PlantRun Installation Guide

Contents

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 infor-

mation contained in this guide.

PlantRun Server PC

Communications Panel

DTM04 Outstations

DTM Nodes

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

1

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 anti-

vibration 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)

2

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 prox-

imity to the Communications Panels.

3

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)

4

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)

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.

+V 0V

IN

+V 0V

OUT

Scrn B

IN

A Scrn B A

OUT

Communications Panel

FUSE

+24V

0V A B

Br/Wh

Wh/Br

Bl/Wh

Wh/Bl

Br/Wh

Wh/Br

Bl/Wh

Wh/Bl

DTM Interface

Asset 1

POWERRS485

5

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.

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 signifi-

cant 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.

Asset 2Asset 1

+V 0V

IN

+V 0V

OUT

Scrn B

IN

A Scrn B A

OUT

Br/Wh

Wh/Br

Bl/Wh

Wh/Bl

DTM Interface

POWERRS485

+V 0V

IN

+V 0V

OUT

Scrn B

IN

A Scrn B A

OUT

Br/Wh

Wh/Br

Bl/Wh

Wh/Bl

DTM Interface

POWERRS485

6

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

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.

If cable spurs need to be used they

should be less than 0.5m in length.

Z Y B AScrnBr/Wh

Wh/Br

Bl/Wh

Wh/Bl

DI3

DI4

DIC

DI1

DI2

+VIN

+5V

0V

RXD

TXD

Bl/Wh

Wh/Bl

Br/Wh

Wh/Br

Incoming

Cable

Outgoing

Cable

Incoming

Cable

Outgoing

Cable

Incoming Cable

Outgoing

Cable

DTM Node

+V 0V

IN

+V 0V

OUT

Scrn B

IN

A Scrn B A

OUT

Br/Wh

Wh/Br

Bl/Wh

Wh/Bl

DTM Interface

DTM Node

+V 0V

IN

+V 0V

OUT

Scrn B

IN

A Scrn B A

OUT

DTM Interface

DTM02 Outstation

Br/Wh

Wh/Br

Bl/Wh

Wh/Bl

7

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.

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 pre-

defined 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.

DTM Interface

-

+DI2

Volt Free

Contact

IN

-

+DI3

IN

8

PNP sensor wiring PNP proximity and optical sensors generating pulses

are typically connected as shown on the right.

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.

NPN sensor wiring NPN proximity and optical sensors generating pulses

are typically connected as shown on the right (note

the jumper has been fitted).

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.

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.

DTM Interface

-

+DI2

IN

-

+DI3

IN

PNP Sensor

Blue Sensor -V

Brown Sensor +V

Black Sensor O /P

DTM Interface

-

+DI2

IN

-

+DI3

IN

NPN Sensor

Blue Sensor -V

Brown Sensor +V

Black Sensor O /P

DTM Interface

-

+DI2

Volt Free Contact

IN

-

+DI3

IN

DTM Interface

-

+DI2

IN

-

+DI3

IN

PNP

Sensor

Blue Sensor -V

Brown Sensor +V

Black Sensor O /P

9

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.

• 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

NO

DTM Interface

Interlock Relay

Start Button

COMNC

To Asset

Original Wiring

NewWiring

}}

DO1

NOCOMNC

DO2

Reason Required

10

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

* 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.

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

Pin Scanner

2 RS-232 Tx

5 0v d.c.

9 5v or 24v d.c.*

Keypad

RxD

0V

5v or +VIN*

• Code 39 • EAN 128

• Code 128 (ISO 15417) • Code 93

• C128 ISBT • MSI

• Code 11 • Databar

• Codabar • Etc.

11

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.

All industrial chassis are fitted with fan filters that

need replacing regularly. The maintenance inter-

val will be dependent upon the environment that

the system is installed in.

DTM04 Outstation 300 x 200 x 80 mm

The DTM04 Outstations are fitted

with a DTM Interface, indicator

lamps and DTM04 Keypad.

DTM Node 173 x 82 x 44 mm (without connectors)

All connections are through plug-in connectors

which are located on the front of the unit.

300 mm

260 mm

200 mm

160 mm

20 mm

20 mm

20 mm

20 mm

8.7 mm

8.7 mm

Front View

80 mm

Side View

Front

Rear

Rear Mounting Points

300 mm

82 mm

173 mm

41 mm

15 mm

Front View


15 mm

12

Communications Panels Communication Panels are supplied in a number of standard formats:

DTM C1 & DTM C2 300 x 300 x 155 mm

DTM C1

Supports 1 communications loop and up

to 10 DTM04 Outstations.

DTM C2

Supports 2 communications loops and up

to 20 DTM04 Outstations.

DTM C4 380 x 380 x 210 mm

Supports 4 communications loops and

up to 40 DTM04 Outstations.

DTM C8 500 x 500 x 210 mm

Supports 8 communications loops

and up to 80 DTM04 Outstations.

It also provides LAN connections for

2 Shop Floor Display Nodes.

300 mm

260 mm

300 mm

260 mm

20 mm

20 mm

20 mm

20 mm

8.7 mm

8.7 mm

Front View

155 mm

Side View

Front

Rear


300 mm

380 m

m

340 m

m

380 mm

340 mm

20 mm

20 mm

20 m

m

20 m

m

8.7

mm

8.7

mm

Front View

210 mm

Side View

Fro

nt

Rear


380 m

m

500 m

m

460 m

m

500 mm

460 mm

20 mm

20 mm

20 m

m

20 m

m

8.7

mm

8.7

mm

Front View

210 mm

Side View

Fro

nt

Rear


500 m

m

13

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.

14

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 communi-

cations 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 re-

maining 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

15

DTM04 factory settings

Function Parameter Setting

Set RS232 Port 1 Baudrate 9600

2 Wordlength 8.N,1

3 Handshake None

General Settings 1 Local Echo ON

2 Autonewline ON

RS232 Terminator 1 Upload serial port message on Timeout

Set RS485 Port 1 Address 01

2 Baudrate 38.4

DI1 Active Edge 1 Edge Positive

2 Debounce 0050 ms

DI1 Data Upload 1 Mode Request

DI1 Report Period 1 Active->Active


2 Debounce 0050 ms




2 Debounce 0050 ms






2 Debounce 0050 ms

DO1 Watchdog 1 Watchdog Normal


Backlight 1 Turn off 10 min




... ... ...

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

Newburgh Court,

Belasis Hall Technology Park,

Billingham

TS23 4EE, UK.

T: +44 (0)1642 370666

F: +44 (0)1642 370012

E: [email protected]

W: www.plantrun.com

PR-MM-IG-161129

Documents

PlantRun Installation Guide