
The Alarms menu provides five second level menus

• Alarm Level
• Parameter Enabled
• Deadband
• Holddown
• Global Enable
Each option provides a drop down menu –

Select the required option and key Return (Submit) to enter edit mode.
35
Alarm Level
This menu allows alarm and trip levels to be set
Selecting the Alarm Level option opens an additional drop down menu allowing specific
parameters to be selected – a further menu level allows alarm and trip levels to be set on the
specific parameter
Alarm and trip set points should be entered on all four levels
LO TRIP
LO ALARM
HIGH ALARM
HIGH TRIP
Enter the required set points and key Return (Submit) to return to the drop-down menu.
The Trip/Alarm levels entered are then buffered until the Save Changes option is selected from
the Main Menu
Repeat for each Parameter – Ensure that no parameter setting is liable to accidentally trip the
VSD when the parameter is accidentally enabled
Set up the appropriate Trip and Alarm levels on each parameter as required
Where a Trip Level is set up then the corresponding alarm level should also be set
Even although only one relay is wired it is essential that both Trip and Alarm Levels are set
up (see User Manual Part B Section 4 Alarms Menu) – If both trip and Alarm Levels are not set
then the relay WILL NOT activate
Parameters Enabled
Where a Trip (Alarm) facility is required on a specific parameter then the Enable option must be
turned ON for that parameter (in addition to setting Trip and Alarm Levels)
Select the required parameter from the drop down menu and key Return (Submit).
A second level drop down menu opens to allow for the alarm and trip to be enabled (YES) or
disabled (NO)
Repeat for each parameter – Ensure that only the relevant parameters Trip/Alarms are activated
Avoid setting alarm and trip levels or enabling alarms and trips on parameter which may cause
spurious VSD trips
It is recommended that the Global Enable facility is ignored – Use the Alarms/Parameters Enable
facility to select the applicable parameters
Alarms/Deadband
Deadband is set to prevent nuisance alarms and trips.
Deadband is set as a percentage of the Trip (or Alarm) value the parameter has to drop below the
Trip (or Alarm) set point (Level) before the system will come out of a Trip (or Alarm) situation.
Select the required parameter from the drop down menu Return (Submit)
In the dialogue box enter the required Deadband (as a percentage of the Trip /Alarm set Level)>
36
Key Return (Submit) to enter the value
Repeat for each Parameter that alarms and trips have been set up on
Remember for each parameter that a Trip Level is set up on, the corresponding Alarm Level must
also be set 2 (percent) is a common Deadband setting but will depend on the individual situation
Alarms Holddown
Holddown, like Deadband is set to prevent nuisance alarms and trips
Holddown is the number of consecutive data points (from the down hole Sensor) required after an
Alarm or Trip level has been breached before the Alarm (Trip) relay will activate.
Setting Holddown to 1 disables this function – ie 1 data point over the set Level will activate the
Trip (Alarm) – This means a data spike would activate the Trip (Alarm).
Note that with the ZenithTM Sensor, parameters are updated from the Downhole sensor at
differing time intervals.
Intake pressure is the most frequently updated parameter (approximately every 7-9 sec).
Vibrations are the least frequently updated parameter (approximately every 22-25 sec)
Therefore if Holddown is set to 3 then 3 consecutive data points above the Trip (Alarm) Level
before the relay will activate.
If a Trip was then set on Pi the system could trip within 3 x 9 = 27sec after the level was
breached.
If a Trip was set on Tm then the system could take up to 3 x 15 = 45 sec after the set Level was
breached
Select the required parameter from the drop down menu and key Return (Submit).
In the dialogue box enter the required Holddown
Key Submit (Return from Keypad) to return
Repeat for each Parameter that alarms and trips have been set up on
Remember for each parameter that a Trip Level is set up on, the corresponding Alarm Level must
also be set. Holddown is normally set to 2 or 3 but will depend on the individual situation
37
Alarms/Global Enable
This Option provides a shortcut to enabling either all Lo or Hi Alarms /Trips where appropriate
Levels have been set.
Ensure the appropriate Trip/Alarms have been properly configured before exercising this option
to prevent accidental tripping of the ESP
This option should only be exercised with extreme caution and it recommended that it be
disregarded (use the Alarm/Parameter enable menu to set enable/disable specific parameters)
Once the appropriate Trip (Alarm) Levels have been set, the appropriate parameters enabled and
the conditions (Holddown and Deadband) applied then exit the Alarms to apply the new
configuration
Select Save Changes - Yes to apply the new configuration to the ZSP
Selecting Save Changes – No (or Discard Changes) will be discarded any changes made and re-
apply the previous set up
Checking Alarm and Trip Set Up from the Display Screens

Whenever alarms and trip levels are set on a specific parameter, set up and levels should be
checked on the display screen after exiting the Configuration mode.
Alarm and trip set up can be confirmed from two display screens
The Data display screen

Where a parameter displays XX at the end of the line, this indicates Alarm and Trips for that
parameter is disabled.
Where AT is displayed confirma alarms and trip values have been set is
The Active Alarms screen

Where X is displayed on the Active alarms screen indicates that alarms and trips have not been
set (Levels invalid) - These parameters will not trip the VSD
Where a blank space is shown in the respective column indicates the trip or alarm is Enabled (ON)
– These parameters will trip the VSD if the trip set point is breached (and dead band and hold
down conditions are met)
Where YES is shown in a respective column indicates that a set point has been breached and the
trip or alarm is Active –If YES is shown on the trip level then the level has been breached, the
relay has been activated and the VSD should be stopped
Where X is shown this indicates that the alarm and trip level settings are invalid – This will
Selecting the Levels option on the Active Alarms screen will display the current value of the
parameter, along with to alarm and trip level settings (where the settings are invalid - eg all four
38
levels set to zero) then the message Alarm Levels Invalid will be displayed – where this message
is present then the relay will not trip the VSD
The ZSP works on a Normally Closed Relay – the relay will open when an alarm or trip activates
39
Analogue Menu
The ZSP can accept up to eight analogue outputs and can (if requested) provide up to eight
analogue inputs
Analogue input requires factory set up and this facility should be requested prior to shipping the
ZSP.
The source of the analogue inputs can be down hole tool parameters or surface analogue inputs.
Analogue output can be any of the ZSP parameters (surface or down hole)
Both analogue input and output systems both operate on a 4 – 20mA mode
The Analogs menu provides five second level menus

Output source
Scaling Input
Scaling Output
Calibrate Inputs
View Inputs
Each option provides a drop down menu

Select the required option and key Return (Submit) to enter edit mode.
Calibrate inputs and View Inputs options are only available in keypad configuration mode
Output Source
From the drop-down menu, select the desired analogue output (e.g. A1)
From the next level drop down menu select the required parameter (e.g. Pi)
This assigns that parameter (Pi) to the selected analogue output (A1)
Key Return (Submit) assign the parameter and return to the Analogue menu.
Repeat for each required parameter
Scaling Inputs
From the drop-down menu, select the desired analogue input.
The dialogue box then allows for the required min and max scaling values to be entered
Key Return (Submit) to enter changes and return to the Analogue menu.

Normally the scaling range should be that of the analogue input transducer
40
Scaling Outputs
From the drop-down menu, select the desired analogue output.
The dialogue box then allows for the required min and max scaling values to be entered
Key Return (Submit) to enter changes and return to the Analogue menu.

Normally the scaling range will be chosen to match the ZSP parameter range
Calibrate Inputs
This menu is for factory use only
This option is only available in keypad mode
View Inputs
Lists the values on the eight analogue input channels (A1 to A8) – This screen is for
information only
This option is only available in keypad mode

Select Continue (key 1) to return to the main analogues menu screen
Selecting Save Changes – No (or Discard Changes) will be discarded any changes made
and re-apply the previous set up
Data Menu
The Data Menu allows for configuration of data update and storage rate
This menu also allows data and events logs to be downloaded and/or cleared.
It is strongly advised that the Password Reset Option is disregarded
Where a ZSP has been locked out with a forgotten password, the reset can normally only be
done by Zenith Engineering in UK.
Where a password is changed by the client from default (AB51) it is the client’s responsibility to
ensure that a safe and secure record of the password change is retained
41
Data Menu - Keyboard Option
The Keyboard option provides ten second level menus – Of these ten options only the first four
and last options are relevant for E series applications
Data Fetching
DataSaving Rate
Delete Logged Data
Delete Status Log
Password reset
Pump Lobes
Flux
Reset Ts
Reset Td
Reset Clp
Data Menu – Browser Option

The Browser option provides twelve options
It provides all options as for keyboard except Reset Clp – This option is only available from
keypad mode
The Browser option does however include an additional three options

Output Data Log
Output Status Log
Flush Logged Data
The Output Data and status log options allow for logs to be the flash memory log to be
downloaded to PC –
The SD card option has now replaced the need for log downloads – however these options
remain in the browser menu as a back up facility
It should be remembered that the logs are stored to Flash memory then copied to SD
card. In the event of a corrupted SD card the log could still be ownloaded via the
browser.
42
Data Fetching Rate

This is the rate at which data is updated from the ESP interface board. This rate can be set to
between 1 to 3600 seconds
Normally this value will be set to 5 or 10 seconds –
Data update from down hole sensor is roughly once every 6-7 seconds for Pi with other
parameters taking up to 25-30 seconds for full update – It is therefore somewhat pointless to
have an fetching rate faster that the tool update rate
Enter the required time on screen and select Ret to return to the main menu screen (select
Submit in browser)
Data Saving Rate

This is the rate at which data is saved in the internal data logger. This rate can be set to between
1 to 3660 seconds
As above it is somewhat pointless to set a data logging rate at a value faster than tool update
rate.
Enter the required time on screen and select Ret to return to the main menu screen (select
Submit in browser)
Note:
The data logger does not overwrite when full and therefore should be cleared on a regular basis
Delete Logged Data

This option deletes the data log from the Flash memory.
Confirmation of the request is required (YES)
From keypad, the password AB51 must then be entered before the log and Ret selected before
the log is cleared
From the Browser menu the user name (zenith) and password (AB51) must then be entered
before the log will be cleared
When the log has been successfully deleted, a massage Data Log Deleted will be displayed
before the screen returns to the data menu
In Browser mode the message SUCCESS will be displayed on screen when the log has been
deleted
The data log should only be deleted after the log has been downloaded and the download
checked – Where an SD card is available the card should be removed and the data log
transferred to PC (and checked) before the Falsh memory is erased
43
Delete Status Log
This option deletes the status log from the Flash memory.
Confirmation of the request is required (YES)
From keypad, the password AB51 must then be entered before the log and Ret selected before
the log is cleared
From the Browser menu the user name (zenith) and password (AB51) must then be entered
before the log will be cleared
When the log has been successfully deleted, a massage Status Log Deleted will be displayed
before the screen returns to the data menu
In Browser mode the message SUCCESS will be displayed on screen when the log has been
deleted
The status log should only be deleted after the log has been downloaded and the download
checked – Where an SD card is available the card should be removed and the log transferred to
PC (and checked) before the Falsh memory is erased.
Password Reset
It is recommended that this option be ignored The DATA Menu screen also allows for the
password to be changed – Entry of the old password (AB51) and new password (twice) is
required.
It is the client’s responsibility to ensure that any password change is recorded and kept safe and
secure for future reference
Pump Lobes
Flux
Reset Ts
Reset Td
These four options are not applicable to E series sensor applications
44
Reset Clp
The ZenithTM E series sensor records a tool current – This value is normally around 10.0mA
Historically ESP monitoring systems have tended to show a ‘Passive Current Leakage’ as opposed
to a tool current.
This Passive leakage current was basically a calculated value of the change in current between
ESP system running and ESP system off
Selecting Reset Clp on the ZenithTM system stores a reference tool current value - this reference
value is then used to calculate the change in tool current being drawn when the ESP system is
running
The Reset Clp option should be exercised after the system has been landed and down hole
conditions have been allowed to stabilise
It is normal practice to select the Reset Clp option just before initial start up of the ESP (Clp(REF))
Current Leakage is then calculated from (Clp(ESP Off) - Clp(REF))
Confirmation is requested (YES/NO) before the reference value is stored – display then returns to
the main data menu
45
Data and Events Log Overview
Logging is set up from two different menus
Parameters Menu
Parameters Logged
This Menu option selects which parameters are to be logged to memory – All parameters that are
shown on the data display screens (Screen 2 a to d) will be logged to memory
Data Menu
Data Saving Rate
This Menu option sets the rate at which data is to be logged (1 – 3600 seconds)
It is recommended that the minimum rate set is 10 seconds to give a regular update of the
fastest parameter.
Data and events logs should be down loaded (and cleared) on a regular basis.
Data and events logs must be down loaded and cleared before any editing changes are made to
the ZSP configuration.
This is of particular importance if a date/time change is to be made to the ZSP
Parameters Logged option cannot be changed until after the log has been down loaded (and
cleared)
It is good practice to download (and clear) both data and events logs at the same time. Logs
must always be down loaded before clearing
Log Down Load via Browser

There are two options for downloading ZSP logs – The most convenient being the removal of the
SD card and subsequent transfer from SD card to PC (see ZKey menu option)
However logs can also be downloaded (direct from Flash memory to PC) via the web browser.
Selecting the Output Data (Status) Log allows for the Flash memory log to be downloaded to PC
Log donnload from browser is covered in detail in section 5
46
Figure O – Down load Pop Up
Clear Data and Status Log

Data and Status logs should be cleared after download and checking. The logs are cleared via
the two options
Delete Logged Data

Delete Status Log
ZKey Menu (SD Card Removal and Re-install)

The SD card copies data from Flash memory to provide a faster, simplified method of data
transfer from ZSP to PC
The SD card must NOT be removed directly from the ZKey
The appropriate removal procedure must be followed – Removal can only be done via keypad
configuration – See Section 6 – Appendix - Procedure for the specific procedure for SD card
removal, copying logs and SD card re-installation
There is no facility in browser menu to allow for SD card removal

From the main configuration menu select Zkey
Selecting the ZKey option provides two second level menus

Remove SD Card
Max lines per file
47
Remove SD Card
Highlight the remove SD card option and key return
The message -Copying to SD card - XX% Complete is displayed as data is transferred to SD
card.
When data transfer is complete the message - Remove SD Card is displayed – The card must not
be removed until this message is displayed
On removal of the SD card and the display then returns to the ZKey menu screen.
Select Exit option to return to Save Changes screen – Select YES to save changes
The ZSP will then run through the re-boot sequence to the screen displaying the message
Unsafe SD card removal

Reinsert SD card
Goto Config/Zkey/Remove SD card
Press any key to continue
A back up SD card could be installed at this point or the message could simply be ignored -
By pressing any key the display then returns to the data screen (screen 2a) and even although an
SD card has not been installed the ZSP will still continue to log to ZKey (Flash Memory)
When an SD card is re-installed this data will then be copied to card
Max Lines per file

This option allows operator to set file size by specifying the maximum number of lines (X 1000) for
the SD card file
When the maximum number of lines is reached a second SD card file is created
The SD card can be re-inserted at any time – There is no specific menu or house keeping
procedure required for re-installing – Simply insert the SD card (label should face towards the ZSP
door) into the ZKey
After a few seconds a message – Copying to SD Card – Please Wait is displayed before the
display again returns to data display screen 2a
SD card data and status log is covered in more detail in section 5 of this manual
Use the Exit (Keypad) to return to the save changes screen
Selecting Save Changes – No will be discarded any changes made and re-apply the previous set
up
48
Date / Time Menu
Date MUST be set in European format DD-MM-YYYY with the time set as HH-MM-SS
Date and time must only be reset after the data and events logs have been down loaded and
cleared and before logging is re-started.
The Date & Time option provides two second level menus
Set Time
Set Date
Set Time
Select Time to open the time set up screen
Enter the current time as HH-MM-SS
Select Return (Submit) to return to the Date/Time menu screen
Set Date
Select Date to open the date set up screen
Enter the current time as DD-MM-YYYY
Select Return (Submit) to return to the Date/Time menu screen
49
Screen Menu
The screen menu offers five lower level options
Flash Screen
Contrast
Backlight
Invert screen
Well Name
Flash Screen
The Flash screen drop down menu allows for the flash screen to be turned on or off – The Flash
screen is the ZenithTM Logo screen seen for a short period as the ZSP is first powered up
Contrast
Allows screen contrast to be adjusted (on a scale of 1 to 31)
Backlight
The drop down menu allows the back light to be turned on or off
Invert Screen
Sets screen to reverse video
Well Name
Allows the appropriate well name to be entered via the alpha numeric touch screen
The well name should always be entered - The name entered here will be attached to all down
loaded logs helping to identify logs and minimise the potential for errors
50
Section 5– Log Download
51
Log download via browser
Data and status logs are downloaded from ZSP to PC with the Engineers E-Net cable
The ZSP data log can only be accessed through the Configuration Data menu, and hence the
system operation will then be halted whilst in configuration mode.
This means that a small section of down hole date will not be logged during the download period
Data logging will re-start when the ZSP exits the Configuration mode.
Download time will depend on the size of data log – however a large log may take 20 minutes or
more to download – Down hole data will be lost during this download period
• Open the PC browser (User name – zenith and password AB51 required – Note the user
name is lower case, the password is UPPER case)
• Select the Data menu
• Select Output Logged Data option
• A File Download dialogue box will then be displayed on screen
• Select Save on the File Download dialogue box and select a suitable location for the
download
• The file name proposed is date and time and Well name stamped for identification
purposes and is best left unchanged – the down load file will be saved as a .csv file
• Select Save from the Save As screen – The file download will then proceed
• When the download has finished open the download file and check that the download
was successful
• Change the file name extension from .csv to .xls and save
• The ZSP Data log can then be safely deleted
It is recommended that the download file is then checked before proceeding to clear the log.
Status log is downloaded in exactly the same manner – However for the status log download file
this is usually saved as a text file
Screen shots of the log download process are given below
52
Data Log down load via browser
Log download from SD card

Data and status log are copied to SD from the ZSP Flash memory (ZKey)
The SD card provided a far simpler and faster method of collecting panel logs
The SD card can be removed from the ZSP at any time following a simple housekeeping
procedure as specified in section 6
The SD card data log download file is then be converted to csv file and copied from SD Card to
PC where the data log file is then saved as an excel file
The Status log file is saved directly to PC as a text file
Section 6 details the specific procedure for removal of SD card, - converting and copying down
load files and the re-install of SD card
Clearing Flash Memory Logs

It is recommended that the ZSP Flash memory logs are not cleared until the SD card files have
been saved to PC
Note:
The Flash memory must not be cleared whilst SD card is installed as this may also clear data still
to be uploaded from Flash to SD card
53
Section 6 – Appendix A
Standard Operating Procedure
54
SOP : ZSP with ZKey – SD Card Removal, Data log transfer and Card Re-install
1. General
1.1 This procedure details the Procedure for the use of a removable data storage medium
to capture the ZenithTM Surface Interface Panel (ZSP) data log.
The removable data storage medium, referred to as the Z-Key, is a standard 256MB SD
card. It is recommended that only good quality SD cards are used.
1.2 SD Cards must be formatted before first time use.
2. Overview
2.1 The SD Card is located inside the ZSP. This entails opening of the panel door for install
and removal of the SD Card. This operation must only be carried out by suitably
competent personnel
2.2 It is recommended that the SD Card is only inserted with ZSP power on. Monitoring the
red and green LED’s immediately above the card holder will confirm the card detection
2.3 To ensure the data log capture to SD Card, and to prevent possible software corruption
the SD Card MUST BE REMOVED AS PER SECTION 3 PROCEDURE
2.4 The SD card copies the data and status logs as they are written to the ZSP Flash
memory. When the SD card is removed (via the appropriate procedure) data continues to
be written to the Flash memory.
When the SD card is then re-instated, the Flash memory content is then automatically
copied (flushed) to the SD card.
This procedure means there should be minimum data loss over the period when SD
card has been pulled. It also means that in addition to logs being saved on the SD card a
back up copy exists on the ZSP Flash memory which could if required be downloaded by
conventional methods
It must be stressed however that the Flash memory log must be cleared on a regular
basis. The Flash memory DOES NOT overwrite when full and hence no further data will
be transferred to SD card until the Flash Memory has then been cleared
2.5 ZSP logs can be cleared at any time with SD card in or out. However it is recommended
that logs should only be cleared after the data has been transferred, checked and saved
on PC.
2.6 ZSP logs are cleared, as per normal procedures, via the ZSP Keypad through the Config
Data Delete logged Data menu options – A password (AB51) is required to clear
the data log
55
3. Removal of the SD Card
3.1 Select Config menu option
3.2 Select Data option
3.3 Select Remove SD Card option. The screen display then switches to the message -
COPYING TO SD CARD - ----100% COMPLETE. – This process should take around 1
minute maximum
3.4 When Data transfer is complete then the screen then displays REMOVE SD CARD
3.5 If the data transfer to SD card is not successful then the message: COPYING TO SD
CARD -0% COMPLETE. Will be displayed. - REMOVE SD CARD message will not be
displayed.
In this case exit the Config menu. (Select BACK to return to the Config menu and exit as
per steps 3.7 to 3.9 – Remember to select YES from the Save Changes selection) - Then
repeat procedure from step 3.1
NOTE:
The SD card must NOT be removed before the ‘REMOVE SD CARD’ message is
displayed
The SD Card must not be ejected whilst the red LED D2 is illuminated or whilst either
message is displayed
3.6 Open the ZSP door and remove the SD card (Press to eject)
3.7 Once the SD card has been ejected the screen display then returns to the data menu
screen
Select Exit to return to the Config Menu screen –
NOTE:
The system will not display or log data whilst in Configuration mode
3.8 Select Exit to return to the Save changes screen

3.9 Select Yes to acknowledge the changes and exit the configuration mode.
3.10 The ZSP will then run through the re-boot sequence and will display the message –
FLASH MEMORY FOUND - LOGGING TO ZKEY before returning to the data display
screen
3.11 An error message will then be displayed
Unsafe SD Card Removal

Reinsert SDCard
Go to Config/ZKey/Remove SD Card
Press any key to continue
3.12 A second SD card may be inserted or the message may simply be ignored pressing any
key (twice) to return to the data display screen (screen 2a)
3.13 Note that it is recommended the ZSP is not in configuration mode when the SD card is
inserted (see section 5)
56
4. Data transfer from SD Card to PC
4.1 Ensure the SD card is unlocked
4.2 Insert the SD card in the card reader and open. The card will contain an MS-DOS file
called RUNME.BAT and a one or more files titled XXXXDATA.XXX
4.3 Double click on the RUNME file and following the screen instruction, press any key to
continue. The data file will then automatically be converted to a .CSV file. This data log
file will be stamped with well name (as per ZSP set up) with date and time of download.
4.4 Save this data log csv file to PC
4.5 Check the saved data log csv file and confirm the data log download was successful –
The download file can then be renamed and saved as an ezcell file
4.6 Once the download log has been successfully saved to PC. delete all files from the SD
card – This must be done from PC – The SD Card cannot be cleared from the ZSP
keypad.
4.7 Once the download has been successfully saved to PC, the SD card can then be cleared
and re-installed in the ZSP
5. Installation of the SD Card

5.1 Ensure the SD Card is unlocked. (Format the SD Card before first time use)
5.2 Ensure the ZSP is not in Configuration mode – It is recommended that the SD card is
inserted with the ZSP powered up
5.3 Open the ZSP door and insert the SD Card in the card slot immediately above the ZSP
analogue terminals. SD card label should face towards door
5.4 On inserting the SD Card, green LED D3 will flash for several seconds followed by rapid
flashing of red LED D2 - Red LED D2 will then stay whilst any data from Flash memory is
transferred to the SD Card
5.5 When the SD card is inserted two message will be flashed on screen SD card inserted
followed by Copying to SD Card – Please wait
The SD Card must not be ejected whilst the red LED D2 is illuminated or whilst either
message is displayed
5.6 Red LED 2 (and copying to SD Card message) may stay on for 1 – 2 minutes before
returning to normal. A steady green LED D3 indicates the SD Card is correctly installed
and the ZSP is logging to memory.
Note:
If the SD Card is installed with the ZSP in configuration mode then LED D2 will
remain illuminated until the configuration mode is exited
5.7 If the SD card does not install as per above then remove as per section 3 and check all
data has been deleted from card (Reformat card if necessary) and re-install as per
section 5
57

User Manual Zenith Sensor Panel

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Baker Hughes a GE Company

ZenithTM Production Monitoring & Optimisation Systems

Zenith™ Production Monitoring & Optimisation Systems

ZenithTM down-hole Monitoring System

Windows™ is a trademark of Microsoft Corporation.

ZSP Set up and Configuration

Baker Hughes, a GE Company

Tel: +44 (0)1467 628866

And most of all remember

Section 1 - ZSP Overview

The ZSP provided

The ZSP is supplied pre-wired and ready for field installation

Power supply (110-220VAC) – Cable and ZSP gland provided

3 Motor Temperature 40004 Unsigned Integer Degrees C * 10 OR F * 10

4 Vibration X 40005 Unsigned Integer g* 1000

5 Vibration Z 40006 Unsigned Integer g * 1000

6 Tool Current 40007 Unsigned Integer mA * 10

7 Tool Voltage 40008 Unsigned Integer Volts * 10

8 Intake Pressure 40009 Unsigned Integer Psi * 10

9 Discharge Pressure 40010 Unsigned Integer Psi * 10

10 Intake Temperature 40011 Unsigned Integer Degrees F * 10

11 Motor Temperature 40012 Unsigned Integer Degrees F * 10

Modbus Map – ZSP

ZSP Units – Set up for Metric or Imperial Units

ZKey and SD Card

Section 2 - ZSP Keypad and Display

Copying to SD Card SD Card Inserted

ZKey and SD Card

A message is then displayed when it is safe to remove the SD card

Screen 1 – Config Screen

The contacts screen offers 3 keypad options

Screen 2 – Data display screen (a)

Screen 3 – Trend Screen

The Trend screen offers 4 keypad options

Screen 4 – Active Alarms Screen (a)

The Active Alarms screen offers 4 keypad options

Screen 5 – Modbus Table (a to s)

The Modbus Table screen offers 3 keypad options

The Communications screen offers 2 keypad options

This screen also indicates if the SD card has been detected

The Data Logging screen offers keypad options

Section 3- Browser Set Up

Figure 3.1 Figure 3.2

PC to ZSP E-Net Connection.

E-Net Port connection MUST NOT be made to the R-Net Port.

From the Start Menu

Select - Control Panel

Set up the connection IP address as shown below

Select “OK” to save the property changes

Select “Obtain an IP address automatically”

Figure 3.3 Figure 3.4

Figure 3.5 Figure 3.6

• Connect the Engineers Port E-Net cable from PC to ZSP

Opening the ZSP Browser

The ZSP login screen (Figure 3.7) will then open

Figure 3.7 – Browser Log in screen

User Name: zenith (lower case)

“System halted whilst configuration is modified”

Figure 3.7 - ZSP Browser Log in Screen

Figure 3.8 – ZSP Browser Main (Top) Menu Screen

Section 4 - ZSP Set Up and

“System halted whilst configuration is modified”

View Param and Displays Configuration file