Contents 1
Shop Floor Access
7
Industrial Grade PCs
3
Touch Screen Operator Displays
8
Process Measurements
3
Tablet Operator Displays
9
DTM09l Display Node Specification
4
Communications Options
10 DTM04 Outstation Specification
5
Overhead Information Displays
11 Example Site Layout
Introduction This brochure provides a summary of the hardware that is available to build your PlantRun system. It has been designed to accompany the PlantRun Technical Overview. PlantRun can run on any modern PC architecture and interface to any make or model of peripheral device. It will communicate with any make or model of bar code, swipe card, or RFID reader. It can drive any format of label or document printer. It can link via any form of network infrastructure and communicate with any other business package, etc. For these reasons, please view these hardware items as a flavour of the equipment used rather than a definitive list. If you have a particular item of hardware or interface equipment that you would like to incorporate into your PlantRun system then just ask, and we will be pleased to help.
Shop floor access Rugged, compact, low cost PlantRun DTM04 Outstation has been specifically designed to provide a compact operator terminal with built in machine interface that is both robust and low cost.
Versatile Outstations provide a four line back lit display, wipe clean alpha-numeric keyboard, seven digital inputs, four relay outputs, RS485 or Ethernet communications and an auxiliary RS232 communications port as standard. The digital input channels can monitor machine status from any on/off signal or monitor machine state and determine production speed/count from any pulsed signal. The relay based digital outputs are used to provide an interlock across the machine start circuit, which ensures that operators enter a downtime reason at the end of each significant machine stoppage. High visibility status lamps indicate when the interlock is on and a downtime reason is required to be selected. The IP rated wipe clean keypad features function buttons that allow your staff to interact with PlantRun without leaving the area. Current production status can be viewed from the display. The all metal enclosure, available in painted or stainless steel, is ideal for shop floor environments as it provides excellent mechanical protection whilst also shielding the terminal from the strong electro-magnetic fields present around most industrial equipment. It is ideal for retrofitting to existing assets, either as a bolt on module or utilising the standard VESA mount point on the back of the enclosure.
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Straight forward to install DTM04 Outstation requires only three electrical connections: one to pickup machine state; one to interlock with the machine start circuit; and one for combined power and communications. All connections to the DTM04 Outstation use screw terminals so no special tools are required. This ease of installation means that most customers can install the equipment using their own maintenance staff. This minimises install costs and any disturbance to production. It also means your staff gain knowledge to help future system support. Electrical termination is provided using cadged nut screw clamps with dual terminals for looped connections, which removes the need to have more than one wire per terminal. Outstations connect in daisy chain to a PlantRun communications panel that provides independent power for the Outstations and data transfer over your existing network to a central PC server. A range of standard communications panels is available to connect 10, 20, 40 or 80 machines or assets. To aid installation all PlantRun systems come with full electrical drawings, a printed Installation Guide and remote engineer support. A full installation service and on site engineer support is also available.
Simple to maintain PlantRun stores the configuration details for each Outstation on the central PlantRun PC. This means that in the unlikely event that you need to replace one you don’t need to re-program it. Simply enter the address (a two digit number is printed on the back of the keypad) and you are ready to go.
Barcode, RFID and peripheral devices The auxiliary RS232 communications port can be connected to a wide range of peripheral devices including bar code readers, RFID tag readers, label & bar code printers. The bar code reader option is particularly useful for companies that already track their products, batches and crew codes using bar code technology as it helps to speed up data entry and eliminate data entry errors. 2
Touch screen operator displays For applications that require a fully featured PC interface on the shop floor, PlantRun can be supplied on a wide range of industrial rugged touch screen PCs. (TPC) With a choice of screen sizes from 6” to 19” and processor options from the cool running Intel Atom series through to powerful Intel processors you are sure to find a platform to suit your requirements and budget. Touch screen PCs displays can be fully customised which makes them highly adaptable and ideal where the use of graphical information is required.
Guideline specification Screen sizes: Resolutions: Processors: Hard disk size: Memory: O/S: USB2: RS232/485: Expansion: Optical:
12”, 15”, 17” 19” 21.5” all with res/cap touch screen 800X600, 1024x768, 1280x1024, 1920x1080 Atom1.86Ghz, (fan less) 80Gb to 750Gb With RAID 0/1 option DDR1/2/3 1Gb to 8Gb Windows 7 / 10 2 to 6 depending upon base model 3/1 typical 1/2 PCI or PCI-e half length slots CD/DVD RW drive options
Tablet operator displays Tablets offer a cost effective alternative to full PC operator interfaces for data entry or manual operations in particular. Tablet interface display screens can be fully customised. PlantRun SmartView functionality enables interactive screens to be displayed over the internet on tablets with the latest browsers. 3
Communications options Standard fit or custom build, the choice is yours Each PlantRun system can be supplied with one or more purpose designed communications panels to provide reliable communications and power between your PlantRun server PC, Outstations, panel PCs and Display Nodes. Communications panels are supplied with a range of industrial power supplies, Ethernet switches and communications converters. These are housed in IP65 sealed painted or stainless steel enclosures to ensure maximum environmental protection to guarantee long term reliability.
Standard range Standard communications panels are available that will link to an Ethernet network to provide 1, 2 4, or 8 communications loops, each capable of driving up to ten DTM Outstations. Multiple communications panels can be used to provide coverage for larger numbers of assets or to provide distributed communications for larger installations. Part No.
Loops
Max DTM Terminals
Available Ethernet Ports
Dimensions
DTM C1
1
10
0
300x300x155
DTM C2
2
20
0
300x300x155
DTM C4
4
40
0
380x380x210
DTM C8
8
80
2
500x500x210
Custom panels for easy installation Customisation of these standard communications panels can sometimes yield significant savings during installation. For instance, the installation of additional Ethernet switches could be useful if you need to link to several DTM Display Nodes or would like to ‘daisy chain’ several communications panels to reduce cabling requirements. The addition of process I/O equipment, fibre optic converters or wireless devices can also help to streamline the installation, saving time and reducing costs. Please ask for further details. 4
Overhead KPI information displays Large format, full colour & high resolution at low cost PlantRun Display Node makes use of the latest developments in large format TV, monitor, and projector display technology to present key production information to everyone in production, workshop, meeting, and reception areas.
Display Key Performance Indicators Target v Actual output, OEE etc. Inform & motivate your staff Andon function - request assistance, etc. Unlimited display capability Full colour graphical displays 24 – 65 inch display sizes + projectors Information relevant to each work area Display Health & Safety slides
These high resolution full colour displays remove the limitations and expense associated with old fashioned seven segment LED displays. They provide the freedom to display your performance information in new ways that inform and motivate your staff.
Real time - live data PlantRun displays real time, live data. Its fully automated shop floor data capture feeds live performance information directly to customised displays wherever you want. Progress bars and smiley graphics show instantly how each asset is performing against its target. Graphs show the changing trend in performance over any time period. Colour change can highlight which assets are running slow, stopped or underperforming. The way you display your performance data is fully under your control.
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Custom messaging As well as displaying live information captured by your PlantRun system Display Node will also display MS Powerpoint slides and web pages. This makes it easy to show custom messages such as health and safety notices, employee of the month, visitor welcome messages.
Andon board Displays can be used as Andon boards for engineer calls to stoppages, showing asset and operator ID as well as response waiting time. Andon messages can be prioritised to automatically display within the current sequence of screens on a Display Node.
Health & Safety Messaging A Health & Safety messaging pack is available for use with Display Node. This provides a ready made set of health and safety messages with full colour graphics that can be set to change at regular intervals. Display Node can prioritise displays for fire, evacuation or emergency procedures.
Display Node is a small format fan-less PC with software pre-installed, which is designed to automatically connect to the central PlantRun PC server on power up. The configuration of the information displays, which displays are generated by each Display Node and the display durations is held on the system PC server. This ensures that minimal access is required to display hardware which is typically installed overhead or inaccessible. Display Node can be set to display a static screen of information or several screens scrolling every few seconds. 6
Industrial grade PCs High availability, fault tolerant PlantRun installations utilise high reliability, industrial rugged and fault tolerant PCs to ensure maximum system availability running continuously. The PC server occupies 4U of 19” rack mount space and features forced air cooling, hot swappable cooling fans and air filters, power supply rail monitoring, chassis temperature, fan speed and PSU alarms, and hard drive anti-vibration mounts. The following options are available to further upgrade performance.
System watchdog This circuit monitors a software trigger signal that is generated at regular intervals when the system is in a healthy state. The absence of this trigger for more than 10 seconds causes the PC hardware to generate a hardware alarm and perform a system reset.
Redundant power System power is provided by either a high reliability industrial PC power supply or from an optional dual redundant power supply with hot-swap capability to provide fault tolerance to a single PSU failure.
RAID Hard disk storage can be provided by four high reliability RAID series drives mounted into a four bay drive caddy system, accessed via the lockable front door to provide quick change of a failed drive. This level of storage protection can survive two consecutive drive failures with no remedial user action and no loss of system data or availability.
Chassis Industrial rack mount 4U Processor Intel Core i3, i5 or i7 Memory DDR3/4 up to 64 Gb Storage 1Tb to 6Tb, Std or RAID 5 Power 500W to 700W Std or dual redundant Graphics single or dual HD capable display Network 1 to 4 GbE interfaces System watchdog optional 7
Process measurements Capture process measurements at source Temperature, pressure and relative humidity are just some of the factors that can influence the throughput of your machines and even the performance of your operators. This is true for a wide range of manufacturing processes including plastic moulding, injection, wire drawing, forging, coating, vacuum forming, extrusion, painting and drying. These factors also effect the performance of non process equipment such as packaging lines and even manual assembly processes. If you don’t monitor these factors then you may never fully understand what causes the day to day fluctuations of your manufacturing performance. PlantRun includes a large number of communications drivers that allow it to connect to your existing PLCs, machine controllers, sensors and instruments to capture vital process information. For applications where these measurements are not already available, PlantRun systems can be supplied with custom designed process measurement panels that will enable connection to new or existing instrumentation to provide automatic data capture at source.
6000 series for distributed monitoring If you need to monitor just a small number of process measurements distributed over a large factory area, the 6000 series modules provide an ideal solution. Each 6000 series module can be linked directly to your factory network for communications back to the PlantRun server. Each module can be powered from a 10 to 30Vdc supply, which means that power can often be sourced from your existing equipment panels.
5000 series for concentrated monitoring If you need to monitor a large number of measurements local to one area then an outstation using the 5000 rack based interface modules provides a more cost effective solution. Each remote outstation can accommodate from one to four interface racks with each rack being capable of holding up to eight interface modules. Each interface module provides up to 16 input channels, which means that each rack can accommodate up to 512 inputs. 8
Display Node Ultra slim compact fan-less PC that can be mounted on to the back of a large format display. Auto start-up connection to the system PC server on power up. Optional splitter allows connection of multiple devices each showing the same displays. Features Industrial Design
Compact PC that can be easily mounted behind a large format
CPU RAM SSD LAN
Dual core AMD processor 1.0GHz 4Gb typical 250Gb 1 x Integrated 10/100/1000
USB
2 x USB 3.0 2 x USB 2.0
Video User Interface O/S
2 x HDMI, supports full HD (1920 x 1080) Keyboard and mouse optional Windows 10 Pro 64-bit as standard, other options are available
Watchdog
N/A
Housing Case
Ultra slim case
Environmental Temperature & RH Power Supply Protection Dimensions
0 to 50°C, 20% to 95% RH non-condensing 10—15Vdc, approx. 7—15 Watts N/A Overall 25mm H 160mm W, 160mm D
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DTM04 Outstation The most cost effective way of adding machine monitoring facilities to existing assets. It combines a DTM04 terminal housed in a rugged IP65 sealed steel enclosure with a pair of high visibility status lamps and a DTM Interface PCB. Built in VESA mount aids easy install. Features Industrial Design
Large LCD Display I/O Configuration Human Interface
Lamps Optional Input Digital Counter/Frequency Output Digital Communications Digital Comms Baud Rate Environmental Temperature & RH Power Supply Front Protection Mounting Dimensions Certification
Powder coated mild steel (stainless steel optional) hinged enclosure with DTM04 keypad terminal and LED warning lamps. Fitted with a DTM Interface board Easy to read, 4 lines of 20 characters. Alpha/Numeric capability. 7 digital inputs and 4 relay outputs included as standard Keys for: information; logging on; selecting products; entering scrap; and entering reasons for stoppages. 10 definable function keys, numeric keypad, 2 scroll keys, enter, delete, Yes & No 28mm LED lamps, amber (Reason Required), red (Interlock) Bar code reader, RFID tag reader, label & bar code printers 7 digital Inputs <3Vdc = OFF, >3.5 Vdc >30Vdc =ON Digital inputs can act as counter inputs. 4 at 240Hz, 3 at 9Hz Contacts SPDT 5 Amp resistive at 240V AC Manual override switch for machine interlock RS485 2 wire multi-drop or Ethernet 38400 baud, 8 bit, no parity, 1 start bit, 1 or 2 stop bits Optional RS232 point to point Proprietary protocol 0 to 55°C (-20 to 80°C storage) 20% to 95% RH non-condensing 12 to 30Vdc, approx. 3 Watts IEC IP66, Keypad IP65 VESA 100mm x 100mm on rear of enclosure 300mm H, 205mm W, 90mm D CE 10
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Andon Light
Asset 2
Barcode Scanner Asset 3
Display Node Factory Floor
DTM04 Outstation
Existing Office PCs
Asset 4
Touch Screen PC
Area B LAN Switch
(temperatures, pressures, flows, energy etc.)
Process Measurements
I/O Hardware
Display Node Reception Meeting Area
Example System Layout
RFID Reader
DTM04 Outstation
Viewstation / Workstation / SmartView
Asset 5
PC with Workstation
PLC
Display Node Workshop
In this example we can see how PlantRun is used to monitor two separate factory areas. Each area has its own large format factory floor display to provide performance feedback to the operators. This emphasis on performance and quality is repeated for visitors as they pass through the main reception. Factory area A has made use of the low cost DTM04 Outstations for the operator input combined with optional bar code scanner, RFID reader and Andon light stack. In factory area B we can see that PlantRun is monitoring some key process parameters, and features PC and touch screen operator interfaces and connection direct to PLC. Senior management access live performance and historic reports using their existing desktop PCs, laptops and smart phones, whilst production disturbances are brought to attention via the SMS, email & public address alert systems.
Asset 1
Public Address
SmartView (smartphones, tablets) Office LAN LAN
Communications LAN Panel Switch
DTM04 Outstation
RS-485
Area A
PlantRun Server
SMS
About PlantRun Hardware Chosen for itâ&#x20AC;&#x2122;s high reliability and low total cost of ownership, the hardware outlined in this brochure has been carefully selected to provide the ideal platform for your PlantRun system. However, please remember that PlantRun can be installed on any make or model of PC hardware, which allows PlantRun to fit in with your company standards at all times.
Tascomp Tascomp are the developers of the Prodigy and PlantRun software packages, which it supplies to manufacturers around the world through a network of approved resellers and system integrators.
Tascomp Limited
PR-MM-HR-180918
13
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