HMI

Human Machine Interface (HMI) Systems provide the controls by which a user operates a machine, system, or instrument. Sophisticated HMI Systems enable reliable operations of technology in every application, including highspeed trains, CNC machining centers, semiconductor production equipment, and medical diagnostic and laboratory equipment. HMI Systems encompass all the elements a person will touch, see, hear, or use to perform control functions and receive feedback on those actions.

The task of an HMI System is to make the function of a technology self-evident to the user. A well-designed HMI fits the users image of the task he or she will perform. The effectiveness of the HMI can affect the acceptance of the entire system; in fact in many applications it can impact the overall success or failure of a product. The HMI System is judged by its usability, which includes how easy it is to learn as well as how productive the user can be.

It is the mission of everyone involved in the HMI design, the engineers, management, HMI consultant, and industrial designer, to meet the defined usability requirements for a specific HMI System.

A well-designed HMI System does more than just present control functions and information; it provides an operator with intuitive active functions to perform, feedback on the results of those actions, and information on the systems performance.

How to Design an HMI System

A highly-reliable HMI System that delivers safe, cost-effective, consistent and intuitive performance relies on the application of engineering best practices throughout design and panel layout, production, testing, and quality assurance processes.

Just as critical, in-depth knowledge of and compliance with all relevant ergonomic, safety, and industry standards must inform each step of the design and manufacturing cycle. Clear definitions of the functional requirements, the operators level of expertise, and any communications/interactions with other systems provide the starting point in the knowledge-intensive design process.

Defining Operational/Functional Requirements

The tools needed for effective operator control of the equipment as well as the requirements of the overall application determine the selection of interface functions.

General Functionality

How many functions will be controlled by this interface? Where a single function might be served by pushbutton, keylock, and rotary switches, multiple functions could require several screen displays to cover operator functions and

options. What kind of visual, auditory, or tactile feedback will best serve the operator in performing the defined functions?

Does the operation require real-time indicators? Multiple data-entry points? How many times is a button pressed? Are there safety considerations? Are emergency stop switches required? Which standards apply industry, safety, international?

Degree of Input Complexity

Input can be as simple as an on/off switch or a touchscreen display. Touchscreen HMI Systems are increasingly popular in public transaction applications, because they can simplify complex operations and tolerate a moderate degree of rough use. Defining input requirements will help decide which control technology is best suited for a specific application.

Operator Feedback

Feedback is critical to operator effectiveness and efficiency. Feedback can be visual, auditory, tactile, or any combination necessary for the application. Feedback is essential in systems that have no mechanical travel, such as a touchscreen or a capacitive device that when triggered has no moving parts. In some cases feedback provides confirmation of an action, while in others it adds to the functionality.

Interface/Interconnection with Other Systems

HMI Systems must be able to interface/interconnect with the system under control as well as other related systems. For example, in an industrial setting the HMI might connect via hardwire or a serial bus to I/O points that provide machine status. Additionally, it might be networked to a manufacturing execution system and a supply logistics/inventory system.

Environmental Considerations The application environment encompassing both physical location and vertical industry environment determines HMI System durability requirements. Environmental stresses include exposure to moisture and the elements, temperature extremes, wear and tear, vandalism, and general rough use characteristic of harsh environments such as an industrial production floor.

Lifecycle Durability

Not only should the HMI System be rugged enough to withstand the elements and heavy use, but it should also last for the duration of the equipment lifecycle. For example, a Magnetic Resonance Imaging (MRI) HMI System interface should last at least 10 years.

Style

HMI System style is a high priority for many consumer goods and especially luxury products. In the marine industry, the consoles for high-performance racing boats feature contemporary styling and an array of ergonomic technologies. HMI style considerations are effective when they create a level of product differentiation that delivers a unique selling proposition.

Regulatory/Standards Considerations

A thorough knowledge of technical ergonomic, design, and manufacturing standards is fundamental to HMI System design. These include engineering standards, such as MIL-STD-1472F, which establishes human engineering design criteria for military systems, subsystems, equipment, and facilities; federal standards set by the Americans With Disabilities Act; and industry guidelines such as those from SEMI S2-93, the global semiconductor industry association, covering HMI for semiconductor manufacturing equipment. Additional HMI specifications are defined by ANSI, IEEE, ISO, and others.

Define the Operator

Know your operator the key to a successful HMI System implementation requires a well-grounded definition and understanding of the operators. Will the operator be a passive/intuitive user? If so, commands/functions should be simple with an easy-to-comprehend interface. For this type of user, repeatability is also important information and actions should appear consistently from use to use. For an expert user, where more sophisticated control is desirable, there may be multiple layers or levels for interfacing with equipment.

For any user along the range from intuitive to expert, interface ergonomic considerations should include: panel layout, HMI Component selection, information presentation, feedback, and safety considerations.

Panel Layout

The panel layout should be designed to provide the operator functional groups of related information in a predictable and consistent manner. In addition, the system must require an operator to initiate action and keep the operator informed by providing timely feedback on those actions. The layout should be organized so that the operator is clearly prompted in advance when the next operator action is required.

HMI Component selection

HMI designers can simplify their search for the appropriate switch or HMI Component by carefully analyzing their application requirements then determining the following:

Electrical ratings. Actuation preferences (momentary, maintained, rotary, etc.).

Physical configuration and mounting needs. Special requirements such as illumination, marking, environmental sealing, etc.

Color scheme The key to effective use of color is simplicity. Avoid too many colors or flashing alarms. Stick with the traffic light model for key actions:

Red for stop/failure/fault. Yellow for warning. Green for OK/start/go/pass.

Information presentation Once again, simplicity is the key. Dont crowd a screen avoid cluttering it with irrelevant data. Forcing an operator to search for the required information increases response time and potential errors. Have a consistent set of menu buttons and functions from screen to screen.

User Feedback

Feedback is critical to ergonomic industrial design. Make sure the results of pressing a control button, toggling a switch, or entering a command are absolutely clear. Determine if operator feedback is visual, auditory, tactile, or a combination of multiple techniques.

Choosing the Best Control Technologies

Once you have defined HMI functionality, you are ready to investigate control technologies. Each technology has advantages and disadvantages related to the HMI system, equipment, and application.

Cursor Control (Trackball, joystick, keypad, touchpad, etc.)

The selection between different control technologies is primarily determined by the resolution of control that is required by the application. A trackball or joystick enables granular, pixel-by-pixel control, a far higher resolution than possible with a typical PC point-and-click controller.

Switches (Pushbutton, rocker, slide, keylock, rotary, etc.)

Pushbutton switches allow the option of illumination to indicate open/close switch status when a quick visual indication is desired. They are also useful in machinery and machine tools, electronic production, rail and bus transportation, medical treatment and diagnostics, or other environments for easier manipulation when gloves are worn.

Rotary-switch and keylock technologies serve best when the application requires position indicators such as those used in heater or fan control. Keylocks provide an additional layer of security to the application. Rotary switches also can be used for an application requiring multiple positions. Slide switches are the technology of choice when ease-of-use and low-cost switching is desirable commonly found on notebook cases and handheld on/off functionality.

Short travel technologies (Conductive rubber, membrane, keyboard, keypad, etc.)

Short travel technologies have been developed for industries where ease of cleaning or disinfecting is mandatory, for example pharmaceutical, chemical, and food processing, or in a hazardous environment where a sealed system is required. Short travel technology can include cost effective, conductive rubber keys in a typical keyboard, dome keys under an overlay, or a multi-layer membrane.

Touch and switching technologies, (Capacitive, Piezo, high frequency, etc.)

Applications operating in aggressive environments such as public access or, for example, soda dispensing, where the syrupy liquid tends to get into crevices and gum up the machinery require a rugged, completely sealed surface. Piezo, capacitive, and high frequency technologies all offer rugged switch technology with long life cycles and low maintenance costs.

Capacitive or high-frequency signals electronically activate an on/off function by changing capacitive load. Capacitive/high-frequency technologies require the use of nonconductive front panel materials which can be up to 15 mm thick, for example those operating under protective glass within hazardous environments.

Display technologies (LCD, Active Matrix, OLED, FED, Plasma, etc.) The basic function of displays in HMI applications is to provide an information source operators interact to obtain information or to prompt for the next screen. Display technology choices are dictated by the HMI System environment and its degree of ambient illumination, as well as by color requirements. Active matrix LCD technologies are commonly used for color functionality, while legacy LCD technology is used in applications where monochromatic feedback is sufficient. OLEDS, organic (carbon-based) light-emitting diodes can currently support smaller displays.

Interactive Displays, Touchscreen

Touchscreen technologies offer a range of functionalities and characteristics that govern HMI Systems choice according to application and environment. It is important to determine which touch technology will be used in the early stages of the design cycle as the different options offer quite unique electrical and mechanical requirements.

Capacitive touchscreen transmit 75 percent of the monitor light (compared to 50 percent by Resistive touchscreens), resulting in a clearer picture. They use only conductive input, usually a finger, in order to register a touch.

Infrared touchscreen technology projects horizontal and vertical beams of infrared light over the surface of the screen. When a finger or other object breaks those beams, the X/Y coordinates are calculated and processed. These cost-effective touchscreens can also be used by workers with gloves and are relatively impervious to damage.

Resistive touchscreen technology offers cost-effective, durable performance in environments where equipment must stand up to contaminants and liquids, such as restaurants, factories, and medical environments. When touched, the conductive coating on the screen makes electrical contact with the coating on the outer layer, the touch coordinates are registered by the controller to activate the on/off function.

Surface Acoustic Wave (SAW) touch technology sends acoustic waves across a glass surface from one transducer to another positioned on an X/Y grid. The receiving transducer detects if a wave has been disrupted by touch and identifies its coordinates for conversion to an electrical signal. SAW serves well in outdoor and harsh environments because it can be activated by a heavy stylus or gloved fingers.

Motion Control

Motion control most often employs joystick technology for applications requiring macro control, such as controlling the bucket on a payloader, a robotic arm, or directional control for a piece of materials handling equipment, or pull mechanisms.

Connecting/Communicating with an HMI System

Once you have established how your HMI will look, feel, and operate, you need to consider how the HMI will connect to and communicate with the core equipment or system under control. Typically, communication can be achieved through several approaches: hard wired connection, serial bus connection, or wireless connection.

Hard-Wired Connections

Conventional, hard wired systems are still used in many transportation and industrial legacy systems. Hard wired systems require no special tools and are simple, visible, and easy to understand, especially where the HMI interface controls a single machine. There are many drawbacks, including difficulty integrating changes or new features new features require new wiring. Conventional wiring also requires more space due to the number of wires and the actual size of the wires and larger connectors due to higher pin counts.

Serial Bus Systems

As equipment and control systems became more complex and data hungry, transmission of data became a critical issue. To facilitate faster data transmission rates, devices incorporated serial bus connections especially in electronics, semiconductor, machining, industrial, process and transportation. A serial bus approach eliminated data

transmission slowdowns due to cable length and delivered reliable, real-time operations and work-in-process feedback. Bus systems provide many advantages over hard wired connections, including easy addition of new functionality typically through software without adding or replacing hardware. Wiring is much simpler and more flexible with smaller cables and connectors allowing for more compact design, and easier hardware updating and relocation.

Field bus protocols evolved for interconnecting industrial drives, motors, actuators and controllers. Field buses include: PROFIBUS, DeviceNet, ControlNet, CAN/CANOpen, InterBus, and Foundation Field Bus.

Higher level networks connect with field bus protocols primarily across variations of Ethernet. These include: PROFINET, Ethernet/IP, Ethernet Powerlink, EtherCAT, Modbus-TCP and SERCOS III.

Wireless Connections/Communications

Industrial applications have employed wireless technologies over the last 20 or so years, primarily to take advantage of real-time data transmission, application mobility, and remote management capabilities. Interference, reliability, and security continue to present difficulties for wireless in the HMI universe.

Safety Considerations

For HMI Systems design, safety considerations are a critical part of the system. Human error is a contributing factor in most accidents in high-risk environments. Clear presentation of alarms as well as the ability to report errors, are crucial elements in any HMI.

In addition, emergency stop switches, generally referred to as E-Stops, ensure the safety of persons and machinery and provide consistent, predictable, failsafe control response. A wide range of electrical machinery must have these specialized switch controls for emergency shutdown to meet workplace safety and established international and domestic regulatory requirements.

International and U.S. Standards for HMI Systems

Key to the entire HMI System design cycle is a thorough knowledge of federal, industry, ergonomic, safety, and design standards. These include Human Engineering standards, such as MILSTD-1472F, which establishes human engineering design criteria for military systems, subsystems, equipment, and facilities; federal standards like those set by the Americans with Disabilities Act; and industry guidelines such as those from SEMI, the global semiconductor industry association, covering HMI for semiconductor manufacturing equipment.

Additional HMI specifications are furnished by ANSI, IEEE, ISO, and others. The EU provides specifications in its EU Machinery Directive for any equipment for domestic, commercial, or industrial applications that have parts actuated by a power source other than manual effort. Meeting this directive earns the equipment a CE mark.

There are also standards for public access HMI Systems, including security and cryptography standards for systems that handle payment cards; specific flammability standards and test procedures for transportation systems, and medical device and equipment standards.

Depending on the ultimate product application, observing appropriate standards assures that a product will meet industry criteria. This includes placement of components, legend size and color, emergency stop switch configuration and guards, and other ergonomic factors that improve usability, efficiency, and safety.

For more information on switches, check out www.eao.com.

SCADA

How This Tutorial Will Help You

SCADA monitoring and control can save you a lot of money and increase profitability but your SCADA implementation can be a sinkhole of cost overruns, delays and limited capabilities. This Tutorial will explain the essentials of SCADA technology, give you guidelines for evaluating SCADAtechnology and help you decide what kind of SCADA system is best for your needs.

Contents
Section I: What Is SCADA, and What Can It Do for You? 4 Where Is SCADA Used? 4 What's The Value Of SCADA to You? 5 Real-Time Monitoring And Control Increases Efficiency and Maximizes Profitability 5 Section 2: How SCADA Systems Work 6 The World's Simplest SCADA System 7 Data Acquisition 7 Data Communication 8

Data Presentation 9 Control 9 Section 3: How to Evaluate SCADA Systems and Hardware 10 The Two Most Important Components of Your SCADA System 10 A Brief Note on Sensors and Networks 10 What to Look for in a SCADA RTU (Remote Telemetry Unit) 11 What to Look for in a SCADA Master 12 Section 4: T/Mon NOC - An Integrated SCADA Monitoring and Control Solution 13 How Do You Know That T/Mon NOC Will Work for You? 14 What Do Real People Who Use T/Mon NOC Say? 14 Why You Need Help With Your SCADA Implementation 14 I'm Ready to Take a Serious Look at T/Mon NOC - What Do I Do Next? 15 My Promise to You 15 DPS Telecom's Sales Department: Monitoring Consultants Who Put You First 16 T/Mon NOC Product Data Sheet 18

Section 1: What is SCADA, and what can it do for you?

SCADA is not a specific technology, but a type of application. SCADA stands for Supervisory Control and Data Acquisition - any application that gets data about a system in order to control that system is a SCADA application. A SCADA application has two elements: 1. The process/system/machinery you want to monitor a control - this can be a power plant, a water system, a network, a system of traffic lights, or anything else. 2. A network of intelligent devices that interfaces with the first system through sensors and control outputs. This network, which is the SCADA system, gives you the ability to measure and control specific elements of the first system.

You can build a SCADA system using several different kinds of technologies and protocols. This white paper will help you evaluate your options and decide what kind of SCADA system is best for your needs.

Where is SCADA Used?

You can use SCADA to manage any kind of equipment. Typically, SCADA systems are used to automate complex industrial processes where human control is impractical - systems where there are more control factors, and more fast-moving control factors, than human beings can comfortably manage. Around the world, SCADA systems control: Electric power generation, transmission and distribution: Electric utilities use SCADA systems to detect current flow and line voltage, to monitor the operation of circuit breakers, and to take sections of the power grid online or offline. Water and sewage: State and municipal water utilities use SCADA to monitor and regulate water flow, reservoir levels, pipe pressure and other factors. Buildings, facilities and environments: Facility managers use SCADA to control HVAC, refrigeration units, lighting and entry systems. Manufacturing: SCADA systems manage parts inventories for just-in-time manufacturing, regulate industrial automation and robots, and monitor process and quality control. Mass transit: Transit authorities use SCADA to regulate electricity to subways, trams and trolley buses; to automate traffic signals for rail systems; to track and locate trains and buses; and to control railroad crossing gates. Traffic signals: SCADA regulates traffic lights, controls traffic flow and detects out-oforder signals. As I'm sure you can imagine, this very short list barely hints at all the potential applications for SCADAsystems. SCADA is used in nearly every industry and public infrastructure project - anywhere where automation increases efficiency. What's more, these examples don't show how deep and complex SCADA data can be. In every industry, managers need to control multiple factors and the interactions between those factors. SCADA systems provide the sensing capabilities and the computational power to track everything that's relevant to your operations.

What's the Value of SCADA to You?

Maybe you work in one of the fields I listed; maybe you don't. But think about your operations and all the parameters that affect your bottom-line results:

 Does your equipment need an uninterrupted power supply and/or a controlled temperature and humidity environment? Do you need to know - in real time - the status of many different components and devices in a large complex system? Do you need to measure how changing inputs affect the output of your operations? What equipment do you need to control, in real time, from a distance? Where are you lacking accurate, real-time data about key processes that affect your operations?

Real-Time Monitoring and Control Increases Efficiency and Maximizes Profitability

Ask yourself enough questions like that, and I'm sure you can see where you can apply a SCADA system in your operations. But I'm equally sure you're asking "So what?" What you really want to know is what kind of real-world results can you expect from using SCADA.

Here are few of the things you can do with the information and control capabilities you get from a SCADA system: Access quantitative measurements of important processes, both immediately and over time Detect and correct problems as soon as they begin Measure trends over time Discover and eliminate bottlenecks and inefficiencies Control larger and more complex processes with a smaller, less specialized staff. A SCADA system gives you the power to fine-tune your knowledge of your systems. You can place sensors and controls at every critical point in your managed process (and as SCADA technology improves, you can put sensors in more and more places). As you monitor more things, you have a more detailed view of your operations - and most important, it's all in real time.

So even for very complex manufacturing processes, large electrical plants, etc., you can have an eagle-eye view of every event while it's happening - and that means you have a knowledge base from which to correct errors and improve efficiency. With SCADA, you can do more, at less cost, providing a direct increase in profitability.

How SCADA Systems Work

A SCADA system performs four functions: 1. Data acquisition 2. Networked data communication 3. Data presentation 4. Control These functions are performed by four kinds of SCADA components: 1. Sensors (either digital or analog) and control relays that directly interface with the managed system. 2. Remote telemetry units (RTUs). These are small computerized units deployed in the field at specific sites and locations. RTUs (Remote Telemetry Units) serve as local collection points for gathering reports from sensors and delivering commands to control relays. 3. SCADA master units. These are larger computer consoles that serve as the central processor for the SCADA system. Master units provide a human interface to the system and automatically regulate the managed system in response to sensor inputs. 4. The communications network that connects the SCADA master unit to the RTUs in the field.

DPS Telecom Remote Site Survey

RTU (Remote Telemetry Unit) Capacity and Function
1. How many remote sites do you need to monitor? 2. Do you want video surveillance at those sites? 3. Do you want a building access control system to manage entry to those sites? 4. How many alarm points do you need to monitor at each site? 5. How much growth, in sites and alarms at each site, do you anticipate over the next 5 years? 6. Do you need any analog inputs (e.g., voltage, temperature, humidity, signal strength)?

7. How many ASCII device (e.g., switches, routers, etc.) will you monitor at your remote sites?

Installation
1. How do you currently connect to your remote sites? (LAN, overhead, digital or analog circuit, terminal server, microwave?) 2. Do any of your sites support an alternate path communications link? 3. What type of power do you have at the master and remote sites? (-48 VDC, 110 VAC, other?) 4. How do you want to mount your RTUs (Remote Telemetry Units)? (23" rack, 19" rack, wall, tabletop?) 5. Who will install your RTUs? This is just a small sample of the DPS Telecom Remote Site Survey. The full Remote Site Survey is a complete 5-page guide to evaluating your network alarm monitoring needs. For your copy of the Remote Site Survey, call DPS Telecom at 1-800-693-0351.

The World's Simplest SCADA System

The simplest possible SCADA system would be a single circuit that notifies you of one event. Imagine a fabrication machine that produces widgets. Every time the machine finishes a widget, it activates a switch. The switch turns on a light on a panel, which tells a human operator that a widget has been completed. Obviously, a real SCADA system does more than this simple model. But the principle is the same. A full-scale SCADA system just monitors more stuff over greater distances. Let's look at what is added to our simple model to create a full-scale SCADA system:

Data Acquisition

First, the systems you need to monitor are much more complex than just one machine with one output. So a real-life SCADA system needs to monitor hundreds or thousands of sensors. Some sensors measure inputs into the system (for example, water flowing into a reservoir), and some sensors measure outputs (like valve pressure as water is released from the reservoir). Some of those sensors measure simple events that can be detected by a straightforward on/off switch, called a discrete input (or digital input). For example, in our simple model of the widget fabricator, the switch that turns on the light would be a discrete input. In real life, discrete inputs are used to measure simple states, like whether equipment is on or off, or tripwire alarms, like a power failure at a critical facility. Some sensors measure more complex situations where exact measurement is important. These are analog sensors, which can detect continuous changes in a voltage or current input. Analog sensors are used to track fluid levels in tanks, voltage levels in batteries, temperature and other factors that can be measured in a continuous range of input. For most analog factors, there is a normal range defined by a bottom and top level. For example, you may want the temperature in a server room to stay between 60 and 85 degrees Fahrenheit. If the temperature goes above or below this range, it will trigger a threshold alarm. In more advanced systems, there are four threshold alarms for analog sensors, defining Major Under, Minor Under, Minor Over and Major Over alarms.

This RTU (Remote Telemetry Unit) Grows with Your Network

When you're planning your alarm monitoring, think about the future. You don't want to get locked into an alarm system that's inadequate for your future needs - but you don't want to spend too much for alarm capacity you won't immediately use, either. The NetGuardian 832A remote telemetry unit expands its capacity as your needs change. Install a NetGuardian at your remote site now, and get exactly the right coverage for your current needs. Then, as your remote site grows, you can extend your alarm monitoring capabilities by addingNetGuardian DX Expansion units. Each NetGuardian DX adds 48 more alarm points, and you can daisy-chain up to three NetGuardian DXs off each NetGuardian 832A base unit. Unit Base NG 832 1 DX 2 DX 3 DX Capacity 32 80 128 176

Data Communication
In our simple model of the widget fabricator, the "network" is just the wire leading from the switch to the panel light. In real life, you want to be able to monitor multiple systems from a central location, so you need a communications network to transport all the data collected from your sensors. Early SCADA networks communicated over radio, modem or dedicated serial lines. Today the trend is to put SCADA data on Ethernet and IP over SONET. For security reasons, SCADA data should be kept on closed LAN/WANs without exposing sensitive data to the open Internet. Real SCADA systems don't communicate with just simple electrical signals, either. SCADA data is encoded in protocol format. Older SCADA systems depended on closed proprietary protocols, but today the trend is to open, standard protocols and protocol mediation. Sensors and control relays are very simple electric devices that can't generate or interpret protocol communication on their own. Therefore the remote telemetry unit (RTU) is needed to provide an interface between the sensors and the SCADA network. The RTU (Remote Telemetry Unit) encodes sensor inputs into protocol format and forwards them to the SCADA master; in turn, the RTU (Remote Telemetry Unit) receives control commands in protocol format from the master and transmits electrical signals to the appropriate control relays.

What RTU (Remote Telemetry Unit) Features Do You Need?

How do you find the right RTU (Remote Telemetry Unit)? Here's 5 essential features to look for

1. Discrete alarms: Monitor device failures, intrusion alarms, beacons, and flood and fire detectors. 2. Analog alarm inputs: Monitor voltage, temperature, humidity and pressure. 3. Control relays: Operate remote site equipment directly from your SCADA master. 4. Redundant backup communication: Backup serial ports and/or internal modems will keep your monitoring online even during a LAN failure. 5. Redundant backup power inputs: Dual power inputs and battery backup keep monitoring online, even during power failures. DPS Telecom offers RTUs that meet all these requirements - and offer local visibility via Web browser, email and pager notification, and more. For more information about DPS RTUs, see us on the Web at www.dpstelecom.com/rtus. How to select an RTU that covers all your remote monitoring needs

Migrate to LAN Without Killing Your Budget

Installing LAN connections at remote sites is a significant cost - but you can spread if over several budget cycles through LAN migration. Here's how:

Step One: Install a LAN + Dial-Up/Serial RTU (Remote Telemetry Unit)

First, install an RTU (Remote Telemetry Unit) that supports both LAN and your existing dialup or serial transport, like the NetGuardian 832A

Step Two: Install a LAN Connection

When it fits into your budget, install a LAN connection at the remote site. The same NetGuardian unit can be immediately switched to reporting over LAN with minimal configuration - and you don't have to rewire any alarms. Gradually migrate different sections of your network to LAN, as your budget and installation manpower allows.

Benefits of LAN Migration

Installation costs are spread over several budget cycles Buy just one RTU (Remote Telemetry Unit) for both LAN and legacy transport

 Deploy SCADA NOW at all your locations More Info Resouces on the Web

The DPS Telecom White Paper Series offers a complete library of helpful advice and survival guides for every aspect of system monitoring and control. www.dpstelecom.com/white-papers

Data Presentation
The only display element in our model SCADA system is the light that comes on when the switch is activated. This obviously won't do on a large scale - you can't track a lightboard of a thousand separate lights, and you don't want to pay someone simply to watch a lightboard, either. A real SCADA system reports to human operators over a specialized computer that is variously called a master station, an HMI (Human-Machine Interface) or an HCI (HumanComputer Interface). The SCADA master station has several different functions. The master continuously monitors all sensors and alerts the operator when there is an "alarm" - that is, when a control factor is operating outside what is defined as its normal operation. The master presents a comprehensive view of the entire managed system, and presents more detail in response to user requests. The master also performs data processing on information gathered from sensors - it maintains report logs and summarizes historical trends. An advanced SCADA master can add a great deal of intelligence and automation to your systems management, making your job much easier.

Control
Unfortunately, our miniature SCADA system monitoring the widget fabricator doesn't include any control elements. So let's add one. Let's say the human operator also has a button on his control panel. When he presses the button, it activates a switch on the widget fabricator that brings more widget parts into the fabricator. Now let's add the full computerized control of a SCADA master unit that controls the entire factory. You now have a control system that responds to inputs elsewhere in the system. If the machines that make widget parts break down, you can slow down or stop the widget

fabricator. If the part fabricators are running efficiently, you can speed up the widget fabricator. If you have a sufficiently sophisticated master unit, these controls can run completely automatically, without the need for human intervention. Of course, you can still manually override the automatic controls from the master station. In real life, SCADA systems automatically regulate all kinds of industrial processes. For example, if too much pressure is building up in a gas pipeline, the SCADA system can automatically open a release valve. Electricity production can be adjusted to meet demands on the power grid. Even these real-world examples are simplified; a full-scale SCADA system can adjust the managed system in response to multiple inputs.

T/Mon NOC Automatically Troubleshoots and Corrects Problems

The same alarm can instantly go from minor to critical if something else goes wrong. For example, a low battery might not be a big deal until AC power and the backup generator both fail, and then it's an emergency. T/Mon NOC's Derived Alarms feature gives you the power to instantly track these kinds of changing alarm conditions. Derived Alarms combine inputs from multiple alarm points into a single, software-configured alarm, using simple Boolean logic. Let's say your low battery is a minor alarm. Low battery AND an AC power failure OR generator failure is a major. Low battery AND AC power failure AND generator failure is a critical alarm.

Correct Alarms Instantly With No Human Intervention

T/Mon NOC's Derived Controls are even more useful, correcting problems before any human operator even knows something is wrong. If critical network equipment fails, T/Mon NOC can automatically start backup equipment and notify a service tech. If a security door is breached after-hours, T/Mon NOC can automatically lock security gates, turn on lights, and page security staff.

How to Evaluate SCADA Systems and Hardware

SCADA can do a lot for you - but how do you make sure that you're really getting the full benefits of SCADA? Evaluating complex systems can be tricky - especially if you have to learn a new technology while still doing your everyday job. But you've got to be able to make an informed decision, because the stakes are incredibly high. A SCADA system is a major, business-to-business purchase that your company will live with for maybe as long as 10 to 15 years. When you make a recommendation about a permanent system like that, you're laying your reputation on the line and making a major commitment for your company. And as much as SCADA can help you improve your operations, there are also some pitfalls to a hasty, unconsidered SCADA implementation: You can spend a fortune on unnecessary cost overruns Even after going way over budget, you can STILL end up with a system that doesn't really meet all your needs Or just as bad, you can end up with an inflexible system that just meets your needs today, but can't easily expand as your needs grow So let's go over some guidelines for what you should look for in a SCADA system.

The Two Most Important Components of Your SCADA System

Although you need sensors, control relays and a communications network to make a complete SCADAsystem, it's your choice of a master station and RTUs that really determine the quality of your SCADA system.

A Brief Note on Sensors and Networks

Sensors and control relays are essentially commodity items. Yes, some sensors are better than others, but a glance at a spec sheet will tell you everything you need to know to choose between them. An IP LAN/WAN is the easiest kind of network to work with, and if you don't yet have LAN capability throughout all your facilities, transitioning to LAN is probably one of your longterm goals. But you don't have to move to LAN immediately or all at once to get the benefits of SCADA. The right SCADA system will support both your legacy network and LAN, enabling you to make a graceful, gradual transition.

The Flexible RTU (Remote Telemetry Unit) That Handles All Your Transports

With the NetGuardian 832A, multiple transports are no problem. The NetGuardian supports LAN, dial-up and serial connections simultaneously. So as your network upgrades from legacy transports to LAN, you can use the same NetGuardian units at all your sites.

What can the NetGuardian do for you?

You can use one RTU (Remote Telemetry Unit) at all your remote sites, no matter what transport is available. You don't have to install new transport to collect alarms. As your network changes, you don't have to buy new remotes for new transports. You only have to maintain one set of spare units and spare parts for your entire network, for great cost savings and convenience.

What to Look for in a SCADA RTU (Remote Telemetry Unit)

Your SCADA RTUs need to communicate with all your on-site equipment and survive under the harsh conditions of an industrial environment. Here's a checklist of things you should expect from a quality RTU: Sufficient capacity to support the equipment at your site but not more capacity than you actually will use. At every site, you want an RTU (Remote Telemetry Unit) that can support your expected growth over a reasonable period of time, but it's simply wasteful to spend your budget on excess capacity that you won't use. Rugged construction and ability to withstand extremes of temperature and humidity. You know how punishing on equipment your sites can be. Keep in mind that your SCADA system needs to be the most reliable element in your facility. Secure, redundant power supply. You need your SCADA system up and working 24/7, no excuses. Your RTU (Remote Telemetry Unit) should support battery power and, ideally, two power inputs. Redundant communication ports. Network connectivity is as important to SCADA operations as a power supply. A secondary serial port or internal modem will keep your RTU (Remote Telemetry Unit) online even if the LAN fails. Plus, RTUs with multiple communication ports easily support a LAN migration strategy. Nonvolatile memory (NVRAM) for storing software and/or firmware. NVRAM retains data even when power is lost. New firmware can be easily downloaded to

NVRAM storage, often over LAN - so you can keep your RTUs' capabilities up to date without excessive site visits. Intelligent control. As I noted above, sophisticated SCADA remotes can control local systems by themselves according to programmed responses to sensor inputs. This isn't necessary for every application, but it does come in handy for some users. Real-time clock for accurate date/time stamping of reports. Watchdog timer to ensure that the RTU (Remote Telemetry Unit) restarts after a power failure.

3 RTUs to Fit Your Spec and Budget

The NetGuardian RTU (Remote Telemetry Unit) family scales to fit your needs

Full-featured NetGuardian 832A: 32 discretes, 32 pings, 8 analogs and 8 controls 8 terminal server serial ports NEBS Level 3 certified Dial-up backup Web browser interface Pager and email notification Dual -48 VDC, -24 VDC or 110 AC 1 RU for 19" or 23" rack

Heavy-duty NetGuardian 480 80 discretes, 4 controls For SNMP , TL1 or T/Mon NOC Dual -48 VDC 1 RU for 19" or 23" rack

Economical NetGuardian 216 16 discretes, 2 analogs, 2 controls 1 terminal server serial port For SNMP , TL1 or T/Mon NOC Single or dual -48VDC or 110 VAC 2 compact form factors for rack or wall mount

What to Look for in a SCADA Master

Your SCADA master should display information in the most useful ways to human operators and intelligently regulated your managed systems. Here's a checklist of SCADA master must-haves: Flexible, programmable response to sensor inputs. Look for a system that provides easy tools for programming soft alarms (reports of complex events that track combinations of sensor inputs and date/time statements) and soft controls (programmed control responses to sensor inputs). 24/7, automatic pager and email notification. There's no need to pay personnel to watch a board 24 hours a day. If equipment needs human attention, the SCADA master can automatically page or email directly to repair technicians.

Detailed information display. You want a system that displays reports in plain English, with a complete description of what activity is happening and how you can manage it. Nuisance alarm filtering. Nuisance alarms desensitize your staff to alarm reports, and they start to believe that all alarms are nonessential alarms. Eventually they stop responding even to critical alarms. Look for a SCADA master that includes tools to filter out nuisance alarms. Expansion capability. A SCADA system is a long-term investment that will last for as long as 10 to 15 years. So you need to make sure it will support your future growth for up to 15 years. Redundant, geodiverse backup. The best SCADA systems support multiple backup masters, in separate locations.. If the primary SCADA master fails, a second master on the network automatically takes over, with no interruption of monitoring and control functions. Support for multiple protocols and equipment types. Early SCADA systems were built on closed, proprietary protocols. Single-vendor solutions aren't a great idea - vendors sometimes drop support for their products or even just go out of business. Support for multiple open protocols safeguards your SCADA system against unplanned obsolescence.

For more in-depth look at SCADA

Alarm Master Choice: T/Mon NOC

T/Mon NOC has many features to make your alarms more meaningful, including: 1. Detailed, plain English alarm descriptions include severity, location and date/time stamp. 2. Immediate notification of COS alarms, including new alarms and alarms that have cleared 3. Standing alarm list is continuously updated.

4. Text message windows displaying specific instructions for the appropriate action for an alarm. 5. Nuisance alarm filtering, allowing your staff to focus its attention on serious threats. 6. Pager and email notifications sent directly to maintenance personnel, even if they're away from the NOC. 7. Derived alarms and controls that combine and correlate data from multiple alarm inputs and automatically control remote site equipment to correct complex threats. For more information, check out T/Mon on the Web at www.dpstelecom.com/tmon.

Section 4: T/Mon NOC - An Integrated SCADA Monitoring and Control Solution

My company, DPS Telecom, manufactures T/Mon NOC, a master unit that serves as the core of an integrated SCADA system for all your equipment. T/Mon NOC can meet all the criteria I've listed for a superior SCADA master and can do a whole lot more.

What Can T/Mon NOC Do for You?

T/Mon NOC provides a single, one-screen view of all your monitored equipment. T/Mon NOC will tell you 100% for certain whether anything has gone wrong with any of your monitored equipment, so you can be absolutely sure there are no secret problems anywhere in your system. T/Mon NOC can monitor up to 1 million alarm points, giving you ample capacity to monitor everything in your facilities.

 T/Mon NOC presents information in simple, plain English, including detailed text messages telling system operators exactly what to do in case of an emergency. T/Mon NOC's Derived Alarms and Derived Controls let you automate every aspect of your systems using simple Boolean logic. You can filter alarms for the needs of different users. You can select which alarms are immediately forwarded to technicians via pager and email, which alarms can be viewed locally on the T/Mon NOC console, and which alarms are just logged to a history file for recording and later analysis. At every level of your organization, people can see the information they want without being bombarded with nuisance alarms. Actually, this list just scratches the surface of T/Mon NOC's capabilities. For more information about what T/Mon NOC can do for you, see the T/Mon NOC Product Data Sheet on page 16.

5 Ways T/Mon NOC Saves You Money

1. It's a single unit solution. Instead of replacing every RTU (Remote Telemetry Unit) in your network, you can immediately deployT/Mon NOC and start using SCADA monitoring NOW. 2. Minimal installation costs. A DPS installer will set up and configure your T/Mon NOC for you compare that to the manpower costs of installing new RTUs at all your remote sites. 3. Replace RTUs when YOU want. With T/Mon NOC, your legacy RTUs are just fine doing what they're currently doing until you decide to replace them. You can keep them until they die or replace them whenever replacement will have the smallest impact on your budget. 4. Keep your data transport. Whether your legacy RTUs report over a serial line, a dedicated circuit, an overhead channel or microwave, T/Mon NOC supports your existing data transport. 5. No vendor lock-in. When you upgrade to T/Mon, you're not trading in one closed system for another you're trading up to a true multiprotocol alarm system.

How Can You Know That T/Mon NOC Will Work for You?

T/Mon NOC is not a new or untested product. T/Mon units have been in the field for years, successfully performing for clients who need stable, bulletproof monitoring and control to support their mission-critical operations.

What Do Real People Who Use T/Mon NOC Say?

"DPS Telecom gave us a reliable way of accessing a variety of equipment, regardless of the brand or provider. We now have a common interface for our existing system." Harold Moses, KMC Telecom "DPS told us we didn't have to pay if it didn't work. It works and it's sweet." Glenn Lippincott, Southern Company "It's hard to find companies with the intelligence and aptitude to meet the customer's exact needs, and I believe that is what DPS is all about." Lee Wells, Pathnet

Why You Need Help With Your SCADA Implementation

Implementing an SCADA system can seem deceptively easy - you just look on the Web, find a few vendors, compare a few features, add some configuration and you're done, right? The truth is, developing a SCADA system on your own is one of the riskiest things you can do. Here are some of the typical problems you might face if you don't get expert advice when you're designing your system: 1. Implementation time is drawn out: It's going to take longer than you think. Network monitoring is a highly technical subject, and you have a lot to learn if you want a successful implementation. And anytime you are trying to do something you've never done before, you are bound to make mistakes - mistakes that extend your time and your budget beyond their limits. 2. Resources are misused: If you're not fully informed about your options for systems integration, you may replace equipment that could have been integrated into your new system. Rushing into a systemwide replacement when you could have integrated can cost you hundreds of thousands of dollars. 3. Opportunities are missed: If you install a new SCADA system today, you're committing your company to that system for as long as 10 to 15 years. Many companies design what they think is a state-of-the-art SCADA system - and then find that their technology is actually a generation behind.