Automation and Robotics 20ME51I_Week_4_Practicals.pdf

PLC, SCADA & HMI: INDUSTRIAL AUTOMATION
PRACTICAL HAND BOOK Page 79

15. HMI (Human Machine Interface) - Types- Selection- Specifications
HMI, which stands for Human Machine Interface, refers to the user interface that allows
humans to interact with machines or systems. It enables users to control and monitor various
functions and processes within a machine or system.
Types of HMI:
1. Push-button interfaces: These are
simple interfaces that use physical
buttons or switches to control
machine functions.
2. Touchscreen interfaces: Touchscreens
are widely used in modern HMIs due to
their spontaneous nature. They allow
users to interact directly with graphical
elements displayed on the screen.
3. Graphical user interfaces
(GUIs): GUIs provide a visual
representation of the machine or
system with interactive
elements such as buttons, icons,
menus, and status indicators.
4. Mobile interfaces: With the rise
of mobile devices, HMIs can be
designed to work on
smartphones and tablets.

5. Web-based interfaces: Web-
based HMIs are accessed
through web browsers, enabling
users to interact with the
machine or system using any
device with internet
connectivity. Figure: An IoT-
enabled web panel
6. Augmented reality (AR) interfaces:
AR HMIs overlay digital information
or graphics onto the user's real-world
environment. Users can view and
interact with virtual elements
superimposed on physical objects,
enhancing their understanding and
control of machines or systems.
7. Virtual reality (VR) interfaces: VR HMIs immerse users in a completely virtual
environment, allowing them to interact with digital representations of machines or
systems.

Selection Considerations:
1. Based on its functionality: Specific functions require from the HMI, such as control
capabilities, data visualization, alarms, historical data logging, recipe management,
remote access, etc.
2. User experience: Consider the comfort of use, spontaneous navigation, and overall
user-friendliness of the interface.
3. Environmental factors: Evaluate the environmental conditions where the HMI will
be deployed. Factors such as temperature, humidity, dust, and potential exposure to
water or chemicals should be considered to select an HMI with appropriate
protection ratings.
Specifications:
1. Display: Size, resolution, and colour capabilities of the display.
2. Connectivity: Necessary communication protocols such as Ethernet, serial ports,
USB, or wireless options like Wi-Fi or Bluetooth.
3. Processing power and memory: Processing capabilities and memory of the HMI to
handle the required tasks efficiently.
4. Software compatibility: Compatibility of the HMI with the software used for
programming and configuring.
5. Reliability and durability: Factors such as shock resistance, vibration tolerance, and
the expected lifespan of the device.

16. PLC with colour Touch screen Human Machine Interface (HMI)
A Programmable Logic Controller (PLC) with a colour touchscreen Human
Machine Interface (HMI) is a common configuration in industrial automation systems. The
PLC serves as the control center, while the HMI provides a graphical user interface for
operators to interact with the system.
The PLC is programmed for
controlling industrial processes and
machinery. It receives input signals
from various sensors and devices, such
as switches, sensors, and analog inputs.
Based on its program logic, stored in
memory, the PLC processes the inputs
and generates output signals to control
actuators, motors, valves, and other
devices.
The HMI is the interface between the operator and the PLC. It allows users to
monitor and control the industrial process visually. The colour touchscreen display
provides a user-friendly interface with graphical elements, icons, and images.
Operators can interact with the HMI by touching the screen, enabling them to
control the process, monitor parameters, and receive feedback. The HMI can display real-
time data, historical trends, alarms, and other relevant information.
Integration of PLC and HMI:
1. The PLC and HMI are interconnected to exchange data and information.
2. The PLC program communicates with the HMI software through a communication
protocol such as RS-232, Modbus, Profibus, or Ethernet/IP.
3. The PLC sends data to the HMI for visualization, and the HMI can send commands
and inputs to the PLC for process control.

Practice: Interfacing Delta PLC DVP-14SS2 with WECON touch screen HMI (PI3070ie)
Step1: Select the icon PIStudio the startup window opens
Step 2: Click New Project and select the HMI model as PI3070ie, communication connect
COM1, PLC type DELTA, DELTA DVP Series and click Finish.
The window below appears once the project is created.

17. Practice HMI programming involving alarms and trends
Alarms:
Human-Machine Interface (HMI), alarms are an essential feature used to notify
operators about abnormal or critical conditions within a system or process. HMI alarms provide
visual/audible notifications to alert operators about possible issues, allowing them to take
appropriate actions to prevent problems.
HMIs typically support various types of alarms,
1. Process alarms,
2. Equipment alarms,
3. Safety alarms, and
4. System alarms
Key aspects and best practices related to alarms in HMI systems:
1. Alarm Configuration: The configuration allows operators to define alarm parameters,
including trigger conditions, messages, and related actions.
2. Alarm Trigger Conditions: Alarms are triggered based on predefined conditions. These
conditions can be set to monitor variables such as temperature, pressure, flow rate,
level, or any other parameter relevant to the process or equipment. When conditions are
met, the alarm is triggered.
3. Alarm Presentation: When an alarm is triggered, it is presented to the operator on the
HMI display. Typically includes visual/audio cues. Visual cues may involve flashing
icons, color changes, or pop-up windows, while auditory cues can include alarms
sounds or voice notifications.
4. Alarm Acknowledgment: When an alarm occurs, operators should be able to
acknowledge the alarm to indicate that they have seen it.
5. Alarm History and Reporting: HMIs often keep a historical record of alarms, including
time of occurrence, duration, operator responses, and resolution actions.
6. Alarm Prioritization: Allows operator to prioritize the most critical issues receive
immediate attention.

Alarm Record:
PI software support bit alarm and
word alarm. The alarm data can be display
in HMI by [Alarm record display] object.
There are typically two types of alarm records available: Current Alarm Record and
History Alarm Record.
Current Alarm Record: The current alarm record displays the active or current alarms
in real-time. It provides information about alarms that are currently active and require attention.
History Alarm Record: The history alarm record provides a historical log of alarm
events that have occurred in the past. It captures information about alarms that have been
acknowledged, cleared, or resolved. The history alarm record enables operators/engineers to
review past alarm events.
1. HMI Bit Alarm
A bit alarm typically refers to an alarm condition associated with a specific binary
(ON/OFF), often referred to as a bit. The alarm is triggered when a particular binary signal
meets certain criteria, or entering an abnormal state. When a bit alarm is triggered, it usually
indicates an abnormal condition that requires the attention of the operator.
2. HMI Word Alarm
It refers to an alarm condition associated with a specific word or data value in an HMI
system. A word alarm is triggered based on the value of a larger data word or a combination of
bits within that word. These could include values such as temperature, pressure, flow rate, or
other process variables. A word alarm is typically configured to monitor these data values and
trigger an alarm when specific conditions are met.

Create a Bit alarms table (Record) in Wecon HMI PiStudio:
1. Click [Project]-->[Bit Alarm] as below shows;
2. Click [Add] button to open [Bit Alarm] setting window;
3. Set [Bit Address];
4. Set [Alarm Condition];
5. Set [Content];
6. Other settings can be set according to the actual situation;
7. Click [OK] button to complete settings;
Procedures of adding one alarm

1. Basic settings
Bit address: Read address for bit alarm (Input);
Group No: Group number of bit alarm;
2. Alarm condition: It sets alarm trigger condition, there are two types, alarm when ON
and alarm when OFF;
3. Alert: When the alarm occurs, the [Control Bit] will set ON (Output);
4. Alarm Screen: Pop up alarm screen (it needs to be sub-screen);
Position: The location of the screen alarm display.
Pop up Interval: The time of reopen the alarm screen when alarm screen closed.
Pop up once: Pop up alarm screen once.
Close window when alarm off: Automatically close the alarm screen when alarm off.
5. Beep when alarm ON: Beep works when the alarm is triggered, in the default mode,
the beep works until the alarm is released.
Beep once: Beep works once, when alarm is triggered;
6. Content: It is used for setting alarm content (command/notification message);
Alarm Record Display settings
Optional

Description
1. Settings
Alarm type: There are two types for alarm function; one is [Current alarm record] and the
other is [History alarm record];
Group No.: This group number is located to alarm settings; this object only displays the alarm
content within the setting range;
Display in reverse order: The latest alarm information will be displayed at the top of object;
Alarm Record Setting: This is for setting display items in object, the setting window as below
shows;
2. Start time
It configures start query time.
Span: set the time span from start time to end time of query;
Result: When all configurations are completed, when the HMI is running, alarm display object
will display.

Create Word alarm table (Record) in Wecon HMI PiStudio:
Description of word alarm setting
1. Basic settings
 Alarm name: User can set alarm name for it;
 Alarm Address: It is used for setting read address for word alarm;
 Data format: It is used for setting [Alarm Address] data format, and set integer
and scale digits;
2. Alarm Condition
Alarm is triggered when designated address meets the alarm condition, it provides
four conditions;
 High alarm: Alarm is triggered when it reaches high limit.
 Low alarm: Alarm is triggered when it reaches low limit.
 Range alarm: Alarm is triggered when it reaches the range.
 Equivalent alarm: Alarm is triggered when the value equals to the present value.
3. Alarm Info: It is used for setting alarm content (command/notification message);
4. Alert: When the alarm occurs, the [Control Bit] will set ON;
5. Alarm Screen: Pop up alarm screen (it needs to be sub screen);
 Position: The location of the screen alarm display.
 Pop up Interval: The time of reopen the alarm screen when alarm screen closed.
 Pop up once: Pop up alarm screen once.
 Close window when alarm off: Automatically close the alarm screen when alarm
off.

6. Beep when alarm ON: beep works when the alarm is triggered, in the default mode,
the beep works until the alarm is released.
Beep once: Beep works once, when alarm is triggered;
7. Operation buttons
 These buttons can perform corresponding editing operations on the [Alarm List].
8. Alarm List
 It displays all the word alarm lists; it will show the alarm information;
Operating procedures of adding one alarm
1. Click [Project]-->[ Word Alarm] as below shows;
2. Click [Add] button to open [Word Alarm] setting window;
3. Set Basic information of word alarm;
4. Set [Content];
5. Other settings can be set according to the actual situation;
6. Click [OK] button to complete settings;

Trends in HMI
Trend chart is used for displaying the real time/historic data in HMI as curve graph
form, which X axis represent as time, Y axis represent as data related to various process
variables (Pressure, temperature, flow, etc) or any other data parameter relevant to the process
or equipment.
Trend chart settings

1. Basic settings
 Curve Name: It is for setting curve name; Enter suitable text for the name.
 Curve (1~8): It is for setting the number of curves (processes).
 Dots of one curve: It is for setting dots number of each curve, the default is 1000,
but the maximum dots are 10,000 for all the curves;
2. Sampling type
It is for setting sampling type for curve chart, there are two types, one is Cycle sample,
and the other is Trigger cycle sample. If users select Trigger cycle same mode, it requires a
control bit for it, as following picture shows.
3. Quick setting
It is for setting all the curves, select the data format for all curves, and setting the reading
addresses for curves.
For example:
 Users set HDW0 as start address, and the data format is 16-bit signed, then the
HDW0 is for Curve 1, HDW1 is for Curve2, HDW2 is for Curve 3, etc.
4. Right side window: It is for setting curves one by one;

Real-time trend in Wecon HMI using PiStudio:
Trend graph shows the data as a
dynamic curve, X axis represent the time
span, Y axis represent the data.
Source
1. Curve buffer: Select data from
[Trend Chart], and display data in
term of curve;
2. Curve displays: HMI will display
curves according to select [Trend
Chart], and user could select which
curves need to be displayed and
select [Line type] and [Color] for
each curve;
Range
Set data range limit of curve (max and min).
Result: When all configurations are completed, when the HMI is running, observe the Trend
plot.

History trend in Wecon HMI using PiStudio:
The history trend will display data record with graph. X axis represents as time, and Y
axis represents as data.
1. Source
 Curve buffer: Select data from [Data record], and display data in term of curve;
 Curve displays: HMI will display curves according to select [Data record], and
user could select which curves need to be displayed and select [Line type],
[Color] and select [Channel] for each curve;
2. Range
 Set data range limit of curve (max and min). Also could set variable to control
data range;

3. Function
 Start address: Custom object for query function, HMI system assigns address
according to the settings, and four control key and query screen will be created, user
could see the query details in this query screen.
 Use Dynamic channel: It occupies 8 addresses; each address corresponds to the curve
channel number. For example, the address is set to HDW10, it takes up HDW10 to
HDW17. Where the value of HDW10 is 3, then the first curve in the trend graph shows
the value of channel 3.
 Start time: Set start time and span for curve display.
Result: When all configurations are completed, when the HMI is running, observe the Trend
plot.

18. Practice on SCADA: (I/O discrete and I/O real)
Introduction
SCADA stands for Supervisory Control and Data Acquisition. It is a system used to
monitor and control industrial processes and infrastructure, such as power plants, water
treatment facilities, manufacturing plants, etc. It gathers data from various sensors and devices
located throughout the industrial process. It receives real-time information and sends control
commands to the field devices to adjust the process parameters as needed.
Generalised procedure to define I/O discrete/ I/O Real Tagnames in Intouch Wonderware
SCADA
Tagname that read or write their values to or from another Windows program (RSLinx)
are I/O type Tagname. These includes all inputs and outputs from programmable logic
controller (PLC).
If we define an I/O Discrete type Tagname when we need an I/O Tagname with a value
of either OFF or ON.
To define the details for a I/O discrete Tagname
1. Select I/O Discrete as the type for Tagname, the following details dialog box appears
2. Click the Initial Value that we want stored in the Tagname when the runtime database
is first loaded. (OFF equals 0, ON equals 1.)
3. On the Special menu, click Access Names, the Access Names dialog box appears.

4. Click Add. The Add Access Name dialog box appears.
5. In the Access Name box, type the name you want InTouch to use for this Access Name.
For simplicity, use the same name that you will use for the topic name here.
6. In the Application Name box, type RSLinx for the I/O Server program from which the
data value will be acquired.
7. In the Topic Name box, type the file name you want to access.
8. Select the protocol (DDE) that you are using.
9. When you are done specifying the access name(s), click OK. The Access Names dialog
box reappears showing the new Access Name selected in the list.
10. Click Close to close the dialog box and return to your tagname definition.
11. In the Item box type I/O Address of the PLC hardware. Save and close the window.

Exercise 1: Devise a PLC Ladder program for a DOL starter. Supervise and Control
using SCADA- I/O Discrete.
Communication protocol
RSLinx application to MicroLogix 1000 DH-
485 hardware
RS 232 Communication
RSLinx application to InTouch SCADA DDE (Dynamic Data Exchange)
PLC Program
SCADA Layout

Exercise 2: Devise a PLC Ladder program for Interlocking of two motors. Supervise
and Control using SCADA- I/O Discrete.
485 hardware
PLC Program
SCADA Layout

Exercise 3: Devise a PLC Ladder program for counting number of objects moving on
conveyor. Supervise and Control using SCADA- I/O Discrete and I/O Real.
485 hardware
PLC Program
SCADA Layout

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