EsoCoreEsoCore

EsoCore Installation Guide

Complete installation guide for deploying EsoCore industrial IoT monitoring across your facility. This comprehensive guide covers hardware
installation, network configuration, sensor deployment, cloud platform setup, and system integration for production deployments.

Prerequisites

Hardware Requirements

Per Monitored Machine:

  • 1× EsoCore Edge device (STM32H747-based)
  • 1-5× Sensor modules (based on monitoring requirements)
  • Power supply (12-24V DC, 2A minimum) OR PoE-capable network switch
  • Industrial microSD card (8GB+, SLC or MLC with wear leveling)
  • Ethernet cable (Cat5e or better) OR WiFi access
  • RS-485 cable (4-conductor shielded, Belden 3105A or equivalent)

Tools Required:

  • Screwdrivers (Phillips and flathead)
  • Wire strippers and crimpers
  • Multimeter for voltage verification
  • Drill and mounting hardware
  • Cable ties and labels
  • Laptop or tablet for configuration

Network Requirements

Connectivity Options:

  • Ethernet with DHCP (recommended)
  • Static IP assignment
  • PoE (IEEE 802.3af) for power and network
  • WiFi (2.4 GHz, WPA2 minimum)

Bandwidth:

  • Minimal: <1 KB/min per device normal operation
  • Peak: 10-50 KB during anomaly events
  • Cloud sync: 50-100 MB/month per device

Firewall Requirements:

  • Outbound HTTPS (port 443) for cloud sync
  • Optional: Inbound HTTPS (port 443) for local web UI access
  • Optional: Modbus TCP (port 502), PROFINET for integration

Skills Required

Basic Installation:

  • Industrial equipment familiarity
  • Basic electrical knowledge (12-24V DC safety)
  • Network configuration basics
  • Reading installation diagrams

Advanced Installation:

  • Industrial protocol knowledge (Modbus, PROFINET)
  • System integration experience
  • Network troubleshooting capabilities

Installation Planning

Step 1: Equipment Assessment

Identify Monitoring Priorities:

  1. List all equipment to be monitored
  2. Classify by criticality (High/Medium/Low)
  3. Document historical failure modes
  4. Determine sensor requirements per machine
  5. Calculate total hardware requirements

Site Survey:

  • Verify power availability (12-24V or PoE)
  • Check network connectivity at each location
  • Identify sensor mounting locations
  • Plan cable routing paths
  • Document environmental conditions

Create Installation Plan:

  • Deployment schedule (phased approach recommended)
  • Resource allocation (personnel, tools, time)
  • Downtime windows for installation
  • Testing and validation timeline
  • Training schedule

Step 2: Hardware Procurement

Edge Devices:

  • Quantity needed: [_____]
  • Configuration: Standard or custom
  • Accessories: Mounting hardware, power supplies
  • Lead time: 2-4 weeks typical

Sensor Modules:

  • Vibration sensors: [_____]
  • Temperature sensors: [_____]
  • Current sensors: [_____]
  • Pressure sensors: [_____]
  • Acoustic sensors: [_____]
  • Other sensors: [_____]

Cables and Accessories:

  • RS-485 cable length needed: [_____] meters
  • Ethernet cables: [_____]
  • Power cables: [_____]
  • Junction boxes: [_____]
  • Cable management: Ties, conduit, labels

Spare Parts:

  • Recommend 10% spare sensors
  • 2-3 spare Edge devices
  • Spare cables and connectors

Edge Device Installation

Physical Installation

Location Selection:

  • Within 100 meters of sensors (RS-485 range limit)
  • Protected from physical damage
  • Temperature: -20°C to +60°C
  • Protected from moisture and contaminants
  • Good WiFi signal if not using Ethernet
  • Accessible for maintenance and viewing display

Mounting Options:

DIN Rail Mount:

  1. Measure required rail space (10cm width typical)
  2. Position device on 35mm DIN rail
  3. Press down until clips engage
  4. Verify secure mounting

Wall Mount:

  1. Mark mounting hole locations
  2. Drill holes appropriate for wall material
  3. Install anchors if needed
  4. Secure device with provided screws
  5. Ensure level and secure mounting

Panel Mount:

  1. Cut opening in panel per template
  2. Insert device from front
  3. Secure with provided brackets
  4. Seal edges if needed for environment

Power Connection

Option A: DC Power (12-24V)

  1. Verify power supply voltage: [_____]V DC
  2. Confirm current capacity: 2A minimum
  3. Identify polarity (typically red = +, black = -)
  4. Double-check polarity before connecting!
  5. Connect wires to terminal block:
    • V+ to positive terminal
    • GND to negative terminal
  6. Tighten terminal screws securely
  7. Apply power
  8. Verify power LED illuminates
  9. Check OLED display shows boot sequence

Option B: Power over Ethernet (PoE)

  1. Verify network switch supports IEEE 802.3af PoE
  2. Verify switch has available PoE budget (12.95W per device)
  3. Connect Ethernet cable to device
  4. Connect other end to PoE switch
  5. Device auto-detects and powers on
  6. Verify PoE LED illuminates
  7. Verify power LED illuminates
  8. Check network connectivity

Power Verification:

  • Display shows firmware version and IP address
  • Status LEDs indicate normal operation
  • No error messages on display
  • Device responds to network ping

Network Configuration

DHCP Configuration (Default):

  1. Connect Ethernet cable or configure WiFi
  2. Device obtains IP automatically
  3. Note IP address from OLED display
  4. Verify connectivity: ping [IP_ADDRESS]
  5. Access web UI: https://[IP_ADDRESS]

Static IP Configuration:

  1. Initially connect via DHCP to access web UI
  2. Navigate to Settings → Network
  3. Change from DHCP to Static
  4. Enter static IP configuration:
    • IP Address: [_____]
    • Subnet Mask: [_____]
    • Gateway: [_____]
    • DNS Server: [_____]
  5. Apply settings
  6. Device reboots with new IP
  7. Verify connectivity at new IP address

WiFi Configuration:

  1. Power on device without Ethernet connected
  2. Device enters AP mode: "EsoCore-[SERIAL]"
  3. Connect laptop/phone to this network
  4. Browse to: http://192.168.4.1
  5. Enter WiFi credentials:
    • SSID: [_____]
    • Password: [_____]
    • Security: WPA2 (recommended)
  6. Click "Connect"
  7. Device reboots and connects to WiFi
  8. Note IP address from display
  9. Verify connectivity

Network Troubleshooting:

  • No IP address: Check DHCP server, cable connection
  • Cannot access web UI: Check firewall, use HTTPS not HTTP
  • Intermittent connectivity: Check WiFi signal strength, interference
  • Slow response: Check network congestion, bandwidth

USB Connection (Maintenance and Development)

Purpose:

The USB connection on the EsoCore Edge device is used exclusively for:

  • Firmware flashing: Updating device firmware
  • Serial communication: Terminal access for diagnostics and direct device communication

Important Notes:

  • USB is NOT used for normal operation or data collection
  • USB is NOT used for network connectivity or data transfer
  • Use network interfaces (Ethernet/WiFi) for operational communication
  • USB access requires physical connection to the device

Serial Terminal Access:

  1. Connect USB cable between Edge device and computer
  2. Install appropriate USB-to-serial drivers if needed
  3. Use terminal application (PuTTY, screen, minicom):
    • Baud rate: 115200
    • Data bits: 8
    • Parity: None
    • Stop bits: 1
  4. Access diagnostic commands and system logs

Firmware Updates:

  1. Download firmware file (.bin or .hex)
  2. Connect via USB
  3. Enter bootloader mode (follow device-specific procedure)
  4. Flash firmware using appropriate tool
  5. Device reboots with new firmware

Sensor Installation

Vibration Sensor Installation

Location Selection:

  • Close to rotating components (bearings, gears)
  • Rigid mounting surface (not flexible sheet metal)
  • Accessible for future inspection
  • Away from excessive heat or contamination

Mounting Methods:

Stud Mount (Preferred - Best Accuracy):

  1. Drill and tap mounting hole (M6 or M8 typical)
  2. Clean mounting surface thoroughly
  3. Apply thin layer of coupling compound
  4. Thread sensor onto stud
  5. Tighten to specified torque
  6. Verify sensor is firmly mounted

Magnetic Mount (Quick Installation):

  1. Clean mounting surface (remove paint, oil, rust)
  2. Ensure surface is flat and smooth
  3. Place magnet base on surface
  4. Verify strong magnetic attachment
  5. Apply safety cable as backup

Adhesive Mount (Temporary or Testing):

  1. Clean surface with isopropyl alcohol
  2. Apply industrial adhesive or epoxy
  3. Press sensor firmly to surface
  4. Allow curing time per adhesive specs
  5. Verify bond before leaving

Wiring:

  1. Route 4-conductor shielded cable to sensor
  2. Strip wire ends carefully
  3. Connect to terminal block:
    • Power+ (red)
    • Power- (black)
    • Data+ (green/A)
    • Data- (white/B)
  4. Secure strain relief
  5. Connect shield to ground at one end only

DIP Switch Addressing:

  1. Each sensor needs unique address (1-254)
  2. Set address using binary DIP switches
  3. Example addresses:
    • 00000001 = Address 1
    • 00000010 = Address 2
    • 00000011 = Address 3
    • etc.
  4. Document address for each sensor
  5. Label sensor with address number

Temperature Sensor Installation

Mounting Locations:

  • Bearing housings (direct contact)
  • Motor bodies
  • Hydraulic reservoirs
  • Gearbox housings
  • Process fluids (with thermowells)

Installation:

Surface Mount:

  1. Clean mounting surface
  2. Apply thermal compound for good contact
  3. Secure sensor with clamp or adhesive
  4. Insulate from ambient if needed
  5. Verify good thermal contact

Thermowell Installation (Process Fluids):

  1. Install thermowell in process per specifications
  2. Fill thermowell with thermal compound
  3. Insert temperature sensor
  4. Secure compression fitting
  5. Allow thermal stabilization (15-30 minutes)

Wiring:
Same 4-conductor bus connection as vibration sensors
Set unique DIP switch address

Current Sensor Installation

CT Clamp Installation:

  1. Identify motor power conductors
  2. Select appropriate clamp size for conductor
  3. Open clamp jaws
  4. Place around single conductor (not bundled cable)
  5. Close clamp until it clicks
  6. Arrow on clamp indicates current flow direction
  7. Secure clamp to prevent movement
  8. For 3-phase motors: Install clamp on each phase

Important Safety Notes:

  • Never work on live circuits without proper training
  • Follow lockout/tagout procedures
  • Verify circuits are de-energized before installation
  • Use appropriate PPE
  • Follow electrical codes and regulations

Wiring:
Same 4-conductor bus connection
Set unique DIP switch address

Additional Sensor Types

Pressure Sensors:

  • Install in pressure taps with appropriate fittings
  • Use thread sealant or tape
  • Verify pressure range matches application
  • Consider pulsation dampeners if needed

Acoustic Sensors:

  • Mount near sound source (bearings, valves, leaks)
  • Avoid mounting on vibrating surfaces
  • Use foam isolation pad if needed
  • Protect from moisture and contamination

Proximity/Position Sensors:

  • Mount with specified air gap
  • Align with target surface/object
  • Verify detection distance
  • Secure mounting to prevent movement

RS-485 Bus Wiring

Cable Routing:

  1. Use 4-conductor shielded cable (Belden 3105A or equivalent)
  2. Keep away from power cables (minimum 12" separation)
  3. Avoid parallel runs with AC power
  4. Use conduit or cable tray for protection
  5. Support cable every 3-6 feet
  6. Avoid sharp bends (minimum 4× cable diameter radius)

Daisy Chain Topology:

Edge Device → Sensor 1 → Sensor 2 → Sensor 3 → ... → Last Sensor
  1. Connect Edge device to first sensor (4 wires)
  2. Connect first sensor to second sensor (4 wires)
  3. Continue chain to last sensor
  4. Maximum total length: 100 meters
  5. Shield grounded at one end only (usually at Edge device)

Termination:

  • Install 120Ω termination resistor at last sensor
  • Some sensors have DIP switch for built-in termination
  • Required for proper signal integrity
  • Edge device typically has built-in termination on its end

Bus Power:

  • Edge device supplies +12V to sensor bus
  • Total current limit: 2A
  • Typical sensor consumption: 50-150mA each
  • Calculate total: [Number of sensors] × [150mA] = [_____] mA
  • Must be less than 2000mA

System Configuration

Initial Setup

Access Web Interface:

  1. Note IP address from Edge device display
  2. Open web browser on computer (same network)
  3. Navigate to: https://[IP_ADDRESS]
  4. Accept self-signed certificate warning (first time only)
  5. Default credentials:
    • Username: admin
    • Password: esocore

First-Time Setup Wizard:

  1. Change admin password (required)
  2. Set device name and location
  3. Configure timezone and NTP server
  4. Set network preferences (if not using defaults)
  5. Review settings and apply

Sensor Discovery

Automatic Discovery:

  1. Navigate to: Sensors → Discovery
  2. Click "Scan RS-485 Bus"
  3. System discovers all connected sensors
  4. Review discovered sensors list
  5. Verify expected sensors found

Assign Descriptive Names:
For each sensor:

  1. Click sensor to edit
  2. Change name from default to descriptive:
    • "Motor 1 Drive End Bearing"
    • "Pump Discharge Pressure"
    • "Spindle Temperature"
  3. Assign location/machine association
  4. Set measurement units if applicable
  5. Save changes

Sensor Configuration

Sampling Rates:

Configure appropriate rates for each sensor type:

Vibration Sensors:

  • Analysis windows: 1-3 kHz for 1-5 seconds
  • Window frequency: Every 5-15 minutes
  • Continuous RMS: 1-10 Hz
  • Alert evaluation: Every 30-60 seconds

Temperature Sensors:

  • Sampling rate: 0.1-1 Hz (every 1-10 seconds)
  • Alert evaluation: Every 60 seconds
  • Thermal time constant consideration

Current Sensors:

  • Sampling rate: 100-500 Hz
  • RMS calculation: 1-10 Hz
  • Power analysis: Every 1-5 seconds

Pressure Sensors:

  • Sampling rate: 1-10 Hz
  • Alert evaluation: Every 10-60 seconds
  • Filtering for pulsations if needed

Measurement Ranges:

  • Select appropriate range for application
  • Avoid saturation (clipping)
  • Optimize for signal-to-noise ratio
  • Can be adjusted based on baseline data

Baseline Collection

Understanding Baselines:

  • System needs 2-4 weeks to learn normal operation
  • Automatic process (no interaction required)
  • Alerts disabled during baseline period
  • Must include all operating modes

Monitoring Progress:

  1. Navigate to Dashboard → Baseline Status
  2. View percentage complete for each sensor
  3. Green checkmarks indicate sufficient data
  4. Typical completion: 2-4 weeks

Accelerating Baseline:

  • Operate equipment through all modes
  • Include startups and shutdowns
  • Cover different load conditions
  • Run through full operational range
  • 24/7 operation speeds learning

Alert Configuration

After Baseline Completes:

  1. Navigate to Settings → Alerts
  2. Review suggested thresholds:
    • Warning: 20% deviation from baseline
    • Attention: 40% deviation
    • Critical: 80% deviation
  3. Adjust sensitivity:
    • More sensitive = earlier warnings, more false positives
    • Less sensitive = fewer alerts, potentially late warnings
  4. Start with suggested values
  5. Tune based on experience

Notification Methods:

Email:

  1. Settings → Notifications → Email
  2. Enter SMTP server details:
    • Server: smtp.example.com
    • Port: 587 (TLS) or 465 (SSL)
    • Username: [_____]
    • Password: [_____]
  3. Add recipient email addresses
  4. Select severity levels to notify
  5. Test email delivery

Local Outputs:

  1. Wire relay outputs to alarm devices
  2. Configure trigger conditions
  3. Test before relying on

CMMS Integration:

  1. Settings → Integrations → CMMS
  2. Enter CMMS API endpoint
  3. Configure authentication
  4. Enable auto work order creation
  5. Map alert severities to work order priorities

Cloud Platform Setup (Optional)

Self-Hosted Deployment

Server Requirements:

  • Linux server (Ubuntu 20.04+ recommended)
  • 4 CPU cores minimum
  • 8 GB RAM minimum
  • 100 GB storage
  • Docker and Docker Compose installed

Installation:

# Clone EsoCore repository
git clone https://github.com/newmatik/EsoCore.git
cd EsoCore/server

# Configure environment variables
cp .env.example .env
nano .env  # Edit configuration

# Build and start services
docker-compose up -d

# Run database migrations
docker-compose exec web python manage.py migrate

# Create admin user
docker-compose exec web python manage.py createsuperuser

# Collect static files
docker-compose exec web python manage.py collectstatic

Access Platform:

  • Admin interface: https://[SERVER_IP]/admin
  • API endpoint: https://[SERVER_IP]/api/
  • Configure DNS and SSL certificates for production

Managed Cloud Service

Sign Up:

  1. Visit: https://cloud.esocore.com (if using managed service)
  2. Create account
  3. Select plan based on device count
  4. Enter payment information

Device Provisioning:

  1. Navigate to Devices → Add Device
  2. Enter device serial number
  3. Generate API key
  4. Note API key (shown once)
  5. Device status shows "Pending"

Edge Device Configuration:

  1. On Edge device web UI: Settings → Cloud
  2. Enter cloud platform URL
  3. Enter device API key
  4. Configure sync interval (5-15 minutes recommended)
  5. Click "Test Connection"
  6. Enable "Auto Sync"
  7. Device appears online in cloud platform

System Integration

Modbus Integration

Modbus RTU (RS-485):

  1. Connect Modbus devices to dedicated RS-485 port
  2. Configure in web UI:
    • Settings → Fieldbus → Modbus RTU
    • Baud rate: 9600, 19200, or 115200
    • Device addresses to poll
    • Register map configuration
  3. Enable Modbus polling
  4. Verify data appears in dashboard

Modbus TCP:

  1. Configure in web UI:
    • Settings → Fieldbus → Modbus TCP
    • Enable Modbus TCP server
    • Port: 502 (default)
  2. Configure Modbus master to connect to Edge device IP
  3. Provide register map documentation
  4. Test read/write operations

PROFINET Integration

  1. Settings → Fieldbus → PROFINET
  2. Configure device name (GSD file provided)
  3. Set I/O data mapping
  4. Import into TIA Portal or PLC configuration tool
  5. Configure PLC to read EsoCore data
  6. Test communication

REST API Integration

Authentication:

  • API key authentication
  • Include in header: X-API-Key: [your-key]

Common Endpoints:

GET /api/v1/devices/              # List devices
GET /api/v1/sensors/              # List sensors
GET /api/v1/telemetry/            # Get sensor data
POST /api/v1/alerts/ack           # Acknowledge alert
GET /api/v1/health/               # System health

Example Integration:

import requests

API_URL = "https://edge-device-ip/api/v1"
API_KEY = "your-api-key"
headers = {"X-API-Key": API_KEY}

# Get current sensor readings
response = requests.get(f"{API_URL}/telemetry/", headers=headers)
data = response.json()

Testing and Validation

Installation Verification Checklist

Hardware:

  • All Edge devices powered and online
  • All sensors discovered and responding
  • Network connectivity stable
  • Display shows correct status
  • No error LEDs or messages

Configuration:

  • Admin password changed from default
  • Device names and locations set
  • All sensors named descriptively
  • Sampling rates configured
  • Time zone and NTP configured
  • Network settings correct (static IP if applicable)

Data Collection:

  • Live data visible on dashboard
  • Sensor readings appear reasonable
  • Data logging to SD card verified
  • Cloud sync functioning (if enabled)
  • No data gaps or errors

Alerts:

  • Test email notifications working
  • CMMS integration tested (if configured)
  • Local alarm outputs tested (if used)
  • Alert thresholds set appropriately

Functional Testing

Test Scenarios:

  1. Normal Operation: Verify data collection during normal equipment operation
  2. Network Loss: Disconnect network, verify local operation and data buffering
  3. Power Loss: Simulate power loss, verify safe shutdown and data integrity
  4. Sensor Fault: Disconnect sensor, verify fault detection and alerting
  5. Alert Testing: Create alert condition, verify notification delivery

Performance Verification:

  • Response time: <100ms for edge processing
  • Data accuracy: Compare to reference instruments
  • Alert latency: <1 second from detection to notification
  • System uptime: 99.9% target

Documentation

Installation Records

Create documentation package including:

Equipment List:

  • Edge device serial numbers and locations
  • Sensor serial numbers and locations
  • IP addresses (static or DHCP)
  • API keys and credentials (securely stored)

Wiring Diagrams:

  • RS-485 bus topology
  • Power connections
  • Network connections
  • Integration connections

Configuration:

  • Network settings
  • Sensor configurations
  • Alert thresholds
  • Integration settings

Contact Information:

  • Technical support
  • Vendor contacts
  • Internal IT contacts
  • Maintenance team

User Training

Operator Training:

  • Accessing web interface
  • Viewing dashboard and data
  • Responding to alerts
  • Basic troubleshooting

Maintenance Training:

  • System overview
  • Alert interpretation
  • Planned maintenance based on alerts
  • Advanced configuration

Administrator Training:

  • User management
  • System configuration
  • Integration management
  • Troubleshooting

Maintenance

Routine Maintenance

Monthly:

  • Review system health dashboard
  • Verify all sensors responding
  • Check SD card health
  • Review alert logs

Quarterly:

  • Clean sensors and connections
  • Inspect cable conditions
  • Verify sensor mounting secure
  • Update firmware if available

Annually:

  • Sensor calibration verification
  • Battery backup replacement (if applicable)
  • SD card replacement (preventive)
  • System configuration backup

Troubleshooting

Common Issues:

See Quick Start Guide for detailed troubleshooting steps.

Support Resources

Comprehensive installation complete! Your industrial IoT monitoring system is now operational and protecting your critical equipment.

Quick Start Guide | Integration Guide | API Documentation