Design a simple scada system

1. Introduction:

The chief intent of this assignment is to plan a simple SCADA system to supervise and supply supervisory control of a Bytronic Associates Industrial Control Trainer ( ICT ) through an Allen- Bradlley Micrologic 1000PLC utilizing the Sistemi Winlog Pro package. From the design of PLC ladder logic plan which was developed utilizing RS-logic for the ICT, this assignment of the system will add a higher degree of control through package and supply a beginning to the industrial SCADA systems.

Supervisory Control and Data Acquisition ( SCADA ) :

SCADA is Supervisory Control and Data Acquisition. In 1993, SCADA system was required to analyze the site for the distribution systems and besides for the electrical supply. There was a treatment on the SCADA system that which system would be more a suited for the site. Almost for each and every packaged systems are combined with the complete SCADA system purchase which is different to the method of basic constituent as when it is used in individual metres. As we are cognizant of puting both the metres into the switch cogwheels at the substation and besides in edifice switchgears. It is more effectual estimated for the SCADA systems to analyze the position of electrical power supply systems.

In 1994 utilizing the Intelligent Electronic Devices ( IEDs ) and a DOS based SCADA package bundle are utilized by the Utility section to get down the installing for the SCADA systems. The energy direction section is one of the sections in the Utility division required to roll up the information from the edifice metres. The IDEs which provide a communicating to the SCADA package every bit good as an parallel end product signal ( KW ) that can be read by the edifice energy direction system. In this edifice energy direction system, it records the signal to track the electrical energy demand and Kilo Watt Hours ( KWH ) .

The SCADA package is a graphical bundle utilizing a Window NT Operation System. This system is manufactured by the Power Measurement Ltd ( PML ) provides the scheduling required to include existent AutoCad site map, a diagram and besides to show the accurate clip information on the heading of the graphical conditions. Objects like switch position, all the power system parametric quantities, dismaies and so on. Additionally, this system besides let the installations operations like public-service corporation system, electronic image to accomplish the large images to put at the background, and besides the channel down to the individual line as required. SCADA system automatically generates an dismay and can besides easy expandible as per the application required. The new systems can easy expandable and flexible to the usage as IDEs metre are added.

The followers are the map that are utilized more and more as the SCADA system is expanded.

  • Automatic coverage will be taken with the replacing of manual metre reading.
  • They need to react rapidly when the existent clip dismaies and information operators the information.
  • The Utility Department can be practical in supplying the clients about the quality information.

The chief benefits of utilizing the SCADA package are

  1. Switch overing and Paralleling Operationss:
  2. Confirmation of the physical alteration in the switch operator place was non accessible while utilizing of distant SCADA applications

  3. Power Quality:
  4. As needed, by and large after a consequence or upon question from constructing users the power quality studies are requested.

  5. Hospital and Medical School Emergency Services Status:
  6. From the Cogeneration Plant, Hospital Emergency Power Feeders are monitored to verify the handiness of the services, on a continual footing. This prevents the distant possibility that the service is non available or available.

  7. Outage Record:
  8. Position incident analysis is indispensable to avoid reoccurrence of similar outages and power failures.

  9. Substation Security Fires and Door Alarms:
  10. Early on on in the design of the SCADA application, it was determined that fire/smoke sensors were required in all substation switch cogwheel suites. This public-service corporation, along with the door dismay contacts, provides the system operators with the ability to react instantly to these types of actions.

2. System Description:

PLC Diagram Description:

In PLC the plans are fabricated based upon the ‘gates ‘ at the same time with the inputs, timers, counters, end products, internal memory spots, parallel inputs, comparators, parallel end product etc.

Input signals: The physical connexions that are connected to the PLC are switches, pushbuttons, detectors and anything which acts like a switch or signal to the province of ON and OFF place. The electromotive forces that accept to some of the devices are 24V DC and some may non ; it may change.

The switch when it is in ON province, so position of the device spot is ‘1 ‘ and when it goes to OFF province the position of the device spot is ‘0 ‘ .

End product: The consequence that appears from the input devices is the communicating between the PLC and other terminuss. They are used to command the solenoids, detectors, and connections etc to on and off place.

In the PLC, there are 8 detectors and 5 actuators were used. The consequence from each detector response the actuators and other detectors to execute the undertaking. These eight detectors has different undertaking they are

  • Sensor1: It detects the presence of nog in the upper kind country.
  • Sensor2: It detects the constituents in forepart of the solenoid at the upper kind country of the pealing chute.
  • Sensor3: It detects the presence of pealing in assembly country.
  • Sensor4: It is used to get down collection.
  • Sensor5: It is used to end the collection.
  • Sensor6: It is used to observe the complete assemblies.
  • Sensor7: It is used to observe the constituents at the lower kind country.
  • Sensor8: It is used to observe the constituents and assemblies near the reject country solenoid.

The intent of 5 actuator which are used in PLC country are

  • Actuator1: It drives the upper concatenation conveyer motor.
  • Actuator2: It drives the lower concatenation conveyer motor.
  • Actuator3: It knocks the ring in the ring chute.
  • Actuator4: It releases the ring into the assembly country.
  • Actuator5: It rejects the unassembled constituents.

Relay: A relay is a switch which is operated on the electromagnetic.

Counters: when a pre-assigned count value is reached, the digital counters are in the signifier of relay contact.

Timers: Timer consists of internal clock, a count value registry and an collector which is used to number the clip.

When nog and pealing moves in the upper kind country, the nog moves into to the nog chute through the sensing of the sensor1 and the ring moves into the ring chute through the actuator 3. And the actuator 4 is to let the ring in to the infinite where the detector 3 detects the ring for the piecing the ring into the nog in the lower kind country. The detector 6 it to observe the complete assembled constituents. The actuator 4 has some hold clip for leting the ring in to piecing country. The detector 8 is to observe the unassembled constituent and the actuator 5 is to reject the unassembled constituents.

Sensor figure Sensor type, location and map. PLC Input


Download-looking brooding IR detector at the upper kind country.

Detects the presence of a nog near to and in forepart of the solenoid at the top of the pealing chute.

I: 0/4


Sideways-looking brooding IR detector at the upper kind country. Detects a constituent in forepart of the solenoid at the top of the pealing chute.

I: 0/1


Brooding IR detector at the assembly country.

Detects the presence of constituent at the really underside of the pealing chute beyond the rotary solenoid.

I: 0/0


Black pushbutton.

Used to get down piecing say.

I: 0/18


Red pushbutton.

Used to end collection, say.

I: 0/19


Capacitive detector, near the lower kind country.

Detects the presence of go throughing complete assembles near the cull solenoid at the motor terminal of the lower conveyer.

I: 0/6


Brooding IR detector at capacitive detector near lower kind country

I: 0/3


Brooding IR detector at the lower kind country.

Detects the presence of constituents and assemblies in forepart of the cull solenoid at the motor terminal of the lower conveyer.

I: 0/2


Through-beam IR detector, merely after the assembly country.

Detects constituents on the lower conveyer go forthing the assembly country.

I: 0/5

Actuator No. Actuator type, location and desired map PLC Output


Upper conveyer motor.

Drives the upper toothed concatenation conveyer

Oxygen: 0/3


Lower conveyer motor.

Drives the lower field belt conveyer.

Oxygen: 0/4


Solenoid at upper kind country.

Knocks rings into the pealing chute.



Rotary solenoid at the underside of the pealing chute before the assembly country.

Releases rings into the assembly country.

Oxygen: 0/1


Solenoid at the reject country.

Culls unassembled constituents before the complete assembly aggregation tray.

Oxygen: 0/2

Using the winlog Pro package, the PLC system can be operated through the ladder plan by closing down the RSlogix and delegating the detector input pins to the digital Gatess and actuator end product pins to the digital Gatess.

These maps are performed by four sorts of SCADA constituents:

  • Detectors ( either digital or parallel ) and command relays that straight interface with the managed system.
  • Distant telemetry units ( RTUs ) : These are little computerized units deployed in the field at specific sites and locations. RTUs serve as local aggregation points for garnering studies from detectors and presenting bids to command relays.
  • SCADA maestro units: These are larger computing machine consoles that serve as the cardinal processor for the SCADA system. Master units provide a human interface to the system and automatically modulate the managed system in response to sensor inputs.
  • The communications web that connects the SCADA maestro unit to the RTUs in the field.

3. Requirements:

The lower limit demands for the SCADA to execute and command the operation of PLC manually are

  • By replacing the physical push buttons, supplying start/stop to command the ICT from the SCADA.
  • Expose the province of all detectors and actuators utilizing the digital Gatess shows such as LED or lifes.
  • Expose the count of the figure of rings in the chute at any clip ( this may besides widen to the figure of completed assembled and rejected constituents.
  • Supply a agency of resetting the ring count a value among 0 to 5 ( in the event of malfunction ) .
  • Make a templet with a background electronic image that is either a conventional diagram of the ICT or the existent exposure of the kit.
  • At least one dismay status illustration when a constituent is rejected or the ring in the chute is more than four.


  • In the numerical Gatess of winlog pro, the LED constituents can non be kept because these are used merely for numbering the rings in the chute and besides for the rejecting the constituents in the chute.
  • In the digital Gatess of winlog pro, the detectors, actuators, LED and switches are kept. It does non accept the counts.

4. SCADA System Design:

The design of a simple control application based on the micrologix DF1 protocol, but the design of more complex systems can be solved utilizing the SCADA. It is easy to understand and near the winlog Pro package and besides to pass on the other devices.

For every new application, the system has to cognize the external devices, references and communicating protocol to pass on from one device to the other devices.

In PLC, the plan runs between the one of two provinces for every second in order to keep the count. Harmonizing to the SCADA, for each province the LED will be shown and besides

for the count will be shown. The PLC plan will be started and stopped by utilizing the switch on SCADA.

For making the variables database devices in the Gatess of Winlog Pro package, we have to see the numeric, digital and event dismaies harmonizing to our applications.

Numeric gates consists of all the variables that refers to the linear measure like counts, set points and so on that can expressed in the signifier of a bytes, a word, a dual word, an whole number or by a floating point variable. In this application, the numeral Gatess are used for the numeration, rejecting constituents, complete counts and besides for resetting of both complete and reject counts.

Digital gates consists of all the variables that refers to the digital position like dismay conditions, detectors, actuators, constellation option and so on. It can be expressed by a individual spot. In this application, the digital Gatess are used for the input detectors, end product actuators and for solenoids and besides for switches and pushbuttons.

Event/alarm is besides used in this application for the intent of demoing the rings in the chute if the rings in the chute are more than four. This constellation is used for the purpose of triping the solenoid.

The following tabular array shows, the numeral variables constellations are made harmonizing to the applications are ;

Continuance with the tabular array

The following tabular array shows, the digital variables constellations are made harmonizing to the applications are ;

The following tabular array shows the event/alarm gates constellation are made harmonizing to the applications. And this gate can non read from the devices but the position will be displayed while at runtime. This gate is provided for the attending of the ring in the chute if the ring in the chute is more than four and we besides can make more dismaies utilizing this gate constellation.

After making of the Gatess constellations, we must salvage it and make the new templets in order to acquire all the Gatess for the application and these Gatess are used for each and every accomplishment to execute the operation on the peculiar Gatess constellation. After adding all the Gatess, insert all the active label objects like LED, switch and so on and besides include the gate to each label to execute the operation when the gate is used in the ladder plan. After

completion of adding all the Gatess, label, chart and electronic image, salvage the complete constellations. And put to death the plan.

After the completion of the templet design, we must delegate the simple codification utilizing the name as “Main” in the Winlog Pro codification. It is used merely for the map that will open for the chief templet at the application startup.

The undermentioned figure shows the concluding templet design that ‘s required for the applications are ;

The above figure represents the complete design of templet after set uping all the Gatess and chart and electronic image.

5. Testing:

After the creative activity of the templets and Winlog Pro codification in the package, shut the Winlog Pro and run the RSLogix 500 to make the plan and download the Micrologix 1000 ladder plan listed in the subdivision. After downloading, travel to the Run manner and shutdown the RSLogix 500 and besides RSLogix service.

Restart the Winlog Pro package, to run the undertaking in undertaking director and choose Execute from undertaking bill of fare. Then after put to deathing the undertaking, it will travel in tally manner to get down the undertaking harmonizing to the application demands. Winlog Pro samples variables from devices and processes the consequences in graphical representations.

When the undertaking that where done by the users to startup so it automatically achieves the chief templets.

By snaping the switch object label, we can get down and halt the executing of the plan. When the plan is in running manner, we can see the figure of rings that the actuator 3 pushes into the chute and the nog that enter into the nog chute by the sensing of the detector 1

And if the ring in the chute is more than four so the dismaies will be in active ( blowing status ) manner that informs the ring ca n’t let into the pealing chute more. The count display the figure of pealing in the ring chute and edit box is to redacting the value that enter in it. By snaping the toggle switch, we can reset both the completed assembles and rejecting constituents. We can choose the chart to demo the graphical representation of the counts and digital like pushbutton and switches. The chart besides displays the group of variables that we want to expose.

The below figure displays the switch button is in ON status and the numeration of pealing in chute is 5. If the ring count is more than four in the chute so the dismay blows. And resetting all the completed assembles and rejected assembles. The chart 1 describes the switch buttons ( black colour ) and pushbuttons ( bluish colour ) when it is in ON status. The chart 2 describes the count of the rings in the chute ( green colour ) , completed assembled constituents ( light blue colour ) and rejected constituents ( ruddy colour ) .

The below figure shows the numeration of rings in the chute ( green colour ) , completed assembled constituents ( light blue colour ) and rejecting the constituents ( ruddy colour ) when the switch button is in ON status.

6. Discussion:

Utility System Operators need to be able to go on to remotely and outright, place electrical Power System Failures at any location in the distribution system. Accurate existent clip dismaying and historical information is needed to continually run into the demands of a diverse community of energy users. A continuance of the demands for high dependability and accurate public presentation and swerving informations is paramount is the long term benefits of the SCADA systems.

Approaching the SCADA system design for an application is the first clip and in peculiar Winlog Pro package, it can be easy to pass on with other devices utilizing the RS-232 9pin connection.

Winlog Pro package can accessible easy and understand rapidly to the external devices. For different applications, the design of the system for each device should be addressable and the list of all the variables can read or compose to the devices. And for the applications the Gatess constellation should be addressable. Depending on the ladder plan the reference should be made and we can plan different templets.

Without any limitations of all the winlog pro licences package, it can supply the maps, development tools and communicating protocol. The package tool chest acknowledges the uninterrupted attempts of sielco sistemi to do the winlog pro more competitory and attractive. This powerful, low cost and easy to utilize SCADA package is so roll uping increasing understanding among Italian and international users.

Winlog Pro is simple, flexible and more economical in existent clip applications. It provides the differ tool like Gatess builders, templets, codification builders. It allows the drivers to interface and pass on with all the electronic devices like PLCs, I/O faculties and so on.


Using the Winlog Pro package, the consequences that are required for the undertaking are achieved. Using this package, we are delegating all the object labels to the Gatess constellation. The counts the Numberss of rings are assigned to the numeral gate and the digital Gatess like LED, detectors and actuators and solenoids are assigned to this gate. For each and every gate the reference will be allocated. The ladder plan that where written in RSlogic 500 should be downloaded and exchange it to run mode. Close the RSlogic and put to death the undertaking that was done in winlog Pro package undertaking director. Therefore, the plan and the logic were tested and the consequences are achieved successfully without any mistake.


  • Referred notes by J.G.Pierce.
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