Scada Manual

Scantime Engineering Ltd NE42 6QD Prudhoe.
England Tel: +44 (0) 1661 830114
SCANTIME
+44 (0) 7974 005661 email: support.cs@scantime.co.uk www.scantime.co.uk
SCADA PROGRAMMING PART1

COURSE MANUAL
Revision 1.0000
Prepared by David H Simm Scantime Engineering Ltd
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Scantime Engineering Ltd Maingate. Regus House, 1st Floor Team Valley Trading Estate Gateshead. Tyne & Wear NE11 0NQ England email: support.cs@scantime.co.uk www.scantime.co.uk
TABLE OF CONTENTS
SCADA PROGRAMMING PART1 ............................................ 1 COURSE MANUAL ......................................................... 1 Table of Contents ..................................................... 2 REVISION INFORMATION .................................................. 4 WHAT IS SCADA ......................................................... 5 SCADA IN INDUSTRY ....................................................... 7 PROCESS CONTROL & SCADA ............................................... 8 SCADA MAKES ..........................................................10
EXERCISE1 ................................................................ 12
SCADA TERMS ..........................................................13

SCADA TERMS - 2 ......................................................... 16 SCADA TERMS 3 ............................................................ 18 SCADA TERMS 5 ........................................................... 23 SCADA TERMS 6 ........................................................... 26 EXERCISE 2 ................................................................ 28
SCADA ADDRESSING .....................................................29
Scantime Engineering Ltd. Registered Office Prudhoe. Northumberland NE42 6QD England. Registered in England No: 5268346
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DESIGN CONSIDERATIONS ................................................31 INSTALLING MX4 .......................................................38 RUNNING MX4 ..........................................................40 INSIDE MX4 ...........................................................42 RUNNING THE PROJECT 1 ..............................................44 RUNNING THE PROJECT 2 ..............................................46 RUNNING THE PROJECT 3 ..............................................48 CREATING A SCADA .....................................................52 MX4 CONFIGURATION ....................................................54 MX4 EXPLORER .........................................................57 TEMPLATE - 1 .........................................................60 TEMPLATE - 2 .........................................................63 TEMPLATE 3 .........................................................64 TEMPLATE - 4 ..........................................................67 CREATE FIRST PAGE ....................................................73 TEST YOUR PROJECT ....................................................76 DRIVERS & IO SERVER .....................................................77 COMPUTER SETUP .......................................................84 SCADA TAGS ...........................................................92 DYNAMIC PAGES ........................................................95 GENIES ...............................................................99 BACKUP AND RESTORE .................................................. 102 MAIN EXCERCISE ...................................................... 104
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REVISION INFORMATION
Ref
Description
Pages
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ONLINE COURSE MANUAL
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WHAT IS SCADA
SCADA - Supervisory Control and Data Acquisition. What are the differences between HMI (Human Machine Interface) and SCADA:HMI is a localized operator terminal - NONE PC based, connected to usually one PLC via an RS232 connection or in some instances Industrial Ethernet communication link. An HMI allows the operators and engineers access to the process being controlled by the PLC, allowing them to interact with the process Start, Stop, Alarm Acknowledgement, and Process Data Display. SCADA is PC based and tends to be a Remote system, positioned some distance away from the process in an office or central control area, however they are sometimes used locally depending upon the application. The SCADA monitors not only one PLC via serial RS232/422 but it can monitor several PLC's at any one time via a network such as Industrial Ethernet. Below is a typical Scada screen of a process being controlled from a PLC.
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SCADA - Screen layouts do vary and we will be learning about these later in the course.
SCADA screens can be very Dynamic, the term Dynamic refers to where the process can be animated - HMI's have developed to also allow a degree of animation, so that at a glance the operator can see what is happening, however since the SCADA is PC based it can call on the power of Graphics Cards to display images more clearly and very well defined due to the PC high resolutions. Because Scada is about visual displaying of information and graphics the PC or IPC Video is very important, to test the quality of a Video Card, you can check the screen settings in the OS Operating System , with Windows XP Right mouse click the screen and select Properties with Vista select Personalize, then look at Screen settings, Resolutions of 1024 * 768 are OK but 1280 * 1024 is better, 800 * 600 should be avoided as the graphic quality will be very poor, the resolution refers to the number of Pixels Across and Up the screen, so the higher the number the better when Diagonal lines are displayed, lower resolutions display a ragged diagonal line. You also have to ensure the Depth of colour is at maximum such as 32 Bit and NOT 16 Bit. The image shown above show how the quality should appear. One final test is to check the capability of the Graphic Card, Open a Window - anything such as MS Word, reduce the size of the window so that you can see the Desktop background, then Mouse Left click on the Window Top Bar where the Window size buttons are, then rapidly Move the Window around the PC Screen -
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If you see a slow Trailing effect as you move the Window around rapidly then your Graphic Card is of low quality, also in some PCs you share Graphic memory with the PC Ram, this is very poor, you should always have a separate Graphics card such as Nvidia Or Radeon but never Integrated Graphics or Shared Graphics. Being a Scada engineer also means you have to understand how computers operate, understanding how to Format Hard Drives, Set screen resolutions, Update Drivers etc.
HMI over Scada One benefit of an HMI over Scada is that HMI do not have hard drives, the operating system of an HMI is in ROM (Read Only Memory), therefore there is no BOOT Time when it is powered up, whereas SCADA being PC based does have an operating system "Windows XP" and takes several seconds to Boot as all PC's do. (Note Windows Vista is new (c) 2007 and not all Industrial systems use this platform yet). Data collection, reporting from production lines, material handling and automatic testing is made simplified by using a SCADA system. It allows authorized personnel to access data at any point in the production cycle, to obtain performance figures and test results at every stage on the production line; reports can be automatically generated on production output and performance reports and created at specific periods of the day, end of week or month, and all this is done in real time.
SCADA over HMI SCADA also has several other advantages over an HMI - Data Logging, the restriction to how much data can be stored on a SCADA is only dependent upon the size of its Hard Drive, whereas an HMI depends upon its Ram or EEPROM. You can also create SCRIPTS in SCADA using VB (Visual Basic, C Language or a bespoke language developed by the Scada make.
What is IPC IPC is Industrial PC (Personal Computer), it is similar to a PC with Hard Drive, Ram, CD/DVD Drive but it is designed into a rugged construction that is better for being placed in industrial areas and in hazardous locations.
SCADA IN INDUSTRY
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PROCESS CONTROL & SCADA

Manufacturing equipment on the shop floor is interfaced to the PLC via actuators and sensors, the PLC CONTROLS THE PROCESS - NOT THE SCADA. The importance of the PLC is that under all circumstances Except SAFETY, the PLC must always be in control, so the PLC Programmers designs his PLC program in a manner to maintain control of the process at all times, if SAFETY is breached then PILZ Relays take control via Hard wiring and the process will STOP, the PLC will react to a breach in SAFETY (Example EStop activated) and place the program in a safe mode even though the control outputs will have little effect, usually when a PILZ relay is triggered the 24 volt DC supplies are turned OFF, therefore the outputs from the PLC will also all turn OFF, the PLC Program should then enter a safe mode and ensure any signalling to the outputs is further disabled, the PLC program will then wait until process safety is restored and supplies re-established via the PILZ Relay and the operator completes a FAULT RESET allowing the PLC to restart when the operator presses Process Run. Below is a typical Process Control Layout. On the left we can see at the bottom of the image, Actuators, Lamps and sensors, wired back to the PLC via Direct wiring or ASI. ASI is a communication wiring via 2 wires that allows devices to simply be connected onto a 2 wire communication link, with its signalling encoded onto a transmission signal to and
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from the PLC, this simplifies and greatly reduces wiring on the shop floor. In multiple PLC installations the PLCs are usually networked, via an OPEN network such as PROFIBUS communications, a robust communication standard or the newer Industrial Ethernet. On single terminal Scadas you can connect the Scada terminal to your PLC by using Serial communications, such as RS232, RS422 and RS485.
At the top of the design tree on the left is the SCADA terminal(s), these monitor the shop floor data and signalling via the PLC. The SCADA provides operators and engineers the capability of viewing manufacturing progress in real time, and can change manufacturing parameters via the SCADA terminals. However the changing of manufacturing parameters is closely controlled by the PLC, this has to ensure the operator can only make changes in accordance with the manufacturing design and not place the system into position where manufactured Product is badly made, or Safety is breached.
SCADA is a powerful software package, allowing the Scada designers to create programs via Scripts, which can run inside the Scada, however these programs are only supposed to affect the Scada display and not be used to make control decisions on the manufacturing process.
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SCADA MAKES
Learning SCADA such as the makes below is NOT Scada Programming, just like as PLC programming has little to do with Omron, Mitsubishi etc learning RS VIEW or WINcc SCADA is all about how to use the software package. When you know how to program for a process application then you apply this against all SCADA makes. Below are some of the major process control manufactures worldwide. NOTE: ALL SCADA packages work with ANY PLC make; they are OPEN packages allowing the designer to decide which is better for the application. In some cases it makes sense to use a PLC manufacturer package, however in the 1990's PLC manufactures stayed with PLC's and left SCADA (The new boy on the block) to other companies such as Wonderware - Intellution - Citect. When SCADA became popular with industry the PLC manufacturer decided to jump on the ban wagon and come up with their own makes, maximizing their presence in the market place.
WONDERWARE - INTOUCH Wonderware are NOT a PLC supplier, they have focused their operation on SCADA only and have developed a very powerful package that integrates into many areas of today's manufacturing cycle. A US product. Reliable & easy to use, support is worldwide. Works with all PLCs including Mitsubishi, Omron, and Siemens etc. WEBSITE
ALLEN BRADLEY - RS VIEW RSView32 a US product, works on any PLC, it looks very good. Rockwell claim it is an integrated, component-based HMI for monitoring and controlling automation machines and processes. Available in
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English, Chinese, French, German, Italian, Japanese, Portuguese, Korean, and Spanish. RSView32 expands your view with open technologies. WEBSITE
SIEMENS - WINcc WinCC, a German product, launched in 1997. Works again with all PLCs, a very powerful product but back in 1997 when it launched a difficult platform to get to grips with, expensive and support was disastrous. Their product is now much improved and is available in two packages WinCC Flexible a reduced Scada package and WinCC Scada, both are integrated into Siemens STEP7. By integrating WinCC into STEP7 maintains a consistent design approach when designing a system both PLC and Scada can be accessed at the click of a button. To improve your knowledge on 21st century process control, see how PLC and Scada can work together in a manufacturing process, each video below lasts approx 15minutes. Requires Windows Media Player or Real Player VIDEO 1 (32MB) VIDEO 2 (12MB)
iFIX32 - GE FANUC Formerly Intellution, iFIX is now a GE Fanuc product. A very power full package monitoring and supplying data across much a a manufacturing plant. GE Fanuc Automation is a joint venture of General Electric Company and FANUC LTD of Japan, with world headquarters in Charlottesville, Virginia, and global operations serving customers in the Americas, Europe, and Asia. WEBSITE
CITECT An Australian company who assisted Mitsubishi to develop their own Scada software MX4. Established in 1973, Citect has grown to become a leading, global provider of industrial automation, real-time intelligence, and next generation manufacturing execution systems (MES). Citect products are complemented by professional services and customer support and training and sold in numerous industries. WEBSITE
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MITSUBISHI - MX4 (Demo program supplied) The introductory level to SCADA used to be quite steep, several thousand dollars, however - Mitsubishi have now joined with CITECT AUS - many years of selling into the Australian market, jointly they have now released MX4 HMI, the HMI term has been used although this is still a PC based system and not a true HMI, the difference between their MX4 HMI and MX4 Scada is TAG count, you are limited to approx 100 TAGS (IO), this is a low end package costing a few hundred dollars and allows the monitoring of production lines and reporting etc that a SCADA package provides. The next level above MX4 HMI is their MX4 SCADA, this allows UnLimited TAGS..
All SCADA packages if developed correctly enable you to increase your company's return on assets by delivering highly scalable, reliable control and monitoring systems to reduce your operating costs and increase profits.
EXERCISE1
1. What does SCADA stand for? What is special about ASI 2. How many Scada terminals can you have monitoring a manufacturing process? 3. How can you connect a Scada to a PLC? 4. What is the difference between a PC and a IPC, and what does IPC stand for? 5. What determines how clear the Scada screens will be displayed? 6. Which controls the Manufacturing process Scada or PLC or Both, and WHY? 7. Which company developed - WinCC - MX4 and InTouch
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SCADA TERMS
We will look further into each of the topics below later, these are a brief explanation of the terms used in Scada programming.
CONFIGURATION Scada Configuration refers to the setting up of the Scada software for the means of Communication, Device Drivers for PLC make and model, PC Screen Resolution, the Start Page to be displayed when starting the project - sometimes referred to as the Splash screen (Logo and Title etc), Refresh periods from graphic updates. * User expandable Libraries of Graphics symbols and templates * Express wizards for PLC communication setup * Genies to create dynamic custom objects * Ability to Import Tag addressing, settings and descriptions via MS Excel * Use of off the shelf Active X objects
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ALARMS Alarms are fundamental to Scada's, these are the Process alarm messages that appear when they are triggered in the PLC program. When an Alarm occurs in the PLC it will trigger a Bit Address in the PLC, this Bit Address is assigned to an Alarm TAG in the Scada, which is configured to display a message on the Scada Screen. Alarm displays on Scada's are displayed in two areas: 1. Alarm Banner - usually displays the last 3 alarms and is placed on every screen so that the operator can see the latest alarms 2. Alarm Page - displays all the alarms * Time stamped alarms to milli seconds * Ability to interact with Alarms via pages or individually * Custom configure alarm colouring to suit their state. * Several hundred levels of Alarm Priority or Category * Historical Alarm and Event Logging * Alarm Reports can be custom configured and automatically generated
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GRAPHICS DISPLAY The Graphic pages provide operators and engineers with a visual Dynamic overview of the the Manufacturing Process. Every item shown is referred to as an OBJECT - Pipes - Valves - Meters - Bar Graphs - Buttons are all OBJECTS.
Each OBJECT has PROPERTIES these allow the designer to set the colours of the object, also how these colours will change should values in the process change - example: If a Valve is OFF (Closed) then it would be displayed as RED in colour, if the Valve were ON (Open) then it would be GREEN this is the same for Motors, Pipes, Pumps etc.
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SCADA TERMS - 2
* Bitmap and Text Based objects can all have Size, Position, Rotation, Slider, Keyboard and Mouse input and access, controlling their dynamic properties. * Active X objects are supported * Auto resize for different resolutions * Synchronous flashing colours * Fast display of pages * Unlimited number of graphic pages.
Typical Graphic Dynamic Screen
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TRENDS Trends are graph displays of process parameters such as - Temperatures, Pressure Levels, Speed. * Graphical representation of the process feedback - Speed - Temperature - Pressures etc * Printouts * Dynamic selection of Trend Pens for displaying the graphs * Zooming into trend periods Time and Date * Exporting Trend Data CSV (Comma Separated Value), ASCII files * X/Y Plot capability * Periodic and Event created graphical trends
Typical Trend Screen
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SCADA TERMS 3
APPLICATION LANGUAGES While Scada's are graphical displays, Data Monitoring and storage of the process parameters, you can create programs that are triggered upon some event in the process, or the calculation of a value such as changing Degrees Fahrenheit to Degrees Centigrade etc, these programs are called Scripts which you create within the Scada However while a SCADA has the capability to make decisions such as if TAG1 temperature is Greater than 100'C the SCADA must NEVER CONTROL THE PROCESS this is the role of the PLC NEVER the SCADA, the reason is that the PLC is more reliable than the Scada PC and its role is Process Control NOT the SCADA. Scripts and what they can do: Bespoke language created by the Scada Developer such as Siemens, Citect etc V Programming languages such as - VBA Visual Basic or C language They have the ability to interact Indirectly or Directly with Tags (IO) Can undertake Full Mathematical and Boolean functions String manipulations IF - THEN - DO - ELSE - WHILE commands
DATA ACCESS Scada can interact with other MS applications other Data Bases, retrieving information and transferring process data into these other applications, example a company manager may wish to have displayed on his desktop PC production data such as Items Produced, which machines are running and stopped, the Scada can transfer this information into MS Excel or Word or other packages.
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* Network DDE (Dynamic Data Exchange) with any Windows application MS Word, Excel, Access DB, allowing the applications to display Scada data in real time. * OPC Object Link and Embedding for Process control
REPORTS Reports are valuable printouts in sheet form that can be sent to managers to determine how manufacturing is progressing. The Scada programmer configures the Report layout and sets the Trigger signals from the PLC or Time triggered from the printouts to occur. * Display via Screen or Printout * Time Date triggered * Alarms and Trends can be added to reports
SECURITY
Scada is a very important and critical component of the manufacturing process, as many types of people may have access we have to ensure that any access to the Scada screens and controls are protected against unauthorized operation. Basic operators may have VIEW ONLY rights, whereas Engineers may have several levels allowing some engineers to alter set parameters and others can only Start and Stop certain areas or Acknowledge Alarms when they occur or View only some screens. Security can be setup by the Scada Designer over several levels HMI verses SCADA
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DEVELOPMENT & RUNTIME Scada is provided in two packages * Development software - This is the Design & Development software that also can run the Application, as a designer you must have the Development software. * Runtime software This is cheaper than the Development software and is used by the end user to Run the designed product. No design of the application can be configured from this software. You use the runtime environment to control and monitor your plant. You must tailor the runtime system to suit your requirements, using the configuration tools. After configuring your project with the DEVELOPMENT software, they must be compiled to build your Runtime system. It is at Runtime when the SCADA will communicate with your I/O devices, process alarms, animate levels and symbols, and so on. The Runtime system is the graphical interface (of your design) that you use to control and monitor your plant.
DONGLES & TOKENS
The License whose value is dependent upon the number of TAGS required from your design and can cost from 400 ($750 USD) to several thousand. Dongles carry the Development or Runtime License; therefore
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the Runtime Dongle will be cheaper than the Development Dongle. A Dongle is a Hardware connector that is usually plugged into the PC Printer Port at the rear of the PC, the Token is a software code that is installed into the PC from a Disk, and usually this is HIDDEN to prevent copying. The Dongle is better than a Token; this is because Tokens are software codes that can be accidentally lost due to DeFrag of the PC Hard Drive - Formatting - or Anti Virus applications that believe it is a virus.
Dongle this is SAFER than a Token, which can be easily lost due to PC malfunction or Defragging.
CLIENT SERVER The Client Server arrangement allows terminals to be networked. The Server is the MAIN terminal where all Data is stored; the Client is a Display Terminal that displays the Data stored on the Server.
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It is not always necessary to have Client / Servers, the arrangement depends upon the application. However you will find in large Process Control applications such as Oil/Gas Refineries, Automotive companies that Many Scada's will be used and Client / Server is normal. When using Client / Servers, the Development software would be installed in the Server, as this is the main terminal. The Client terminals will use the Runtime software and Runtime Dongles which are cheaper.
The Client terminals will run the same designed Scada application as used in the Server; however some Server screens may be disabled as they are not required at the Client
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SCADA TERMS 5
TAGS This is the term for Scada IO (Input and Outputs), each Tag is addressed to a BIT or Data Register in the PLC. The user pays for IO Tags ranging from 100-600-1000-unlimited.
TEMPLATES These allow the developer to create screens with common features, they can then be stored in a Library and the developer can use the Template to provide a consistent appearance in the Scada application.
OBJECTS These are Buttons Lamps - Graphs etc, everything you see on a Scada screen can be an object, even a simple square of a few milli-metres in size can be Mouse Clicked to start a Motor or Display the Motor status by changing the squares colours.
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Above we see many objects; the START button when clicked opens the Properties Dialogue. In the Properties the designer can setup triggers that will run coded commands. In the above example we can see that when the Button is DOWN (Pressed) a small software routine is initiated. IF Motor1Speed = 0 Then Motor1=1; Else End Both Motor1Speed and Motor1 are TAGs that have been created in the Scada Tag configurator, these are addressed to DATA and BIT locations in the PLC Memory. Motor1Speed this could be assigned to a Data Register D1000, the value in the register could reflect the SPEED of the Motor. Motor1 this is a Boolean value and therefore assigned to a BIT address, so that when the BIT is ON then Motor1 will start.
GENIES These allow the developer to create Dynamic Objects such as Valves that change colour depending upon their state. Example:* RED - VALVE OFF / CLOSED * GREEN - VALVE ON / OPEN * FLASHING RED - VALVE CLOSING * FLASHING GREEN - VALVE OPENING
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The image shown above show several Genies, the MOTOR
, AUGER
, AGITATOR
all
are created as a Genie, when you double click the Genie a Dialogue appears allowing you to enter the TAG name that the Genie will use, example using the Motor Genie allows you to use this OBJECT as many times as you wish in your SCADA Design, assigning each MOTOR Genie to a Tag, so that when each Motor
turns ON the MOTOR Genie changes to GREEN and when each MOTOR turns OFF the Genie will turn RED, this allows you to rapidly create Scada Screens displaying many MOTORS, each one looking the same, but reacting only to the assigned Motor Tag.
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SCADA TERMS 6
ALARMS These are Logged similar to Trend data. When an Alarm is triggered the Alarm must be Acknowledge. The reason is to ensure Operator or Engineers are aware that the Alarm exists, the Acknowledgment of any alarm is Time stamped to see when the operator was aware of the problem. To Acknowledge an Alarm the operator / engineer can either touch the Alarm Banner message, Mouse Left Click the message line or press a configured ACK Button. (ACK - Acknowledge) * Active Alarm Red * Active & Acknowledged Yellow * Non Active and Non Acknowledged White * Non Active and Acknowledged - Cleared from list (An Alarm that has been rectified)
CONFIGURATION ENVIRONMENT
The configuration environment consists of tools (applications) used to build the Runtime system (The Finished Application). The configuration environment is centered around an Explorer environment, which is used to create and manage your projects. The Projects are used to structure your configuration data into logical, well organized, groups. You can design your system to use one or more Projects at a time, depending on the modularity of your plant or system. Below is the MX4 environment, similar to MS Explorer, we will look further at this shortly
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EXERCISE 2
1. Explain briefly what is meant by Configuring the Scada? 2. What is special about an Alarm Banner? 3. What is a Trend used for? 4. Lamps, Buttons etc are referred to as What? 5. If a Valve or Pipe is GREEN what does that tell us? 6. What is a Script? 7. What is a Template used for? 8. If an Alarm occurs what colour would we normally set this to> 9. What is Acknowledging used for? 10. What does DDE stand for?
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SCADA ADDRESSING
Scada addressing is termed TAGS that refers to IO - Inputs and Outputs of the PLC, also the PLC internal Bits and Data Registers can all be assigned to TAGS. * Scada packages are supplied with several hundred and thousand Tags, each level has a cost value that the user must pay. 100 Tags can cost 300 ($500 USD), 500 Tags 700 ($1300 USD) and Several Thousand Tags (UnLimited) can cost 2000+ ($3500+ USD).
* Each BIT address in a PLC can be assigned to 1 TAG, therefore you can see this can be quite expensive. PLC Data Registers are also assigned to Tags. HOWEVER Scada engineers are creative and assign PLC Bits to Data Registers - WHY? this is because each Data Register as we know has 16 BITS, therefore by assigning example 0.00 to 0.15 on and OMRON PLC IO Card to Data Register example D100, allows 1 Tag to monitor 16 of the IO of that Card by assigning D100 as one Tag.
Above is an example of a tag. Name is a Convention used for this project W1 = Winch1, SPD = Speed, HI = High Limit
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Data Type DIGITAL = BIT address Address M562 is a general Bit address for a Mitsubishi PLC IO Device is a Driver used for Communications Comment and simple description
Data Type shows that this is an INTEGER value Address D1505 is the PLC Data Register (Mitsubishi PLC) RAW Zero and Full scale are the PLC Data Register range values fed back from the process sensors ENG Zero and Full scale is what the SCADA has to convert these value to and Display them. The values show no difference, therefore whatever the D1505 register is would be shown by the Scada, if D1505 = 500 then the SCADA would Display 500. Example if we were monitoring the weight of a material storage Silo via a LOAD CELL with a feedback signal 4-20mA, the maximum RAW values fed back in the PLC would be shown in the PLC as 4000 for 20mA and the minimum would be 0 (zero) for 4mA. These fed back values refer to 4mA = 0 Units = 0 TONNES and 20mA = 4000 units = 1000 TONNES of material.
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Therefore we could set the Engineering Units to 0-1000
DESIGN CONSIDERATIONS
The first and most important step in any system development is design. Good design ensures that your system: Performs the control and monitoring tasks that are required. Is implemented with minimal interruption to the application. Achieves the best possible performance. Poor design often results in substantial rework, major disruption to the organization, poor performance, or all three. With SCADA you can easily configure a system to do whatever you want; there are no restrictions on how your system will operate, or how your operators will interact with it.
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Some issues to consider are: How the plant is graphically represented to the operator. How the operator navigates the system. What plant-floor data will be displayed on the screen. What operator controls are required and where they are presented on the page. What plant conditions need to be monitored for alarm conditions. What data logging is required for maintenance and performance monitoring purposes. What reports management will require. What level of security (if any) is required in the runtime system.
USING OTHER DATABASE EDITORS All SCADA databases are stored on disk in a standard dBASE format. You can therefore edit any SCADA database using any database editor that reads dBASE files (e.g., Access, dBASE, Clipper, or FoxPro). When using other database editors, remember the following: 1. All key fields must be uppercase. The SCADA compiler only recognizes upper case key fields. 2. You can add or change (expand or reduce) fields in a SCADA database, but you must not remove existing fields, or problems might occur during compilation. 3. Some databases are indexed. If you add new records or edit the index key field, the index must be rebuilt. The easiest way to do this is to pack the database in the Project Editor after editing. Packing the database deletes all records marked for deletion, and re-indexes all the databases. 4. The majority of SCADA database fields are left-justified. Make sure that any key fields entered by another database editor are also left-justified. 5. SCADA databases only support string data types. 6. Be careful when adding records to the page animation records, such as numbers, colors, strings, buttons, and so on. These databases are linked into the background graphic image; only add records to a page database where the AN already exists. (If an AN does not exist, the record is deleted when the page is edited.) 7. You should Pack the Scada database regularly if you have been deleting or editing the Variables database file using third-party database editors (such as Microsoft Excel).
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SPECIAL CONSIDERATIONS FOR USING MICROSOFT EXCEL When using Excel, you cannot change the width of the fields: all the fields are truncated to the new size, effectively destroying the entire database. In addition, if Excel finds only numbers in a field, it tries to change the type of the field into the number format, also destroying the database.
PROJECT DESIGN STANDARDS Design standards promote consistency and clarity. Consistency and clarity reduce your development time, and reduce the time that your operators need to learn your system. You should, for instance, choose a common screen location for all control buttons of a certain type, keyboard keys that always perform the same operation, and standard colours for displaying similar types of information (e.g. alarms). Naming standards are recommended throughout your configuration, use a naming convention for pages, alarms, commands (and all database records). A standard naming convention can:
Reduce database search time. Reduce data entry. Reduce time and effort when configuring future changes and enhancements. There are many conventions you can use to standardize the names of your database records. The most common method is to include as much (abbreviated) information as possible in the name (up to 16 characters, 79 for variable tag names). For instance, you can include the area and the process, or the machine and the device with which the record is associated.
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Example: Abbreviate the Name of a TAG. If you were working on an OIL Refinery or Rig there may be several hundred Valves and Pumps therefore a simple naming convention could be utilized. V1_STB_OPEN, This could be the OPEN command for Valve1 on the Starboard side of a RIG V1_STB_OPENED, This could be the signal that tells you the Valve is fully opened P1_START, The Start signal to Pump1 Notice the use of _ to divide the name into words, this is far better than V1STBOPENED, at a glance it is difficult to read. On some systems engineers prefer to add the Address in the PLC V1_STB_OPEN_M200, address M200 in a Mitsubishi PLC V1_STB_OPENED_X10F, input address on a Mitsubishi IO card that is ON when the valve is fully opened, a Feedback signal.
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P1_START_M205, note the M address is used again, M addressing in Mitsubishi is for the Internal Bit addressing, you would tend to use these or other internal bits for other PLC makes rather than Directly addressing to OUTPUTS. Example: X01 | M205 ---| |-------| Y110 ---| |-------Above we can se that to START the Pump you can either Press an external Push Button wired to Input X01 OR Initiate a START Signal via a SCADA Button that is linked to a TAG addressed to M205 When Button DOWN, Command = P1_START_M205 = 1 | | X02 M206
---| |----------------|/|---------|/|------O Y110 Output to Pump on Mitsubishi Rack
As we know the above design would Latch ON the Pump, to STOP the pump we could either push the push button wired to input address X02 OR Initiate a STOP Signal via a SCADA Button that is linked to a TAG addressed to M206 When Button DOWN, Command = P1_STOP_M206 = 1
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NOTE: It is important to know that when you use such commands that when you mouse click the Button on the SCADA screen then Button WILL depress and the code P1_START_M205 = 1 will SET the value inside of M205 THEREFORE the UP command in this design must look like BELOW:
THEREFORE - when the START button is mouse clicked - depressed M205 turns to Logic 1 - ON THEN - when the START button is released M205 turns to Logic 0 - OFF
THEREFORE acting like a real electrical push button.
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QUESTION WHAT WOULD YOU DO TO THE COMMANDS FOR THE SCADA STOP BUTTON AND WHY. Email your answer to your Course Tutor.
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INSTALLING MX4
INSTALLATION Installation runs on Windows 2000, XP Home or Professional, Vista Home Premium or Professional
To install MX4 on a PC follow the procedure below. Open the MX4 folder and RUN (Double Click) the SETUP file application.
Allow it to install into the Default - Program Files directory on your C Drive. After several minutes it will prompt you to RESTART your PC. When you have restarted you can then RUN the application.
RUNNING Inside the Melsoft folder is the MX4 Scada folder, this shows 2 IMPORTANT files - Explorer & RunTime
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EXPLORER This is the configuration application, which you use to create your SCADA application. This is for the designer ONLY. SELECT the EXPLORER icon when you the designer wishes to RUN MX4 - NOT the RunTime. IMPORTANT - MS VISTA users ONLY to RUN MX4 Explorer, ALWAYS RIGHT MOUSE click and Select RUN as ADMINISTRATOR
RUNTIME When an engineer finishes creating a SCADA application for a customer, the RUNTIME application is usually placed in the PC StartUp folder, so that when the PC Boots, the RUNTIME application runs and LOADS the the designed SCADA application. RunTime applications allow the USER to RUN, VIEW and CONTROL the Scada design - BUT NOT modify the design or create new screens. SCADA packages can be bought as either CONFIGURATION, allowing you to DESIGN and setup the clients PLC when the design is finished OR as RUNTIME only, which are cheaper to purchase than the CONFIGURATION software.
Many end users sometimes have multiple SCADA PCs, it is impractical to purchase multiple copies of the CONFIGURATION software as this could cost many thousands of dollars, therefore you will find in large companies, only a handful of CONFIGURATION packages, but many copies of RUNTIME Only.
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RUNNING MX4
CITECT EXPLORER When you run MX4 Explorer the following screen will appear.
The left sidebar is the Project TREE, here there is an Example Project. The Work area on the Right show the Folders that will contain the Graphic screens that you create, also Templates, Communication setup, Addressing data TAGS, Alarm setup, and Program Scripting. These are explained in the course TOPIC - MX4 Explorer.
EXPANDING THE PROJECT
Click the + sign next to the Example folder and it will expand, do the same for Graphics folder and then Click on Pages.
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In this example supplied by CITECT, every file after Create New Page is a SCREEN design. Double click the following screens - DO NOT MOVE OR ALTER ANY OBJECTS - VIEW THEM ONLY, THESE ARE IN DESIGN MODE AND WILL NOT YET RUN. EACH SCREEN REPRESENTS THE PLANT THAT IT IS MONITORING AND THE PLC CONTROLLING.
ACTIVE X Control meters that have been created as Active X objects.
GENIES A selection of some genies that have been created, each object is dynamically controlled when addressed and connected to a PLC. NOTE this is NOT how a screen would look in a real Scada project, you have to be professional in your designs.
ALARM This is Citect Alarm Page, there is nothing to look at, however the screen has hidden Cicode Functions that are triggered when an alarm occurs in the PLC.
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ZOOM TREND Two Trend Objects, showing multiple controls and read out display windows. CONTINUED NEXT page.
INSIDE MX4
EXPANDING THE PROJECT
FILTER An example of a Graphic screen, this would become dynamic (Moving and Colour changing) when ran from a programmed PLC.
LOOPPAGE These are Bar Graph controls with Sliders and dynamic readouts and a moveable bar up and down to represent the feedback value to the PLC from the process.
RECIPE This shows several Silos whose contents would be MIXED into one large Silo. THESE ARE ALL EXAMPLES ONLY OF A PROCESS BEING MONITORED.
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CICODE Click on the Cicode Files Folder in the Project TREE. Then double click EXAMPLE in the work area. This is CICODE STRING FUNCTION FormSelectHistoryFile( STRING sFile) INT i; INT iTime; INT iFile; INT iOffset; STRING STRING sBuf; sText;
FormNew("@(Select History File)", 50, 9, 1); IF FileExist( sFile) THEN sBuf = sFile + " END FormListBox(0,0,50,8, sBuf, 0); FOR i = 1 TO 999 DO sFile = StrLeft( sFile, StrLength(sFile)-3); !Strip extension sFile = sFile + i:#0#; IF FileExist(sFile) THEN sText = sFile + " END END FormButton(8, 8, "@(OK,12,C)", 0, 1); " + TimeToStr(FileTime(sFile), 4); FormAddList(sText); !Add extension " + TimeToStr(FileTime(sFile), 4);
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FormButton(30, 8, "@(Cancel,12,C)", 0, 2);
DO NOT WORRY about its complexity, this code was written by Citect and will actually make this example DYNAMIC when we run the design later.
However SCADA design Engineers have to be proficient in this type of programming and also VB Visual Basic, C language. It takes time to learn these but it is necessary to become a professional Systems Integrator (PLC & Scada designer). On this course we will not be doing CiCode that is for later as you develop your Scada skills.
RUNNING THE PROJECT 1
TOOLBAR At the top of MX4 is a Toolbar.
Working LEFT to RIGHT the important tool buttons are:-
The Combo Box drop down is the Project List, we only have one project, but designers may be working on several MX4 projects and therefore the Project TREE would display the Project List.
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NEW PROJECT
RUN THE SELECTED PROJECT
PROJECT EDITOR USED WHEN CREATING GENIES
GRAPHICS BUILDER USED WHEN CREATING SCREENS
CICODE EDITOR
COMPUTER SETUP ALLOWS SPECIFIC SCREEN TO START WHEN THE SCADA RUNS, ALLOWS THE SETTING OF TERMINAL SETTINGS AND ACTIVATION OF SCRIPTS WHEN THE APPLICATION RUNS.
BACKUP & RESTORE, WHEN YOU SEND YOUR WORK TO A CLIENT VIA EMAIL YOU USE BACKUP TO COMPRESS YOUR MX4 PROJECT INTO 1 FILE, ANY PROJECTS CAN BE RETURNED TO YOU AND RESTORED FOR MODIFICATIONS. ALSO RESTORE ALLOWS OTHER PROJECTS DESIGNED BY OTHER ENGINEERS TO BE SENT TO YOU SO THAT YOU CAN OPEN THEM.
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RUN
Click ONCE the RUN Button
DEMO MODE
A WARNING message will appear.
This is only warning you that no protection key is found and so it will RUN in DEMO mode lasting approx 30 minutes, however this is a demo package so you will get more from the Example project, this is normal for all SCADA makes, without a License - DONGLE or TOKEN the Scada will only run in DEMO mode, you can interact with the design and it will communicate with a PLC but only for a limited time period.
CLICK OK
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This is the Scada application designed by another engineer, it is only an example on how it can appear.
REMEMBER that all SCADAs are Terminals that display the Manufacturing Process, the PLC CONTROLS the process and passes the Process Data to the Scada to be displayed - the SCADA DOES NOT CONTROL A PROCESS.
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You will see at the top of the display screen a FLASHING alarm clock, this is a symbol this engineer has selected to show there is an ACTIVE ALARM, at the bottom of the screen is the MOST RECENT alarm shown in what we call an ALARM BANNER.
RUN
Mouse click the ALARM CLOCK once and the ALARM PAGE will appear.
Left Mouse Click the Topmost Alarm and see it disappear, this is what is called ACKNOWLEDGING alarms.
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ALARM ACTIVE When an alarm occurs in this design it will appear BRIGHT YELLOW and be shown as ON.
ALARM NON ACTIVE AND NOT ACKNOWLEDGED When the alarm in the Process has been rectified the alarm message will turn a DULL YELLOW
ALARM NON ACTIVE AND ACKNOWLEDGED When the alarm in the Process has been rectified and ACKNOWLEDGED it will disappear from the list. Watch the Alarm Display for a while - the CiCode demo is running a test program and you may see alarms appear, TRY Acknowledging some alarms ACTIVE and NON Active and see what happens. ALL ALARMS ARE BEING STORED ON YOUR HARD DRIVE IN WHAT IS CALLED AND - ALARM LOG.
GROUPS From the GENERAL MENU at the top of MX4 select GROUPS screen, click the RUN Demo button bottom right. This shows the DYNAMIC capability of a SCADA. Scada Designers creativity can create virtually anything they wish to provide an eye catching screen, however showing a truck move up and down is a gimmick and would never be done in professional circles.
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Click on the GAUGES and HOLD Left Mouse button and you can DRAG the Pointer to any position you wish, see how the Crane moves as you do this. Left click the CABLE RED button and Move the claw up and down.
GENIES Open the Genies screen, left mouse click the right hand BREAKER. Try the SWITCH.
CICODE VBA Open this screen and when you activate the buttons VBA scripts are activated and show temperature changing etc. Remember this example is only displaying the power available to you when using a SCADA. In real applications the PLC does all the CONTROL, this is for SAFETY purposes, if a SCADA failed due to computer fault or communications cabling was broken or disconnected, the PLC maintains CONTROL OF THE PROCESS.
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TREND SCREEN Open the SINGLE TREND screen from the TREND menu. This screen is displaying data from the example process.
Click the Top Right button shown at the bottom of the Trend screen, and change the Time Span to 5 minutes, the Trend screen will change to show the data variations over a 5 minute time span, try 1 minute. To alter simply left click inside the time displayed period and backspace out whatever minutes are showing and type in 01 - Displaying HRS:MIN:SEC Use the quick change buttons 1HR 2HR and 8HR.
Press <- to backspace the time period and re-write a custom period. Remember the format must be 00:00:00. Scada applications all use Trends, providing operators and engineers with valuable process data, which is stored historically on the PC hard Drive. Therefore process data can be displayed from several days or weeks ago, showing how the process was reacting at that point in time. We will create some trends later in the course.
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CREATING A SCADA
SCADA PROJECT ELEMENTS A CitectSCADA project consists of three major elements illustrated below:
Graphics pages, which you view on your computer screen, display the status or condition of the plant. Graphics pages can also contain controls and command buttons that enable an operator to control plant processes. Databases store configuration information about the plant that is used by the runtime system to control and monitor the plant. Some databases are linked to specific graphics pages. Cicode IS Citect's own SCRIPTING Language, the Cicode files store your custom Cicode functions that you create. Cicode is used to perform commands and actions and extend the functionality of your system. All Scada makes have the ability to use Scripting, the writing of software code that would interact with the graphics and data storage based upon signalling from the PLC and PC. Writing code in VB (Visual Basic), C Language (Used by Siemens Scada software WinCC) is also allowed. All CitectSCADA projects are created, selected, opened, closed, deleted, linked to, and have their properties edited from within the Citect Explorer.
CONFIGURING A PROJECT
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Install your copy of MX4 Demo. To configure a CitectSCADA project, you need to do the following: 1. Create the project using the Citect Explorer. Once you have created your project, back it up regularly to minimize the amount of data you'd lose if you have a problem (such as hard disk failure). 2. Set up communication with a device by following the steps given in the I/O device setup procedure. Often, the details of communication are not known when first creating a project, in which case a dummy I/O device can be used, defined as a memory device. 3. Define the data that CitectSCADA needs to read, write and use, by defining variable tags. If you adopt a structured tagging convention, you can define most of your variable tags without knowing the physical address. 4. Create your graphics pages using the Graphics Builder. Once you have created the basic pages, you can add the graphic objects for indication and user interaction. 5. Configure any features that are not page-based in the Project Editor. This includes alarms, reporting, events, logging, and so on. 6. Create and write custom Cicode functions using the Cicode Editor. These steps are listed in a logical order, but not necessarily in the order that you must follow. For example, you'll probably develop your Cicode at the same time as the pages, reports, and so on. Before doing any of these steps first consider your requirements and design your system.
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MX4 CONFIGURATION
CREATING A NEW PROJECT You will need MX4 Scada installed on your PC or Laptop and then Run MX4. 1. Start Citect Explorer. 2. Click the New Project button, or choose File | New Project. 3. Complete the New Project dialog box. You must at least complete the Name field. 4. Click OK to create the project, or Cancel.
Name YOUR project TestProject No Description is necessary The Location is where MX4 will store your project, make a note on where the projects are stored, this may vary depending upon your computer, Ensure Template Style is set to - Standard and Template Resolution is set to SXGA. SXGA is the high resolution setting for modern PC's. Ensure Show Template Title Bar is UNCHECKED Finally set the Background colour to a Light Grey colour.
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Name A unique name for the project. The project name is restricted to 64 characters. It can contain any characters other than the semi-colon (;) or the single quote ('). Since the project name is a unique identifier, CitectSCADA does not permit you to create or restore a project with the same name.
Description A description of the project. This field is useful for giving an explanation of the role of the project. You are urged to complete this field.
Location The directory path where the project files are stored. As the Name field is entered, the directory is automatically generated in the Location field. You can override this by manually entering the location or clicking Browse.
[Page defaults] template style The style (appearance) of the graphics pages in the runtime system. The style you select is the default style for any new pages you add to the project. You can change the style of existing pages and templates using the Page Properties, accessed through the Graphics Builder. Most users prefer the Standard style. You can view the pre-defined styles by looking in the Include project under Graphics, Templates.
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[Page defaults] Template resolution The default screen resolution of the standard graphics pages (such as alarms pages and standard trend pages):
[Page defaults] Show template title bar Determines whether the Windows title bar displays (at the top of each graphics page). The title bar contains the title of the window, maximize, minimize and close buttons (at the right hand end of the title bar), and the control menu button (at the left hand end of the title bar). To display a page in full screen (without a title bar), the size of the page must be the same size as the display (or larger). If the page is smaller than the display, the title bar still displays, even if full screen mode is enabled. Standard templates styles are available for both page sizes.
[Page defaults] Background colour The colour that will display in the background of all new graphics pages.
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CLICK OK BUTTON WHEN FINISHED SETUP MX4 EXPLORER
EXPLORER Creating a Scada project is more complicated that creating a PLC project. Similar to MS Windows Explorer, Citect MX4 shows the Scada Project as several folders.
This is the Project TREE.
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Description of each folder is below.
Graphics: Pages - Screen designs storage folder. Where all your created display screens are stored. Templates - To ensure all the screens follow the same layout, we create Templates and use these as the basis of a consistent layout. It is important when designing a Scada that you provide a consistent and easy to use screen layout, this ensures operators become familiar with common controls such as [FAULT RESET] buttons, [LOGIN] for Username, [TIME & DATE], [MAIN MENU] button and Navigation to allow the operator to switch between screens. Symbols - Graphic data, customised shapes that you create, such as customised Valves, Switches, Pipes etc. Genies - Customised Dynamic Objects Super Genies - Further advanced Dynamics
Tags: The term given to IO addressing, SCADA do not refer to General BITS , Data Registers or Input/Output, all are called TAGS and there are several types. Variable Tags - PLC and Internal Computer variables - PLC IO addressing Bit addressing and Data Registers Trend Tags - The PLC IO addressing to be monitored in Graph style Trends Alarm Tags - The PLC Alarm Bit addressing and Descriptions
Alarms: Alarm Handling setup
System: Scada setup
Communications: Drivers and Comm Port settings between the Scada Terminal (PC) and the PLC, this all has to be setup to enable the Scada terminal to communicate with the PLC or PLCs, a Scada can communicate with many
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PLCs, such as a DCS system (Distributed Control System), power generation at Airports, Power Stations etc. The Data shown on the screens can be form many areas of the plant.
CiCode Files: MX4 Bespoke Scripts - advanced program routines that can be created to run inside the Scada
Citect VBA Files: VBA Visual Basic Application Language - advanced program routines that can be created to run inside the Scada CiCode and VBA scripts can be triggered from Screen Buttons, or signals from the PLC, and can also be set to trigger at set times and dates. The scripts could be to transfer Data Readings from the plant to the PC Hard drive, moving Trend Data from the Scada Trend folder to a backup location on another storage device, we can also use scripts to allow the operator to view 1 screen with a Bar Graph and transfer SILO readings from several SILOS one at a time at the press of a button.
Left shows a created Genie that displays the Level settings for a SILO Tank. The HIHI and LOLO would be alarm levels for the Tank, while HI and LO would be the Max and Min settings for the material in the Tank. The engineer would click the RED SLIDER button and move it to the required level.
<---- SLIDER
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The RED Bar is a Bar Graph that dynamically moves up and down as material level changes.
This area is the engineer settings shown as a Percentage 0 - 100, also the RED would be the actual material level in the tank. Note these readings would be calculated by the PLC not the Scada.
TEMPLATE - 1
CREATING A PAGE TEMPLATE Expand your TestProject folder in MX4 Explorer.
Click on the Graphics folder and open the Templates folder.
Double click Create New template
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The following Dialogue will appear.
Select Standard Blank Resolution XGA for 1024 * 800 for laptop or Low Resolution PC screens. For our test project we will keep it simple, NORMALLY WE WOULD SELECT SXGA FOR MAX RES 1280*1024 The new page will appear, the page will have a Hatch appearance - diagonal lines The Hatch appearance tells us this is a window where all our created pages can be created.
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Select File Menu and Save-As Template01. Ensure the Title Bar is UnChecked. IMPORTANT: Title Bar is the standard Windows Title whenever you run an application the Title Bar is shown at the TOP, this also has the MIN and Close buttons. When you design a SCADA we never show these, Scada projects must never allow a general user the ability to Close a running application or resize the screen, we use special commands that are security protected to do this.
YOU WILL BE PROMPTED TO CREATE A NEW STYLE - call it BASIC
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TEMPLATE - 2
SAVING THE TEMPLATE
Call the STYLE - Basic and then click OK - You will be prompted to Update Pages using this Template - What this means is that if you had created several pages, and then modified the Template you would have to reopen each page using that Template and Save them again to update the DATABASE.
Next - Look again at MX4 Explorer and Re-Open the TEMPLATES folder (To Refresh and see the new folder Click Pages and then Doulble Click Templates- open Basic and XGA and in here you will find your first Template.
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TEMPLATE 3
ADDING OBJECTS TO THE TEMPLATE Let us now add some objects to our Template that we wish to appear in all the pages that will use this Template.
Double Click Template01.
You will see a VERTICAL line running down the Right of the Template, this is the MAXIMUM right of the Template.
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All objects must be placed from the Left of the window to this Vertical Line. We will add a PANEL and the Top and Bottom of the Template screen, this will be where we will add control objects.
Select OBJECTS Menu RECTANGLE
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Draw a Rectangle on the screen - another Dialogue will appear - Rectangle Properties. We will now change the Rectangle Properties to change the Rectangle to a 3D Panel.
Change LINE COLOUR to NONE, this looks like a X - Bottom Left Corner
Click the FILLED checkbox and set the FILL Colour to Light Grey - 3rd down top right.
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TEMPLATE - 4
ADDING OBJECTS TO THE TEMPLATE
Now let us change the Rectangle to a 3D Object>
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Click 3D Effects TAB on the Right of the Rectangle Properties dialogue.
Select Effects - Raised.
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DO NOT CHANGE THE COLOURS.
CLICK OK.
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Our simple Rectangle now appears as a 3D PANEL. NOTE the small squares around the Panel, these are called HANDLES, mouse click a Handle and you can resize the Object.
Click inside the object and position the Panel to the TOP LEFT off the template window, then mouse click the RIGHT side MIDDLE Handle and expand the Panel by Dragging to the Right side vertical Line. This will show the Panel at the top of the Template screen from Left to Right.
Look at the Bottom of the Template screen and you will see the Coordinates and Dimensions of the Panel.
1025 is the width in PIXELS, set the height to 70 PIXELS. (The other coordinates are your Mouse position) Pixels are the small dots that make up the screen of your PC Monitor. NEXT CLICK ON THE PANEL AND PRESS KEYBOARD - CTRL C
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This is MS Command COPY, now click Keyboard CTRL V for PASTE, a second panel will appear, click on the panel and MOVE it to the BOTTOM of the Template window, ENSURE you are at the BOTTOM, check your Right Scroll Bar
NOW WE SHOULD HAVE ONE PANEL AT THE TOP AND OTHER AT THE BOTTOM SAVE YOUR TEMPLATE - FILE SAVE OR CLICK THE FLOPPY DISK BUTTON. ADDING OBJECTS TO THE TEMPLATE Let us now create a SHUTDOWN button. As we stated earlier a real SCADA project does not have standard MS Windows controls, we never display these, if we did then an operator could accidentally shutdown the Scada Application. So we create our own SHUTDOWN controls, we will place this control on our Template01 screen. Select Object Menu - Button Draw a Button on the Template screen and size the button approx 100 width 40 height.
Double click the Button, on the right General Tab set the TEXT to Shutdown.
Next Click the Input Tab at the Top, INPUT allows us to write commands into the Button Object, with all Scadas we create many Buttons, each with their own set of commands. Click the Down Action and Type in the command Shutdown() - this is a CiCode Function that will shutdown the Scada application.
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Click OK.
Place your Button in the Top Panel Right hand side.
Save the Template and Close the template window.
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CREATE FIRST PAGE

In MX4 Explorer click the Pages folder, then click Create New Page.
A Use Template Dialogue will appear, this allows us to select a Template to base the page upon, we will use our Template01. In the Dialogue select: Style - Basic Uncheck - Title Bar Resolution - XGA
Your Template01 should appear.
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Select Template01 and Click OK. A NEW PAGE will appear, this time you will see that Template01 also appears, there are NO Hatch lines. If you Double Click the Shutdown Button a WARNING message will appear telling you this is a Static Symbol for Template01. You cannot alter Template properties or design within a normal Scada screen Page, you can only do this from the Template. Next - Let us ADD a Page Title to the page - in Scada Designs ALL pages should have Page Titles, these tell the Operators and Engineers what the page is that they are looking at.
Select Object Menu - Text. Unlike other objects NOTHING appears simple type - MAIN PAGE and you will see this appear, place the Text object in the TOP Panel of the Page where the Template is in the Centre.
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Let us change this to 3D Text - Double click the Text Object - Set the FONT SIZE to 16 point and BOLD, set the Colour to a Dark Blue and Set 3D Effects via the 3D Effects Tab to Raised.
Next File Save-As Main01 - ensure you have the TestProject selected. Click OK
Back to MX4 Explorer and Click on another folder and then back to Pages and you will see your Main01 page in the work window next to Create New Page.
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TEST YOUR PROJECT

Click the TOOLBAR button at the top of MX4, this will RUN our project. You may get a WARNING that No Device Drivers are selected, ignore this at this stage. A window will appear showing your whole project.
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RUN YOUR PROJECT Click Main01. Your Main01 Page will now appear, depending upon your PC Resolution it may appear NOT full screen, this is because we set the screen to XGA for Laptops and PCs with low resolution, normally we would set the project to SXGA for 1280 * 1024 screens. Now you will see your Scada Project actually Running - Click the Shutdown button and the shutdown Command will shutdown the application.
YOU HAVE NOW CREATED YOUR FIRST WORKING SCADA SCREEN DRIVERS & IO SERVER
All Scadas require setting up to run on a PC or IPC, this ensures that when the Scada design runs, the design takes over the Windows environment and prevents operators and engineers from closing the application and more importantly prevent them from using the terminal for running some other application such as Playing Movies and/or Games. We also have to configure the Scada to enable it to communicate with the PLCs, this is done via Drivers and Communication settings.
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To be able to make Scada operational you have to install drivers and appoint an IO Server. There are several types: Server for Data
Drivers Generic This allows you to use PC memory for Tags. PLC Type - Fx/A/Q or other makes Siemens/AB/Omron you obtain these from Scada supplier. MX Component - for Networking
Setup IO Server & Drivers
Through the MX4 Explorer select the Communications Folder.
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The simplest way to setup Communications is via the WIZARD.
Double click the Express IO Device Setup.
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Click the NEXT button.
Select Create New IO Server and Name it IOServer (all one word no gaps)
Servers are used to not only Run applications but to Store data and Files on its hard drive. It is important in all Scadas that the
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manufacturing process Data is stored on the Server. A Client has applications installed on them, and it accesses and Displays the Data stored on the Server. Both Servers and Clients communicate via Networks, usually this is Ethernet.
Select Create a New IO Device, name it PCmemory (All one word). The IO Device is where Data is Read and written to, PCmemory tells MX4 to use your PC Ram to store data, we will use this similar to General Bits - Internal Memory as used in PLCs. Later in Part 2 we will create a IO device that would communicate with a PLC. Click NEXT
Next we need to tell MX4 to allocate PCmemory to the PC Ram, check the Memory I/O Device.
Click NEXT.
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When creating Scada applications we use PC memory and PLC memory, this allows non Process data to be stored Locally on the Scada rather than on the PLC, hence saving PLC memory for more important Data.
To Finalize the IO Driver setup - Click NEXT
Ensure Link to external Tag database is unchecked, this would only be checked if Tag data was being READ from another database application - Tag data is stored in databases, ours is setup to be stored on your PC in the MX4 Folder.
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Automatic Refresh of Tags should be checked, as data changes on the manufacturing process, MX4 will automatically refresh its Database at periodic intervals. Click NEXT and then Click FINISH on the next Dialogue.
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COMPUTER SETUP
This is where we configure the Scada setup for Servers and Client displays, a Scada may consist of many terminals. Server - Main Scada Terminal used to display and stored process date, usually you would install the Scada configuration software on the Server, this allows you - the designer to modify the design as you test the designed application.
Client - Effectively a dumb terminal, it runs the designed application and displays the data that is stored on the Server, the Scada software used on the Client is usually the Runtime software ONLY, this is cheaper than the Configuration software as it does not allow the design to be altered. Note that if you wish to alter the Design of the Client application you would do this on the Server and then copy the design over to the Client terminal hard drive. To Setup the Computer we use the Wizard. In the MX4 Top Toolbar select the Computer Icon Select Custom Setup, then Click NEXT
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The Server and Display Client is what we will use, this is a stand alone Scada terminal with NO Clients. If we had several Scada Terminals we would select Server and Display Client for the Main Server terminal. If we were setting up the Client terminal we would select Display Client. Manager Client is for a designated Manager terminal where many Clients are created.
Click NEXT
Select the Project name TestProject. This tells MX4 to run this project on this terminal.
Click NEXT
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Because this PC will be the Server, ensure the This Computer is an IO Server is checked. Click NEXT
Check the This computer is an Alarm Server. In all manufacturing processes the PLC handles many Alarms 100+ is not uncommon, these Alarms in the PLC would naturally be allocated to BIT addressing. When we create a Scada we would allocate those BIT addresses to ALARM TAGS. As an alarm occurs it will be read by the sever, Time and date stamped and then stored on the Server hard drive. The Client would not be an Alarm Server
Click NEXT
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Leave these settings to their default. The Alarm scan time is the refresh period that the Scada terminal will read all the alarm tags. In most applications we should leave it at 500ms. The scan of the Scada project will be very fast, however as there are many objects and tags to be read it is impractical and inefficient scanning each one on every scan of the Scada program. Alarm scanning every 500ms is quite fast enough; this allows the Scada to divide the Tags into Groups, scanning each group at specific periods. Imagine a system with several thousand tags, if the Scada read each one in one scan the screen update would be slow as the terminal would be busy reading all the IO Tags and updating the system. Allocating different scan times allows the screens to be updated more efficiently. The Save period is when the Alarm data is saved to the terminal hard drive. Click NEXT Scada terminals can also produce Reports and save / print out each report at specific time and date periods. Reports are custom designed by the designer, each report would be important data that the customer needs to keep printed records, such as Temperatures of a process, number of produced and failed items during a shift etc. We will not create a Report so leave this unchecked.
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Click NEXT
Check this terminal as a Trend Server. Trends we will cover later, they are graphs that can be displayed, such as temperatures or Silo levels etc, this data will be saved on this terminal. Click NEXT
Check the Inhibit Trends at start-up, this would slow down the start-up of the Scada application. Click NEXT Do not check Enable Events - these are Scripts that you can create and trigger at Start up of the Scada. Click NEXT
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Check the Timer Server is the terminal where the Scada will read the current Date and Time, so we would use the Main Server PC for this. Leave the name as shown. Click NEXT
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Un-Check ALL these boxes, this will display the screens without windows title bar and prevent a shut down menu appearing. When designing a Scada we must ensure the control is protected against operators and unqualified engineers messing about with the computer.
Check the following boxes - ALT + Space allows us some windows control on our TestProject, when the Scada is running and if our design crashes then use Alt + Space to switch between MS Windows and allow us to escape.
Inhibit the PC Screen Saver; you do not want this to RUN on a Scada. The Cancel Button will appear at Start-up in case we want to prevent the Scada running, especially if we know there is a fault in the design.
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This dialogue allows us to Select the Start-up Screen, on our simple project set this to Main01. The Page scan time is similar to the Alarm scant time mentioned earlier, this will refresh each Screen (Page) every 250ms. Click NEXT and then FINISH.
The Scada Computer is now setup. As we can see configuring a Scada - Drivers, Communications and Computer is quite involved, however once the configuration is finished we would not need to do this again, unless we wish to make some changes to the settings.
TO TEST THE SETUP - CLICK THE RUN ICON
IN THE TOP TOOLBAR
THE Main01 PAGE WILL APPEAR after the application starts.
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SCADA TAGS
In MX4 Explorer select the TAGS folder and Double Click Variable Tags.
We shall now create some INTERNAL TAGS - similar to a PLC Internal General Bits, these Internal Tags will be stored and read from your hard drive. Name the first Tag - memSwitch_01 - we will use the convention mem to indicate PC memory, _01 to be the number of the Switch. Set the Data Type to DIGITAL, this is a BIT state 0 or 1 The Address et this to D1, D is MX4 for Internal Digital identifier, 1 is our first Digital address. Select the IO Device to our Pcmemory, when you create a PLC application you would have another Driver setup for the PLC. FINALLY CLICK ADD - when this is clicked the Record number at the BOTTOM will increase, this Tag is now added into the Scada Database. DO NOT CLICK REPLACE AS THIS WILL OVERWRITE THE TAG SETTING
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Next Backspace the memSwitch_01 and change to memSwitch_02, set the ADDRESS to D2 and then CLICK ADD. We have now created a second Tag to the database.
Next create another Tag and label it memLamp_01, simply BACKSPACE the name set to address D10. This jump allows us to create more switches before Lamps - CLICK ADD
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Finally we will create an internal INTEGER Tag, simply BACKSPACE out the previous name. Set the name to memLamp_01, the Data Type to INT (Integer), address I1 (i = integer) - CLICK ADD
At this point you should have 4 RECORDS in the Database. Close THE tag Dialogue. TAG ERRORS AND RECORDS CORRUPT If you have MORE than 4 then you have create a tag unnecessarily, use the Right scroll bar and check each tag to see what you have done incorrectly. If you have create a tag incorrectly press the DELETE button, IMPORTANT this will delete the TAG BUT the RECORD will still be in the Database, the MX4 Database is now CORRUPTED, to correct the database, select FILE menu PACK
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DYNAMIC PAGES
A DYNAMIC PAGE is a screen that will animate as data changes in the SCADA DATABASE, such as Lamps, Values, trends etc.
This is the floating TOOL bar, it is the shortcut to the OBJECTS Menu, press F3 if it is not visible. This allows you to Draw Lines - Rectangles - Elipse - Pipes - Buttons - Text, we will look at more of these later.
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CREATING A SWITCH ON OUR MAIN PAGE In MX4 Explorer return to Graphic Pages and double click our Main01 Page. Select OBJECTS menu and Button. Change the Button name to START Set INPUT to ACTION DOWN is checked In the Command window type - memLamp_01=1
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Next Create another BUTTON: Select OBJECTS menu and Button. Change the Button name to STOP Set INPUT to ACTION DOWN is checked In the Command window type - memLamp_01=0
CREATING A LAMP ON OUR MAIN PAGE Next Create a LAMP: Select OBJECTS menu and Elipse. Set the LINE colour to a Dark Grey Set the FILL colour to a Dark Grey Select FILL TabSet the OFF colour to BRIGHT RED Set the ON colour to BRIGHT GREEN Set the ON colour when memLamp_01=1
Your Main page can be laid out as below. SAVE the PAGE.
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RUN YOUR PROJECT CLICK THE START BUTTON AND THE LAMP SHOULD TURN GREEN CLICK THE STOP BUTTON AND THE LAMP SHOULD TURN RED
YOU HAVE NOW CREATE YOUR FIRST DYNAMIC PAGE
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GENIES
Genies are objects designed by the Scada make, all Scada makes have these.
This is the floating TOOL bar, it is the shortcut to the OBJECTS Menu, press F3 if it is not visible. This allows you to Draw Lines - Rectangles - Elipse - Pipes - Buttons - Text, we will look at more of these later.
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ADDING A GENIE Select the GENIE LAMP in the floating tool bar or from the Objects Menu.
Select the AGITATOR - Click OK Place the Agitator on the RIGHT of your buttons. Double click the Agitator and Select the Tag as memLamp_01
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Click OK
Create a Rectangular Lamp - select Rectangle and set its properties to the same as the Ellipse. Rectangle LAMP: Select OBJECTS menu and Rectangle. Set the LINE colour to a Dark Grey Set the FILL colour to a Dark Grey Select FILL TabSet the OFF colour to BRIGHT RED Set the ON colour to BRIGHT GREEN Set the ON colour when memLamp_01=1
RUN the project and see what happens when you click START and STOP. The Agitator should Rotate. And the Agitator should appear GREEN when ON and RED when OFF.
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BACKUP AND RESTORE
BACK UP Backing up a project allows us to compress the whole project into 1 file, we can then email the file to another Scada user and they will be able to open your design by using RESTORE. To backup your project, left mouse click the Project in the Explorer TREE
Next click the Backup ICON in the top tool bar. Set the Backup File to save to your C Drive - C:\TestProject.ctz Ensure Option Use Compression is Checked. And Click OK.
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When it is complete we can then attach the file to emails or store our work in a Project folder.
RESTORE To Restore a project we Run MX4 and Select Restore button in the top tool bar
Above I have selected the Backup file and Changed the NAME to TestProject2, also selected NEW PROJECT. MX4 will then Create a NEW Project and name it TestProject2, all the design from TestProject will be extracted and used within the New Project. NOTE if you created a NEW PROJECT you will have to check that the COMPUTER SETUP is correct, by running the Computer Wizard.
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MAIN EXCERCISE
SEE ONLINE
END PART 1
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Scantime Engineering Ltd NE42 6QD Prudhoe.

England Tel: +44 (0) 1661 830114

+44 (0) 7974 005661 email: support.cs@scantime.co.uk www.scantime.co.uk

SCADA PROGRAMMING PART1

Prepared by David H Simm Scantime Engineering Ltd

SCADA TERMS ..........................................................13

SCADA ADDRESSING .....................................................29

ONLINE COURSE MANUAL

PROCESS CONTROL & SCADA

Typical Graphic Dynamic Screen

Typical Trend Screen

DONGLES & TOKENS

The image shown above show several Genies, the MOTOR

Therefore we could set the Engineering Units to 0-1000

---| |----------------|/|---------|/|------O Y110 Output to Pump on Mitsubishi Rack

THEREFORE acting like a real electrical push button.

EXPANDING THE PROJECT

ACTIVE X Control meters that have been created as Active X objects.

EXPANDING THE PROJECT

FormButton(30, 8, "@(Cancel,12,C)", 0, 2);

RUNNING THE PROJECT 1

TOOLBAR At the top of MX4 is a Toolbar.

Working LEFT to RIGHT the important tool buttons are:-

RUN THE SELECTED PROJECT

PROJECT EDITOR USED WHEN CREATING GENIES

GRAPHICS BUILDER USED WHEN CREATING SCREENS

RUNNING THE PROJECT 2

Click ONCE the RUN Button

A WARNING message will appear.

RUNNING THE PROJECT 3

CLICK OK BUTTON WHEN FINISHED SETUP MX4 EXPLORER

This is the Project TREE.

Description of each folder is below.

Alarms: Alarm Handling setup

System: Scada setup

Click on the Graphics folder and open the Templates folder.

Double click Create New template

The following Dialogue will appear.

YOU WILL BE PROMPTED TO CREATE A NEW STYLE - call it BASIC

Double Click Template01.

Select OBJECTS Menu RECTANGLE

ADDING OBJECTS TO THE TEMPLATE

Now let us change the Rectangle to a 3D Object>

Click 3D Effects TAB on the Right of the Rectangle Properties dialogue.

Select Effects - Raised.

DO NOT CHANGE THE COLOURS.

Place your Button in the Top Panel Right hand side.

Save the Template and Close the template window.

CREATE FIRST PAGE

Your Template01 should appear.

TEST YOUR PROJECT

Setup IO Server & Drivers

Through the MX4 Explorer select the Communications Folder.

The simplest way to setup Communications is via the WIZARD.

Double click the Express IO Device Setup.

Click the NEXT button.

To Finalize the IO Driver setup - Click NEXT

TO TEST THE SETUP - CLICK THE RUN ICON

IN THE TOP TOOLBAR

THE Main01 PAGE WILL APPEAR after the application starts.

YOU HAVE NOW CREATE YOUR FIRST DYNAMIC PAGE

BACKUP AND RESTORE

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