Red Lion ProducTVity Station User Manual

Bulletin No. PTV-B

C

. EQ.

C

Drawing No. LP0879

Released 08/13

Tel [phone]

Fax [phone]

www.redlion.net

ProducTVity Station™ – PLANT FLOOR COMMUNICATIONS SOLUTION

z READY TO DEPLOY PLANT FLOOR VISUALIZATION SYSTEM

U

R

US LISTED

L

U

R

L

PROGRAMMABLE

CONTROLLERS

IND. CONT

US LISTED

3PWL

34AD

FOR USE IN HAZARDOUS LOCATIONS:

Class I, Division 2, Groups A, B, C, and D

z CREATES HI-DEFINITION KEY-PERFORMANCE INDICATOR AND

ANDON MESSAGE BOARDS

z 720p DVI OUTPUT SUPPORTS 720 OR 1080 TVs WITH DVI OR

HDMI INTERFACES

z 200+ COMMUNICATIONS DRIVERS FOR COMMUNICATING

DIRECTLY WITH PLCs, DRIVES, ETC.

z SUPPORTS UP TO 16 CS-SERIES MODULES TO ACCEPT

DIGITAL AND ANALOG SIGNALS

z BUILT-IN WEBSERVER ALLOWS REMOTE VIEW OR CONTROL

FROM ANY INTERNET CONNECTED PC

z PROVIDES EMAIL AND SMS TEXT MESSAGE ALERTS

z INCLUDES 2GB COMPACTFLASH® CARD FOR RECORDING

KPIs AND ANDON EVENTS

z SYNCS DATA LOGS TO FTP SERVERS AND MICROSOFT SQL

SERVER

®

z 32-BIT FLOATING POINT MATH ALLOWS CREATION OF

VIRTUALLY ANY KEY PERFORMANCE INDICATOR

z INCLUDES HDMI CABLE AND HDMI/DVI ADAPTER

TO SUPPORT ANY PC OR MONITOR

GENERAL DESCRIPTION

The ProducTVity Station is a ready to deploy solution for displaying
productivity information, andon messaging, and process status on any off-the­shelf TV, PC monitor and even projectors. The PTV leverages over 200
communications drivers via three independent serial ports and an Ethernet port,
to connect and collect data from virtually any PLC, drive, bar code scanner, etc.
Its 720p (1280 x 720 resolution) DVI output is compatible with both 720p and
1080p/i TVs.

The ProducTVity Station’s built-in data-logger can record any key­performance indicators, as well as andon events for later review. The PTV can
synchronize the log files with any FTP server and/or Microsoft’s SQL Server for
further analysis.

The ProducTVity Station extends production monitoring to remote personnel
by providing email and text alerts, and its built-in webserver allows productivity
information to be monitored via any networked PC or smart-phone. If enabled,
remote personnel can take partial or full control of the system remotely, allowing
a maintenance person to effect changes without a site visit.

The ProducTVity Station ships complete with a 2GB CompactFlash card, as
well as a DVI to HDMI cable (15´), and HDMI/DVI adapter. The PTV is
programmed with Red Lion’s popular Crimson® software.

DIMENSIONS In inches (mm)

3.35 (85.2)

STS

USB HOST

DVI

RS232/PG

5.21

(132.4)

4.18 (106.1)

SOFTWARE

The PTV is programmed with Crimson 3.0 software for Windows® XP
Service Pack 2 or later platforms. The software is an easy to use, graphical
interface which allows the configuration of communications, logging, and
stunning visual displays through simple drag and drop steps.

CONTENTS OF PACKAGE

- ProducTVity Station

- Termination Plug

- Terminal Block for connecting power

- Rubber End Cap

- DVI to HDMI Cable (15´)

- HDMI/DVI adapter

- 2 GB CompactFlash card

SAFETY SUMMARY

All safety related regulations, local codes and instructions that appear in the
manual or on equipment must be observed to ensure personal safety and to
prevent damage to either the instrument or equipment connected to it. If
equipment is used in a manner not specified by the manufacturer, the protection
provided by the equipment may be impaired.

Do not use the controller to directly command motors, valves, or other
actuators not equipped with safeguards. To do so can be potentially harmful to
persons or equipment in the event of a fault to the controller. An independent
and redundant temperature limit indicator with alarm outputs is strongly
recommended.

Read complete instructions prior to installation

CAUTION: Risk of Danger.

and operation of the unit.

RS485RS232

ETHERNET

CF

CompactFlash is a registered trademark of CompactFlash Association.

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SPECIFICATIONS

1. POWER: 24 VDC ± 10%

450 mA min. (1 module)

3.4 Amps max. (16 modules + Expansion Card)
Must use NEC Class 2 or Limited Power Source (LPS) rated power supply.

2. COMMUNICATIONS:
USB/PG Port: Adheres to USB 2.0 specification full speed only via Type B

connection.

WARNING - DO NOT CONNECT OR DISCONNECT CABLES
WHILE POWER IS APPLIED UNLESS AREA IS KNOWN TO BE
NON-HAZARDOUS. USB PORT IS FOR SYSTEM SET-UP AND
DIAGNOSTICS AND IS NOT INTENDED FOR PERMANENT
CONNECTION.

USB Host Port: Complies with Universal Serial Bus Specification Rev 2.0.

Support data transfers at full-speed. Hardware over current protected
(0.5 A max).

DVI Port: Digital Visual Interface version 1.3, single link, provides a digital

video feed, with a resolution of 1280 horizontal x 720 vertical pixels,
progressive scan, adhering to CEA-861-E (720 p). DDC support, HDCP is
not supported. Color depth is 32 K.

Serial Ports: Format and Baud Rates for each port are individually software

programmable. Serial ports are individually isolated.
Communication port to port 1500 VAC
Communication ports to power 1000 VDC
Communication ports to earth 1000 VDC

Note: PTV dielectric withstand test per 1 minute. Communication ports:

RS232/PG, RS232 port, RS485 port, Ethernet port and option cards.

RS232/PG Port: RS232 port via RJ12
COMMS Ports: RS422/485 port via RJ45, and RS232 port via RJ12
DH485 TXEN: Transmit enable; open collector, VOH = 15 VDC,

VOL = 0.5 V @ 25 mA max.

Ethernet Port: 10 BASE-T / 100 BASE-TX

RJ45 jack is wired as a NIC (Network Interface Card). The jack shield is
electrically connected to Earth ground, but the port is isolated.

3. LEDs:
STS – Status LED indicates condition of master.
USB HOST – HOST LED indicates port status/activity.
TX/RX – Transmit/Receive LEDs show serial activity.
Ethernet – Link and activity LEDs.
CF – CompactFlash LED indicates card status and read/write activity

4. MEMORY:
On-board User Memory: 128 Mbytes of non-volatile Flash memory.
On-board RAM: 64 Mbytes
Memory Card: CompactFlash Type II slot for Type I and Type II cards.

5. REAL-TIME CLOCK: Typical accuracy is less than one minute per month
drift. Crimson’s SNTP facility allows synchronization with external servers.
Battery: Lithium Coin Cell. Typical lifetime of 10 years at 25 ºC.

A “Battery Low” system variable is available so that the programmer can

choose specific action(s) to occur when the battery voltage drops below
its nominal voltage.

This unit is NOT field serviceable. All work must be done by a qualified technician.

6. ENVIRONMENTAL CONDITIONS:
Operating Temperature Range: 0 to 45°C
Storage Temperature Range: -30 to +70°C
Vibration to IEC 68-2-6: Operational 5-150 Hz, 2 g
Shock to IEC 68-2-27: Operational 25 g
Operating and Storage Humidity: 80% max relative humidity,

non-condensing, from 0 to 50°C

Altitude: Up to 2000 meters

7. CONSTRUCTION: Case body is black high impact plastic and stainless
steel. For indoor use only. Installation Category II, Pollution Degree 2.

8. POWER CONNECTION: Removable wire clamp screw terminal block.
Wire Gage Capacity: 24 AWG to 12 AWG
Torque: 4.45 to 5.34 in/lb (0.5 to 0.6 N-m)

9. MOUNTING: Snaps onto standard DIN style top hat (T) profile mounting
rails according to EN50022 -35 x 7.5 and -35 x 15.

10. CERTIFICATIONS AND COMPLIANCES:

CE Approved

EN 61326-1 Immunity to Industrial Locations
Emission CISPR 11 Class A
EN 61010-1

RoHS Compliant
UL Listed: File #E302106
UL Hazardous: File #E317425

Refer to EMC Installation Guidelines section of the bulletin for additional

information.

11. WEIGHT: 1.313 lb (596 g)

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HARDWARE

INSTALLATION

DIN rail should be mounted horizontally so that the unit’s ventilation holes
are vertical in relation to cabinet orientation. A minimum clearance of 1 inch
(25.4 mm) should be maintained above and below the unit in order to ensure
proper thermal regulation. A minimum top clearance of 3.00 inch is needed
when using the USB/PG port.

The unit shall be installed inside a UL Listed Industrial Control Panel or
similar type of enclosure. A minimum 3.2 mm distance shall be maintained
between the hazardous live parts of the equipment and accessible parts of the
fire/electrical enclosure.

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2

Figure 1 - Attach PTV Station To DIN Rail and Remove

Rubber End Cap

TOP

1.00" min. clearance; 3.00" when using USB/PG port.

STS

DVI

USB HOST

RS232/PG

DEPRESS

3

4

DIN RAIL

RS485RS232

ETHERNET

CF

1.00" min. clearance

4

BOTTOM

Figure 2 - Attach Slave Bases To DIN Rail

STS

DVI

USB HOST

RS232/PG

RS485RS232

ETHERNET

CF

5

Figure 3 - Attach Termination Plug*

* Supplied with PTV Station.

STS

DVI

USB HOST

RS232/PG

DIN RAIL

RS485RS232

ETHERNET

CF

Figure 4 - Installation Complete

REMOVE

DIN RAIL

PROTOCOL CONVERSION

Mount the PTV as shown under Hardware Installation Figure 1 above. Install
the rubber end cap. The end cap protects
the pins from damage. Configure
the PTV for zero modules.

POWER SUPPLY REQUIREMENTS

It is very important that the power supply is mounted correctly if the unit is
to operate reliably. Please take care to observe the following points:

– The power supply must be mounted close to the unit, with usually not more

than 6 feet (1.8 m) of cable between the supply and the master. Ideally, the
shortest length possible should be used.

– The wire used to connect the PTV’s power supply should be at least

22-gage wire. If a longer cable run is used, a heavier gage wire should be
used. The routing of the cable should be kept away from large contactors,
inverters, and other devices which may generate significant electrical
noise.

– A power supply with an NEC Class 2 or Limited Power Source (LPS) and

SELV rating is to be used. This type of power supply provides isolation to
accessible circuits from hazardous voltage levels generated by a mains
power supply due to single faults. SELV is an acronym for “safety extra­low voltage.” Safety extra-low voltage circuits shall exhibit voltages safe
to touch both under normal operating conditions and after a single fault,
such as a breakdown of a layer of basic insulation or after the failure of a

single component has occurred.
Visit www.redlion.net for a complete list of our PSDR Series of NEC Class 2
power supplies.

EMC INSTALLATION GUIDELINES

Although Red Lion Controls Products are designed with a high degree of
immunity to Electromagnetic Interference (EMI), proper installation and wiring
methods must be followed to ensure compatibility in each application. The type
of the electrical noise, source or coupling method into a unit may be different
for various installations. Cable length, routing, and shield termination are very
important and can mean the difference between a successful or troublesome
installation. Listed are some EMI guidelines for a successful installation in an
industrial environment.

1. A unit should be mounted in a metal enclosure, which is properly connected

to protective earth.

2. Use shielded cables for all Signal and Control inputs. The shield connection

should be made as short as possible. The connection point for the shield

depends somewhat upon the application. Listed below are the recommended

methods of connecting the shield, in order of their effectiveness.

a. Connect the shield to earth ground (protective earth) at one end where the

unit is mounted.

b. Connect the shield to earth ground at both ends of the cable, usually when

the noise source frequency is over 1 MHz.

3. Never run Signal or Control cables in the same conduit or raceway with AC

power lines, conductors, feeding motors, solenoids, SCR controls, and

heaters, etc. The cables should be run through metal conduit that is properly

grounded. This is especially useful in applications where cable runs are long

and portable two-way radios are used in close proximity or if the installation

is near a commercial radio transmitter. Also, Signal or Control cables within

an enclosure should be routed as far away as possible from contactors,

control relays, transformers, and other noisy components.

4. Long cable runs are more susceptible to EMI pickup than short cable runs.

5. In extremely high EMI environments, the use of external EMI suppression

devices such as Ferrite Suppression Cores for signal and control cables is

effective. The following EMI suppression devices (or equivalent) are

recommended:

Fair-Rite part number 0443167251 (RLC part number FCOR0000)
Line Filters for input power cables:

Schaffner # FN2010-1/07 (Red Lion Controls # LFIL0000)

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