Industrial Automation Systems

Computer practicals for

Ladder Diagram Programming using RSLogix 500
and SCADA InTouch (HMI) interfacing
Introduction

 A Human Machine Interface (HMI) software application is a graphical representation of a

manufacturing environment that also allows users to interact with the manufacturing
processes. The tools, materials, and processes used to create a product appear as visual
elements in HMI application windows. Plant operators interact with the application
graphical interface to monitor and control the manufacturing processes.

 RSLogix Micro is a 32-bit Windows ladder logic programming software for

Allen Bradley MicroLogix® PLC controllers.
 RSLogix Micro is compatible with MicroLogix programs created with any of
Rockwell Software programming packages.
 RSLogix Micro software only supports the MicroLogix series of controllers.

Finding information on the Web

For more information about all of the products available from manufacturer for industrial
automation software used in this practical, Rockwell Automation and Wonderware Invensys you
can visit their web sites:

http://www.software.rockwell.com/
http://support.rockwellautomation.com/
http://support.rockwellautomation.com/Knowledgebase
http://wonderware.com
http://global.wonderware.com/eEN/Pages/WonderwareInTouchHMI.aspx
http://trainweb.wonderware.com/getstartit/

   
Developing program for MicroLogix controller and interfacing it with
InTouch SCADA application

Follow the steps below to create a PLC program.

1. Open an existing project for MicroLogix controller and create data files: B (binary), N
(integer) and T (timer).
As shown in Fig. 1 you will need to RightClick (RClk) on Data Files, then select “Create
New Files”.
As shown in Fig. 2 define Files Number, Type, and Number of Elements in the data file.
DoubleClick on the data file to see its content as shown in Fig.2 (b).

Repeat this for all 3 types of Data Files.

Figure 1. Creating new Data Files.

 (a) (b)
Figure 2. (a) Defining a Binary Data File (B10); (b) Content of the data file.

Figure 3. Creating Integer Data File (N11).

 Figure 4. Creating Timer Data File (T12).

2. Create a PLC subroutine called BATCH and call it into the main program.
RClk on Program Files and create new subroutine; name it BATCH as shown in Fig. 5.

Figure 5. Creating subroutine BATCH.

An example of a BATCH subroutine is given in the Appendix 1 at the end of this

document.
3. In the main subroutine LAD2 create a rung for calling BATCH subroutine as shown in
Fig. 6.

Figure 6. Rung in the main program for calling subroutine BATCH.

4. Load your programs to the PLC

 
 

  Click on Comms and choose System

Comms. RSLinx opens Communication window with a list of conterollers. Follow the
communication path and select your controller to download your program. (Check
controller IP address before downloding the program!)
 
Go on line with PLC controller to check if the program is successfully downloaded.

5. Create a Communication link between Wonderware InTouch SCADA and MicroLogix

1500 PLC.

From Windows Start, select All Programs, then Wonderware, and then System

Management Console .

As shown in Fig. 7 under DAServer Manager, Default Group, Local computer, add
ArchestrA.DASABCIP server .

Add configuration , new CIP port and new MicroLogix communication object
(New_ML_EN_000).
  
 
Figure 7. Creating a Communication Link between PLC and SCADA
 
6. Configuration of communication link (OPC server).
Click on New_ML_EN_000. Name the controller (Host Name) that we need to
communicate with (e.g. 130.220.164.17) as shown in Fig. 8.

Figure 8. Configuring the communication link.

Select the next TAB, Device Groups. Name the Group (e.g.) ABPLC. Leave the update
default interval (1000 ms) as shown in Fig. 9.

Figure 9. Configuring the communication Device

 Select the next TAB, Device Items. Create Tag Names (Name) and Item References
(PLC addresses) as shown in Fig. 10.

Create Tag names related to logical 
operation in the PLC program  Link Tags with PLC addresses 

Figure 10. Creating Tags and linking them to PLC data files.

To save changes Clk on Archestra.DASABCIP, Stop the server, Save Changes and
Restart DASABCIP server. Check the small simbols as shown in Fig. 11 to make sure
the server is stopped and them restarted again.

Figure 11. Stopping and restarting the DASABCIP server.

7. Creating a SCADA InTouch Application
From Windows Start, select Program Files, then Wonderware and InTouch. This will
open the new InTouch Application Manager window as shown in Fig. 12.

Figure 12. InTouch Application Manager.

Create a new Application and name it (e.g. BATCH) as in Fig. 13.

Figure 13. Creating a new Application (BATCH)

DClk on the created New Application (BATCH). This will open the InTouch Window
Maker. Create a new window (File New Window) and name it (e.g. Start Screen) as shown in
Fig. 14.

Figure 14. Creating a new Window in InTouch.

8. Creating the interface between your PLC and the your SCADA Application.
Select Special, then select Access Names, then click on Add New Access Name as in Fig.
15.

Figure 15. Adding Access Name for SCADA to access PLC data files

As shown in Fig. 16, enter the Access name (e.g.PLC); the Application Name must be
DASABCIP and the Topic Name must be ABPLC (as entered in Fig. 9). These names were
configured in SMC (System Management Console). Topic Name is a Group Name and
DASABCIP is the server name (Application Name). Node name can be left blank as you are
using a single computer in this application.
  

            

Figure 16. Interfacing the PLC and the HMI

9. Creating HMI and linking Tags with PLC data files

You can create your own HMI or follow the steps below to create an HMI.

To create Tag Display on the Main Screen, open Main Screen (InTouch –Window
Maker) and open object Wizard on the main panel. Select Tag name Value display as
shown in Fig. 17.

Figure 17. Inserting a value display in HMI.

 This creates value display in the Start Screen. Select Display on the screen, then select
Special, then Access Names; select PLC and Dbl. Clk. Press Ok and close Access Name
window as shown in Fig. 18.

 
 
 

Figure 18 Linking Display value with PLC data file

Now, from the Special menu select the Tag Name directory. Create new Tag (Clk. New), select
Type, in this case I/O Integer.

Copy name of the tag from SMC (System Management Console) and use it as Tag Name. Select
Access name PLC From Access Name Window as shown in Fig. 19. Save Tag and Close the
Window.  
  

    

                                             The Access Name is PLC                  Check Use Tag name as Item Name box. 

Figure 19 Creating SCADA Tags for PLC data files

In case this Tag exists but is not used we can delete unused tags.
  

Link the Display value on the Main Screen with the corresponding Tag.

Select Display , DClk on Tag Name, DClk on the Tag name and select tag from Tag Name
Dictionary (Real_Tank_Value) as shown in Fig. 20. Select Number format for display and
press OK 

Figure 20. Linking Display value with its Tag name. 

   
 Make sure DASABCIP Server is running. 

Run the InTouch application by Clicking on Runtime: 

 Running application should display value of the integer N11:1 (Real_Tank_Value) from PLC. 

Use the same procedure for creating a Tag for N11:0 (Requested_tank_Level_Value). Allow
Input from the user. Limit input value from 0 to 1000 (maximum capacity of the tank in our
example). 

 
Now, create Tags for all other PLC data files and any other additional ones that you want to use;
e.g. insert a Switch (Wizards, Buttons, Set/Reset Display). Create new tag (B10:2/7
Enable_Tank_Operation), select I/O Discrete and Access Name PLC. 

      

DClk on the Button, Display Wizard window appears; DClk on Tagname and select Enable_Tank_Switch  
from the Tagname dictionary and press OK. 

   
Set Messages of Operation and press OK. Test and see values in the PLC program. 

Repeat for all other Tags associated with the program (BATCH).

Clk. Tag name Directory and create new tags selecting Type of the tags Names Which can be
copied from SMC, defining access Name topic and save changes.

    

   
Create 3 momentary buttons using wizards (place and arrange using Arrange align options from
main menu). Select buttons for fill, empty and auto mode, assign Tag names and made related
Labels, change action to Direct. 

Create visual control for button. Select 2 Ellipses from panel place it on the screen and arrange
(Use arrange align and make a symbol from main menu); color them together in the manner they
will fit the buttons.  

DClk on ellipse, select Visibility and Blink options. 

   
 

Blink option         Visiability option     Discrete option 

      

Test in Runtime mode (If B10:2/4 bit is active in PLC program, object must blink). Now we can place the 
ellipse over the button’s red area and make it look like one object. 

Ellipse overlaps button red area 

Copy Ellipse object and use it for Fill, Auto buttons. Assign control bits accordingly.  

Create Tank. Choose Rounded rectangle from panel and enlarge radius.  

Clk on the object select vertical fill and analog fill color, adjust Values.

 
 Analog color adjustment example. 

An example of a final SCADA HMI may look similar to the one shown in Fig. 21.

Figure 21. Example of the final HMI.

The HMI is in runtime mode and shows the current level of the fluid in the tank and also the set
value (using slider).

Keep in mind this is just an example and you are expected to create your own HMI, which can be
completely different.   
 Appendix A

Example of BATCH program