Vidya Vikas Educational Trust (R),

Vidya Vikas Polytechnic

27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Department of Mechanical Engineering

Laboratory Manual

Subject : Fundamentals of Automation Technology

Subject Code : 20EE43P

Semester : 4th Semester

Branch : Electrical and Electronics Engineering

Name of the Student: …………………………………………….

Register Number: …………………………………………….

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Syllabus

This Manual is only for this Portion

Section A
For a given automation application select suitable pneumatic components and sensors.
Experiment 01: Moving of Object from one Place to Another
Experiment 02: Filling up of Tank
Experiment 03: Lighting a Bulb
Experiment 04: Starting of Fan

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Dear Students
Before we start to attain knowledge of great resource let me remind you to use the proper licensed version of
the Wonderware InTouch Software. Or use the Demo version which will give free 120 minutes of working
in every session.
InTouch from Wonderware is advanced SCADA software for monitoring and backing up large-area
production process data. Devices managed from a single workstation can be connected with OPC client, S7
MPI, S7 PPI, Profinet (S7 1200), Modbus RTU, Modbus TCP / IP, Host Link Protocol (Omron), Mewtocol
Protocol (Panasonic)). Historical data related to the process of our SCADA system is recorded in the
database. I have used InTouch 10.1 Demo version for the manual. All the Tools and Functions are similar in
different Versions.
You can download the latest version of Wonderware InTouch software by using the link below based on
your system configurations:
Download Locations:
https://lab4sys.com/en/category/software-downloads/
https://www.awztech.org/downloads
If you insist on using the other version as download from any of the links below but be alert for virus and
pirated versions, try not to use crack use demo mode it works for every 120 minutes whenever you open it
also be cautious in x32 bit or x64 bit Installation:
https://drive.google.com/file/d/1SIEOSEn379bcntrjg698bGbFdlrAK1MR/view
https://mega.nz/file/zZlB2YTS#j03Hu3AAylD0Orfd8J-tOU5ExNhV_3cr6CNYKE-7emc

I request all those who use this manual to support https://lab4sys.com/ for giving us Wonderware intouch
software an innovative SCADA software for Education purpose.
For contact and support use the links below:
Follow us on facebook:
https://web.facebook.com/Lab4Sys
Follow us on twitter:
https://twitter.com/Lab4Sys
Follow us on linkedin:
https://www.linkedin.com/company/Lab4Sys
Thanking you all
With regards
THANMAY J S

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
1. Meaning of SCADA
SCADA (supervisory control and data acquisition) is a category of software applications for controlling
industrial processes, which is the gathering of data in real time from remote locations in order to control
equipment and conditions. SCADA provides organizations with the tools needed to make and deploy data-
driven decisions regarding their industrial processes.
SCADA systems include hardware and software components. The hardware gathers and feeds data into field
controller systems, which forward the data to other systems that process and present it to a human-machine
interface (HMI) in a timely manner. SCADA systems also record and log all events for reporting process
status and issues. SCADA applications warn when conditions become hazardous by sounding alarms.

Functions of each component of SCADA system,

There are many parts or components of SCADA system, which include hardware (input and output),
controllers, networks, user interface, communications equipment and software. Altogether, the
term SCADA refers to the entire central system. The central system usually monitors data from various
sensors that are either in close proximity or off site (sometimes miles away).

An industrial SCADA consisting of the following

1. A central host or master station unit or, master terminal unit (MTU);
2. One or more field data gathering and control units or remotes (usually called remote stations,
remote terminal units, or RTU’s);
3. A collection of standard and/or custom software used to monitor and control remotely located
field data elements.
Contemporary SCADA systems exhibit predominantly open-loop control characteristics and utilize
predominantly long-distance communications, although some elements of closed-loop control and/or short
distance communications may also be present.

Major components of SCADA

1) A collection of equipment’s that is provide the operator at remote location with enough information to
determine the status of particular piece of equipment or entire substation or a plant or a dynamic network
and cause actions to take place regarding that equipment or network without being physically present.
2) An arrangement for operator control and separation of remotely located apparatus using multiplexing
techniques once a relatively small number of interconnecting channels.
3) Collecting Data from remote electrical equipment and controlling then through suitable communication
medium.
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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Describe SCADA Hardware and software

A SCADA system consists of a number of remote terminal units (RTU) collecting field data and sending
that data back to a master station, via a communication system. The master station displays the acquired data
and allows the operator to perform remote control tasks.
The accurate and timely data allows for optimization of the plant operation and process. Other benefits
include more efficient, reliable and most importantly, safer operations. This results in a lower cost of
operation compared to earlier non-automated systems.
SCADA system essentially has five levels or hierarchies, as listed below
1. Field instrumentation and control devices: These analog and digital sensors situated at each remote site
2. Marshalling terminals and RTUs: These provides an interface to the field devices
3. Communications system: Communications systems form the backbone of SCADA. The widely used
systems are wire, fiber optic, radio, telephone line, microwave and possibly even satellite. Specific protocols
and error detection techniques are used for efficient and optimum transfer of data pathway for
communications between the master station and the remote sites
4. The master station(s): The master stations gather data from the various RTUs provide an operator
interface for display of information and control of the remote sites
5. Information Technology (IT) Applications: The commercial information technology (IT) or data
processing department computer system.

SCADA Hardware Functions

There are many functions of SCADA; some of them are listed below.
Data Collection: collecting of the information via a RTU (remote terminal unit)
Data Transfer: transferring it to the central site
Data Processing: Carrying out any necessary analysis and control
Information Display: Displaying that information on operator screens or displays
Control Actions: Required control actions are then conveyed back to the process

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
SCADA Software
Generally, SCADA is completely a software package that helps to monitor the entire area of the plant. The
basic architecture of the SCADA begins with a Programmable Logic Controller(PLC) or Remote Terminal
Units(RTUs).
As we know, PLC or RTUs are microprocessors that communicate with the field devices such as valves,
pumps, sensors, HMIs, other end devices, etc. These devices route all this collected data from end devices to
SCADA computers. Then SCADA software processes distribute and display the data on the monitor to
better understand the operator about the field condition.
For example, In a cement plant, there are various weighing scales. The operator is allowed to change the
specific set rate for each weighing scale according to plant requirements. SCADA displays the real-time
process value of each weighing feeder and also logs the data.

Applications of SCADA.
SCADA Systems are widely used in the following:
 Oil and Gas
 Pipeline monitoring and control
 Remote equipment and asset monitoring and control of production, pumping, and storage
locations
 Offshore platforms and onshore wells
 Refineries, petro-chemical stations
 Plant/factory automation
 Water and Wastewater
 Water treatment centers and distribution
 Wastewater collection and treatment facilities
 Utilities
 Electrical power distribution from gas-fired, coal, nuclear
 Electrical power transmission and distribution
 Agriculture / Irrigation
 Manufacturing
 Food and Beverage
 Pharmaceutical
 Telecommunications
 Transportation
 And many others

2. Meaning of HMI and its applications.

A human-machine interface or HMI is a component that is used as an interface between an operator and a
process or piece of machinery. It is a graphic interface that allows complete control of a machine from one
dashboard. They are found on pretty much every piece of equipment you come across in manufacturing and
in the industrial process world.

Types of HMI.
There are three main types of human machine interfaces you will come across:
a) The Push Button Replacement Panel
These are pretty self-explanatory; they replace all of the pushbuttons needed to operate the machine. They
centralize complete process/machine control from one panel without the need for a number of different
physical pushbuttons. A graphical button will be displayed on the screen and they can be used for a number
of different functions, such as start-stop, homing, screen navigation, and resets.
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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
b) The Overseer Panel
This type of panel is used to view SCADA systems or MES systems. They are not just used to control one
machine but can control/monitor a number of machines/processes from one place.
c) The Data Handling Panel
This type of HMI is used to present feedback from a machine’s performance or production report. They can
be used to set different recipes or view/accept alarms that occur on the machine. Graphs can be created on
these types of HMIs along with a visual representation of how the machine is performing.

Advantages of HMI.
For plants and facilities, there are several benefits of installing an HMI system. Below are a few of the many
benefits of having an HMI system:
1. Alarms/Warnings: An HMI can allow plant operators to view alarms and locate a malfunction in the
equipment, allowing them to react more quickly. Alarms can be preventive, so the operator is alerted before
the system reaches an emergency level. Alarms can also track several different problems and increase
productivity by optimizing manufacturing processes.
2. Reliable Messaging: For faxes, pages and more, operators can depend on HMI messaging. As
an example, when a machine should be refilled because of a low fuel level, the operator will be alerted
automatically.
3. Easier Overall Management of Plant: Using HMI technology, your company can also easily manage
and carry out recipes. The high-quality graphics of HMI systems provide realistic views of a plant's
operations so that operators can control the facility from central locations. This also helps with any security
issues. Now an operator doesn’t need to approach dangerous areas, and they can control the monitor from
another location.
4. Accurate Testing with Simulation: Plant managers can test equipment and devices easily through the
use of an HMI with simulation. Testing can be achieved in the office without any piece of equipment. This
function improves overall production and reduces startup time.
5. Cost Reduction: A human machine interface can reduce operating costs by replacing hundreds of
selectors, pushbuttons, indicator lights and more. This means the need for extra cables, panels and consoles
is also greatly reduced.
6. Improved Communications
HMI can also improve communications throughout the facility by using various types of equipment. This
includes the use of:
 Ethernet
 Data Highway Plus
 DDE (Dynamic Data Exchange)
 Remote I/O
 Serial port
Adding an HMI to a workplace benefits a facility by improving its productivity, operation and safety.
Companies such as Red Lion provide a variety of HMI products (available for purchase through Carotron,
Inc.) for even the most demanding industrial applications.

4. Concept of DCS

The name itself represents that DCS is a system including related computers, controllers, and sensors where
all there are in a distributed format all across the plant. Every element in the system performs its own

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
functionality like data attainment and management, process management along with the graphical display,
and

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
data accumulation. The communication between each element in the plant is done through a centralized
computer which is also termed a controlling network. The crucial component of the plant is the “Distribution
Control System” where is utilized for automated decision-making depending on the production updates as
per reality all across the plant.

Hierarchy of DCS.

Functions of each level of DCS.

Referring to the diagram:

 Level 0 contains the field devices such as flow and temperature sensors, and final control
elements, such as control valves
 Level 1 contains the industrialized Input/Output (I/O) modules, and their associated distributed
electronic processors.
 Level 2 contains the supervisory computers, which collect information from processor nodes
on the system, and provide the operator control screens.
 Level 3 is the production control level, which does not directly control the process, but
is concerned with monitoring production and monitoring targets
 Level 4 is the production scheduling level.
Levels 1 and 2 are the functional levels of a traditional DCS, in which all equipment are part of an integrated
system from a single manufacturer.
Levels 3 and 4 are not strictly process control in the traditional sense, but where production control and
scheduling take place.

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Basic Steps to Remember
1: once you open InTouch, in the Main layout right
2: Give Name for your File
click in Windows and Click New

3: Click on Wizard 4: Click Value Display and Tagname Value & OK

5: Paste Timer in Window and Double Click 6: Give Tag Name and Double click on Name

7: Click Tag Name Type and Give Memory Real 8: Click Wizard again and Select Buttons pick
Save and Close Round Panel Pushbutton and OK

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
9: Double Click on Button and change 10: Double Click Tagname and give type as Memory
Tagname and Colour Discrete

11: Copy START Button and Past and Create 12: Right Click on Window and select Window Scripts
STOP Button by repeating the same Steps

14: set Initial Conditions to Zero “0” THEN CLICK

13: First select On Show
Convert Validate and OK

15: Click Wizard select Symbol Factory click 16: Click on Window to get Symbol Factory Buttons
add to Toolbar

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
17: Select suitable Symbol for Process [Example 18: Select Object and click on Break Cell Icon
Containers> Crate 1] below

19: Double Click on Object to get Object Properties 20: Click on Location > Horizontal (Check box) >
dialog click on Horizontal to get Expression Dialog

21: Enter TIME scale and Moment Distance

23: Give TIME input as Memory Real>Save OK>

22: Define TIME input OK
OK>OK

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
24: Right Click on Windows to get Script 25: Select While Showing and Every = 100

26: Write Simple Script then press convert, Validate and Ok

27: Click on Runt Time 28: InTouch Viewer will be Displayed

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
28: Press on START to see Simulation
29: change the TIME to 40 and box horizontal distance to 120
and Press to see STOP to get initial
and see the difference
position

30: Enter Expression as TIME input and Change Time range and Distance range to move

31: run Runtime and see Time increment and Distance increment

32: Repeat the same procedure by giving Vertical distance after TIME is 40 to 60 and lift distance be 70

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

33: Make sure both Horizontal and Vertical is Active with respect to TIME

34: Till 40 the Crater moves Horizontal right for 120 and after 40 the Crater moves 70 Vertical up.

35: Using this type of Simple steps of Moment of Object with respect to TIME as input can be Simulated

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Experiment 01: Moving of Object from one Place to Another

AIM: Program to move objects from conveyor.
Problem Description
 Objects are moving on conveyor
 We need to move objects on conveyor. When box is reached its position, another box should appear.
 Implement this automatic cycle in InTouch SCADA animation.

Problem Solution
 Create Time Value Count
 Create Buttons to Start and Stop
 Create Objects and Elements in InTouch Window
 Give Horizontal Movement
 Write Initial Conditions to zero in Window Script
 Write simple Script to activate
 Note the Time for Box to reach Position
 Edit Script and Visibility to get second Box
 Validate the Results
Components Required Inputs Initial Conditions
[1] Conveyor Belt START = 0;
[2] Box or Crater 2 Numbers STOP = 0;
[3] Start and Stop Button TIME = 0;
[4] Timer
Onscreen Script
IF START == 1 THEN TIME = TIME+1; ENDIF;
IF TIME == 50 THEN STOP=1; ENDIF;
IF STOP ==1 THEN START=0; TIME = 0; ENDIF;
Box parameter
Horizontal: Extension Name TIME; Time Start = 0; Time End = 50; Distance Start = 0; Distance Move =
(Based on Trial); Visibility: Extension = TIME > 40; Visibility on

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028

Sequence 01:

Sequence 02:

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment 02: Filling up of Tank
AIM: From Pump water to be Pumped to Tank
Problem Description
 Pump should Display to Pump Water
 We need to show Water Moment from Pump to Tank
 Implement this automatic cycle in InTouch SCADA animation.

Problem Solution
 Create Time Value Count
 Create Buttons to Start and Stop
 Create Objects and Elements in InTouch Window
 Give Vertical and Horizontal Movement for Water
 Write Initial Conditions to zero in Window Script
 Write simple Script to activate
 Note the Time for Tank to Fill and Stop the Sequence
 Edit Script and Visibility
 Validate the Results
Components Required Inputs Initial Conditions
[1] Sump START = 0;
[2] Pump STOP = 0;
[3] Pipes TIME = 0;
[4] Tank
Onscreen Script
IF START == 1 THEN TIME = TIME+1; ENDIF;
IF STOP ==1 THEN START=0; TIME = 0; ENDIF;
Water parameter
PIPE TIME HORIZONTAL / VERTICAL
1 0 TO 5 Vertical
2 5 to 10 Horizontal
3 10 to 15 Vertical
4 15 to 20 Vertical
5 20 to 25 Horizontal
6 20 to 25 Horizontal
7 20 to 25 Horizontal
8 25 to 40 Vertical

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Sequence 01:

Sequence 02:

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment 03: Lighting a Bulb
AIM: to control a Bulb by Switch
Problem Description
 Switch should be a Discreet Memory
 Electricity flow by time when switch is ON
 Implement this automatic cycle in InTouch SCADA animation.

Problem Solution
 Create Time Value Count
 Create a Switch
 Create wire by small rectangle
 Give Horizontal Movement for Electricity
 Write Initial Conditions to zero in Window Script
 Write simple Script to activate
 Note the Time for Electrical Flow and Stop the Sequence
 Edit Script and Visibility
 Validate the Results

Components Required Inputs Initial Conditions

[1] Timer SWITCH = 0;
[2] Switch TIME = 0;
[3] Bulb
Onscreen Script
IF SWITCH == 1 THEN TIME = TIME+1; ENDIF;
IF SWITCH ==0 THEN TIME = 0; ENDIF;

Current parameter
Horizontal Time Start = 0 End Time =5; Bulb = Blink Continuous after Time 5; Horizontal Time Start = 5
End Time =8 till grounding

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Sequence 01:

Sequence 02:

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Experiment 04: Starting of Fan
AIM: to control a Fan by Knob
Problem Description
 Knob should be a Discreet Memory
 Electricity flow by time when Knob is ON
 Implement this automatic cycle in InTouch SCADA animation.

Problem Solution
 Create Time Value Count
 Create a Knob
 Create Propellor and Circle
 Create wire by small rectangle
 Give Horizontal Movement for Electricity
 Give Orientation to Propellor
 Write Initial Conditions to zero in Window Script
 Write simple Script to activate
 Note the Time for Electrical Flow and Stop the Sequence
 Edit Script and Visibility
 Validate the Results

Components Required Inputs Initial Conditions

[1] Knob KNOB = 0;
[2] Propellor TIME = 0;
[3] Timer

Onscreen Script
IF KNOB == 1 THEN TIME = TIME+1; ENDIF;
IF KNOB ==0 THEN TIME = 0; ENDIF;

Current parameter
Horizontal Time Start = 0 End Time =5; Propeller Orientation = Time > 5;

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka 570028
Sequence 01:

Sequence 02:

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