Page 1


Contents 1 Health & Safety

10 Barcode Scanners

2 Connecting the Server PC

11 Panel Mounting

3 System Topology

13 Configuring Keypads

4 Communications Loop Wiring 7 Machine Interfacing

Introduction This guide provides the necessary information to install and commission the hardware elements of a standard PlantRun information system. Not all systems are identical and, therefore, before starting the installation you should first check that you can identify the constituent parts and understand your system’s topology. Any specific CAD drawings and wiring diagrams supplied with the system should be used in preference to the information contained in this guide. PlantRun Server PC Communications Panel

DTM04 Outstations DTM Nodes


Health & Safety Safety and environmental considerations Safety considerations Most PlantRun equipment operates at low d.c. voltages but some require mains power.

Risk of electric shock Installation should only be carried out by trained and competent electricians.

PlantRun Server PC PlantRun Servers are supplied for industrial environments with features such as antivibration mounts and heavy duty power supplies, however, care should still be taken:

• Ideally sited in an air conditioned Server Room • Requires clean reliable power supply, free from excessive noise. Where this is not available a UPS (Uninterruptable Power Supply) should be used to provide a battery backup in the event of mains failure

Communications Panels • • • •

Conform to IP65 but not intended for use outdoors Requires clean reliable power supply, free from excessive noise. Should not be installed in an explosive atmosphere or hazardous area Installation temperature and humidity: Environmental temperature: 0 to 55°C Environmental humidity: 20% to 95% relative humidity (non-condensing)

DTM04 Outstations • Conform to IP65 but not intended for continuous use outdoors except when fitted with a waterproof overlay

• • • •

Should not be installed in an explosive atmosphere or hazardous area Avoid strong electrical and/or magnetic fields Avoid chemical vapours Installation temperature and humidity: Environmental temperature: 0 to 55°C Environmental humidity: 20% to 95% relative humidity (non-condensing) 1


Connecting the Server PC Office LAN and Communications Panel connections PlantRun Server PCs are typically fitted with two network cards: one for the office LAN; and one to be used to connect to the Communications Panels. This allows the normal site LAN traffic to be isolated from the PlantRun communications, and vice-versa.

CAT 5/6 LAN cables must be used to connect the Server to the Communication Panels, with switches or hubs used as required.

Remote Interactions Viewstation, Workstation, and Web Viewer software packages are available for existing or new office PCs (on the office LAN) so that they can see the current status of the plant in real-time, review running and stopped periods for each Asset, generate printed reports etc.

Display Nodes can be connected to either LAN, depending upon their location and proximity to the Communications Panels. 2


System topology Example installation Each Communications Panel provides both power and communications to a number of DTM04 Outstations. In the example below Loop 1 is used for the keypads on Asset 1, Asset 2, and Asset 3. Loop 2 is used for the keypads on Asset 4, Asset 5 and Asset 6.

As can be seen, each loop is connected in a daisy-chain fashion where the cable is terminated at the Communications Panel and at every Outstation.

Each Outstation will be labelled with its address and intended location. Moving an Outstation to a different communications loop or fitting it to a different Asset will result in a need to alter the PlantRun configuration.

Power and Communications Each communications loop provides:

• 24v d.c. power for the Outstations (sourced from the Communications Panel) • RS-485 communications for each Outstation Cables should meet the following specification:

• Belden 8104 / 8105 or equivalent (this allows one pair to be used for the communications and the remaining pairs are available for the power to counteract any voltage drop down the cable) 3


Communications loop wiring Linking to the keypads Inside each DTM04 Outstation is a DTM Interface board. This provides a set of screw terminals for the communications loop cabling, with points for both incoming and outgoing cables. Power to the keypad is routed through a fuse and ‘SUPPLY’ jumper. Removal of this jumper allows the keypad to be powered down during installation work.

Communications When the keypads are connected and the PlantRun drivers have been started the ’POLLING’ LED on the rear of each keypad will flash to indicate when communications have been received.

Communications Panel to First Asset Separate power and communications terminals are provided for each communications loop in the Communications Panel. The example shown below illustrates one communications loop. For specific wiring details please refer to the system drawing PR-MM-C1-2-4.pdf (for DTMC1, DTMC2, DTMC4) Communications Panel

Asset 1

+24V

RS485

POWER OUT B

IN A

+V

Br/Wh

Wh/Bl

A Scrn

Bl/Wh

IN Scrn B

B

Wh/Bl

A

Bl/Wh

Wh/Br

Br/Wh

0V

0V

OUT +V 0V

Wh/Br

FUSE

DTM Interface

Using a Belden 8104 / 8105 or equivalent cable, one pair of cores (blue/white and white/ blue) should be used to connect the A terminal in the Communications Panel to the IN A connection on the DTM Interface, and the B terminal to the IN B terminal. 4


A second pair of cores (brown/white and white/brown) should be used to connect the +24v d.c. fused terminal in the Communications Panel to the IN +V connection on the DTM Interface, and the 0V terminal to the IN 0V terminal. Where the overall cable length for the communications loop is long, a significant voltage drop will occur and in this case the spare pairs of cores (orange/white and white/orange, and green/white and white/ green) should also be used for the power.

First Asset to Second Asset The OUT terminals on the first Asset then need connecting to the IN terminals on the second Asset, as shown in the example below. Asset 1

Asset 2

DTM Interface

DTM Interface RS485 IN Scrn B

OUT Scrn B

A

POWER IN A

+V

0V

OUT +V 0V

Wh/Br

OUT +V 0V

Bl/Wh

0V

Wh/Bl

Bl/Wh

+V

Wh/Br

IN A

Br/Wh

POWER OUT B

Wh/Bl

A Scrn

Br/Wh

RS485 IN Scrn B

As with the first cable linking the Communications Panel to the first Asset, one pair of cores (blue/white and white/blue) should be used to connect the OUT A terminal in the first Asset Outstation Panel to the IN A connection on the DTM Interface in the second Asset Outstation Panel, and the OUT B terminal to the IN B terminal. A second pair of cores (brown/white and white/brown) should be used to connect the OUT +V terminal in the first Asset Outstation Panel to the IN +V connection on the DTM Interface in the second Asset Outstation Panel, and the OUT 0V terminal to the IN 0V terminal. Again, if the overall cable length for the communications loop is long, a significant voltage drop will occur and in this case the same spare pairs of cores should also be used for the power.

Final Asset - Loop Termination When the cabling has been completed to the last Asset in the loop, the DTM Interface in the final Asset’s Outstation Panel should be fitted with the ‘RS485 TERMINATION’ jumper. All of the other interface boards in the loop should have this jumper removed. 5


DTM Nodes DTM Nodes are normally supplied with the same DTM Interface and associated cabling that is used in a DTM02 Outstation.

This means that the communications loop wiring of a DTM Node is exactly the same as it would be for a DTM02 Outstation, typically with the DTM Node fitted between DTM02 Outstations on the same communications loop as shown below:

Using a DTM Interface

DTM Interface

DTM Interface

0V

OUT +V 0V

IN Scrn B

OUT Scrn B

A

A

Bl/Wh

+V

Wh/Bl

IN A

Wh/Br

OUT B

Br/Wh

A Scrn

Bl/Wh

IN Scrn B

Wh/Bl

OUT +V 0V

Br/Wh

0V

DTM Node

Wh/Br

IN +V

DTM02 Outstation

Without a DTM Interface If DTM Nodes are to be fitted without DTM Interfaces the incoming and outgoing cables must be connected at the DTM Node, as shown in the diagram to the right.

DI1

RXD

DTM Node

DI2

TXD

DI3

+VIN

DI4

Scrn

Z

Y

B

A

+5V 0V

6

Bl/Wh

Bl/Wh

Wh/Bl Outgoing Cable

Incoming Cable

Incoming Cable

If cable spurs need to be used they should be less than 0.5m in length.

Outgoing Cable

Wh/Bl

DIC

Br/Wh Wh/Br

Outgoing Cable

Br/Wh Wh/Br

Incoming Cable


Machine interfacing Running / stopped status and interlocking In most cases, each Outstation only needs two connections to the Asset: one so that PlantRun can determine when the Asset is running and when it is stopped; and one to interlock the Asset and prevent it from being restarted when a reason for a stoppage is required. The DTM Interface provides eight digital (or pulse) inputs. The first (DI1) is reserved by the system to monitor the status of the interlock Override switch (see later pages) and the second (DI2) is used to monitor the running / stopped status signal of the Asset.

Running / Stopped In its simplest form the current status can be determined from a simple digital input. When the contact is ON the Asset is deemed to be running, and when it is OFF it is deemed to be stopped. An indication of the current ON / OFF state can be seen by looking at the ‘DI2’ LED on the rear of the keypad.

On / Off contact wiring Volt free contacts providing an ON / OFF status signal should be connected as shown on the right. The DTM Interface will provide the 24v d.c. power required through the + terminal.

DI2

+ IN -

DI3

+

Volt Free Contact

IN

DTM Interface

Pulse input PlantRun can be configured to accept a pulse input signal. In this case when pulses are being received the Asset is deemed to be running, and when a pulse hasn’t been picked up for a predefined time period the Asset is deemed to be stopped. As with the ON / OFF status, an indication of the pulsing can be seen by looking at the ‘DI2’ LED on the rear of the keypad.

This approach has the advantage that PlantRun will be able to determine the speed at which the Asset is running and the number of products that have been made. 7


PNP sensor wiring PNP proximity and optical sensors generating pulses are typically connected as shown on the right.

DI2

Before connecting your sensors you should check their manufacturer’s specification and wiring diagrams. PNP sensors are very vulnerable to short circuits to earth which can permanently damage them.

+ IN -

DI3

Blue Sensor -V Brown Sensor +V Black Sensor O /P PNP Sensor

+ IN

DTM Interface

NPN sensor wiring NPN proximity and optical sensors generating pulses are typically connected as shown on the right (note the jumper has been fitted).

DI2

+ IN -

Before connecting your sensors you should check their manufacturer’s specification and wiring diagrams. NPN sensors can survive shorts to zero volts but will be permanently damaged if shorted to the positive supply.

DI3

Blue Sensor -V Brown Sensor +V Black Sensor O /P NPN Sensor

+ IN

DTM Interface

Multiple products using the same Asset Where an Asset produces more than one product at the same time, the additional inputs (DI3, DI4, DI5, DI6, DI7 and DI8) are used. If more than seven products are produced at the same time, a DTM Node must also be used. These are wired in exactly the same way as for a single contact or pulse input, as can be seen in the examples below.

DI2

DI3

-

-

+

+

DI2

IN

IN

-

-

+

DI3

IN

DTM Interface

+ IN

Volt Free Contact

DTM Interface

8

Blue Sensor -V Brown Sensor +V Black Sensor O /P PNP Sensor


Interlocking Interlocking the Asset will prevent it from running and, therefore, care should be taken with the installation to ensure that it minimises any disruption to a production area.

Overriding the interlock Each DTM Interface is fitted with an Override switch (SW1). In the NORMAL position this will allow PlantRun to operate the interlock normally, and in the OVERRIDE position the interlock relay is fully electrically overridden so that the PlantRun system cannot effect the running of the Asset. Before starting the installation the Override switch should be put into the OVERRIDE position.

Interlock wiring When PlantRun operates the interlock relay, it should not immediately stop the Asset, it should merely prevent it from being started. An indication of the current interlock state can be seen by looking at the ‘DO1’ LED on the rear of the keypad. Start Button

To Asset

} } New Wiring

Original Wiring

NC COM NO NC COM NO DO2

DO1 Reason Required

Interlock Relay

DTM Interface

• Only interlock the START circuit for the Asset • Do NOT wire the interlock to a STOP circuit or the E-Stop circuit of the Asset 9


Barcode scanners Linking to a barcode scanner DTM04 Outstations can be provided with an interface for a barcode scanner using the RS -232 port that is available on the keypad. These Outstations are fitted with a 9 way D connector located on the base of the DTM04 Outstation.

Default connector configuration Pin

Keypad

Scanner

2

RxD

RS-232 Tx

5

0V

0v d.c.

9

5v or +VIN*

5v or 24v d.c.*

* Scanner specific

Default RS-232 port settings 9600 baud, 8 bits, no parity, 1 stop bit, no handshaking (see the Configuring Keypads section if you need to alter these)

Supported barcode formats These are dependent upon the scanner and may require scanner configuration.

• Code 39

• EAN 128

• Code 128 (ISO 15417)

• Code 93

• C128 ISBT

• MSI

• Code 11

• Databar

• Codabar

• Etc.

An example of the Code 128 version of “PlantRun” is shown below:

10


Panel mounting Standard mounting points Server PC PlantRun Servers are typically housed in industrial chassis that can be fitted into standard 19� rack mounting rails and occupy 4U of space. Access to both the front and the rear of the rack will be required to install the equipment and to carry out preventative maintenance in the future.

8.7 mm

DTM04 Outstation

8.7 mm

All industrial chassis are fitted with fan filters that need replacing regularly. The maintenance interval will be dependent upon the environment that the system is installed in.

Front View

Side View

300 x 200 x 80 mm

20 mm

The DTM04 Outstations are fitted with a DTM Interface, indicator lamps and DTM04 Keypad.

Rear

20 mm

All connections are through plug-in connectors which are located on the front of the unit.

Front View

Rear Mounting Points 173 mm

11

82 mm

173 x 82 x 44 mm (without connectors)

80 mm

15 mm

15 mm

DTM Node

160 mm

20 mm

20 mm

200 mm

41 mm

300 mm

Front

260 mm

300 mm

Rear Mounting Points


Communications Panels

DTM C1 & DTM C2

8.7 mm

8.7 mm

Communication Panels are supplied in a number of standard formats: Front View

Side View 20 mm

300 x 300 x 155 mm

Rear

300 mm

Front

300 mm Front View

20 mm

155 mm

8.7 mm

260 mm

8.7 mm

DTM C4

20 mm 300 mm 20 mm

DTM C2 Supports 2 communications loops and up to 20 DTM04 Outstations.

260 mm

Rear Mounting Points

DTM C1 Supports 1 communications loop and up to 10 DTM04 Outstations.

Side View 20 mm

380 x 380 x 210 mm

Rear

380 mm

Rear

500 mm

Front

380 mm

340 mm

Rear Mounting Points

Supports 4 communications loops and up to 40 DTM04 Outstations.

20 mm 210 mm

20 mm

20 mm

380 mm 340 mm

Front View

8.7 mm

500 x 500 x 210 mm

8.7 mm

DTM C8 Side View 20 mm

Supports 8 communications loops and up to 80 DTM04 Outstations.

Front

It also provides LAN connections for 2 Shop Floor Display Nodes.

460 mm

500 mm

Rear Mounting Points

20 mm

460 mm

12

20 mm

20 mm

500 mm

210 mm


Configuring keypads DTM04 keypad configuration Setup mode The DTM04 keypad can be put into a Setup Mode by pressing the SETUP button. This is located on the back of the keypad and can be operated with a paperclip. The keypad display will change to indicate that it is in Setup. You can exit from Setup Mode at any time by pressing one of the following keys:

F1 - to save and exit

F3 - to exit without saving

Moving between pages The Setup Mode consists of a number of pages. Changing from one page to the next is achieved by pressing one of the following keys:

Up - to go to the Next page

Down - to go to the Previous page

Altering parameters The displayed parameters can be selected by pressing their associated number. If an underscore character appears in place of the parameter value, enter the new value followed by the ENTER key. Where there are only a defined set of options, each time the parameter is selected a new value will appear. For example, when selecting the Baudrate the value will switch between 9600, 38.4, and 115.2.

13


Changing the keypad address - an example To alter the keypad from address 1 to address 9 you should follow the following steps: 1) Press the SETUP button. The Setup screen will appear 2) Repeatedly press the Up or Down key until the display shows Set RS485 Port at the top 3) Press the 1 key to select the first item (Address) 4) Press the 9 key to select address number 9 5) Press the ENTER key to accept the change 6) Press the F1 key to save the change and restart the keypad When changing a keypad, it is important to not have two keypads on the same communications loop with the same address. Therefore, you should first remove the old keypad, and then install the new one but only connect the power (right hand side connector). You will then be able to enter Setup Mode and change the address before pushing in the remaining two connectors.

Typical configuration changes When a DTM Outstation is supplied with a PlantRun system it will be pre-configured for a particular Asset and in most cases should require no further configuration. Occasionally parameters may need adjusting, typical changes are as follows: Keypad address

• RS485 Port - Address • All keypads must have unique addresses on the same communications loop • Keypad addresses should only be set in the range 1 to 32

Noisy pulse signals may require the debounce time to be increased

• DI2 Active Edge - Debounce Fast pulse signals may require the debounce time to be decreased

• DI2 Active Edge - Debounce Timing from the end of one pulse to the start of the next pulse

• DI2 Report Period - Trailing->Active 14


DTM04 factory settings Function Set RS232 Port

General Settings

Parameter

Setting

1 Baudrate

9600

2 Wordlength

8.N,1

3 Handshake

None

1 Local Echo

ON

2 Autonewline

ON

RS232 Terminator

1 Upload serial port message on

Set RS485 Port

1 Address

01

2 Baudrate

38.4

DI1 Active Edge

Timeout

1 Edge

Positive

2 Debounce

0050 ms

DI1 Data Upload

1 Mode

Request

DI1 Report Period

1

DI2 Active Edge

1 Edge

Positive

Active->Active

2 Debounce

0050 ms

DI2 Data Upload

1 Mode

Request

DI2 Report Period

1

DI3 Active Edge

1 Edge

Positive

2 Debounce

0050 ms

DI3 Data Upload

1 Mode

Request

DI3 Report Period

1

DI4 Active Edge

1 Edge

Positive

2 Debounce

0050 ms

DI4 Data Upload

1 Mode

Request

DI4 Report Period

1

Active->Active

...

...

...

DI8 Report Period

1

Active->Active

DO1 Watchdog

1 Watchdog

Normal

DO2 Watchdog

1 Watchdog

Normal

DO3 Watchdog

1 Watchdog

Normal

DO4 Watchdog

1 Watchdog

Normal

Backlight

1 Turn off

10 min

Active->Active

Active->Active

15


About PlantRun Hardware Installation This guide describes the installation of the most commonly used hardware elements in a PlantRun system. Other hardware may have been supplied with your system and this will be accompanied by additional information. Any questions regarding the installation should be directed back to your PlantRun supplier.

Tascomp Tascomp are the developers of the Prodigy and PlantRun software packages, which are supplied to manufacturers around the world through a network of approved resellers and system integrators.

Tascomp Limited

PR-MM-IG-161129

Newburgh Court, Belasis Hall Technology Park, Billingham TS23 4EE, UK. T: +44 (0)1642 370666 F: +44 (0)1642 370012 E: sales@tascomp.com W: www.plantrun.com

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