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Energy Reports 8 (2022) 934–941

www.elsevier.com/locate/egyr

2021 8th International Conference on Power and Energy Systems Engineering (CPESE 2021),
10–12 September 2021, Fukuoka, Japan

Implementation of control and SCADA system: Case study of Allen

Bradley PLC by using WirelessHART to temperature control and
device diagnostic
Teerawat Thepmaneea , Sawai Pongswatda ,∗, Farzin Asadib , Prapart Ukakimaparna
a School of Engineering, King Mongkut’s Institute of Technology Ladkrabang, Ladkrabang, Bangkok, 10520, Thailand
b Department of Electrical and Electronics Engineering, Maltepe University, Istanbul, Turkey

Received 26 October 2021; accepted 8 November 2021

Available online 28 November 2021

Abstract
System integration for process automation promoted the technologies that were accessed to functions and data of field device,
controller, and SCADA system. In addition, the data from filed devices can apply to solve device diagnostic and preventive
maintenance. This paper describes the practical technique to configure and implement of control and SCADA system that focus
on integration of field device, PLC controller, and SCADA system. The paper presents case study of Allen-Bradley (AB) PLC
by using WirelessHART device to temperature control and device diagnostic through SCADA system. PLC’s input/output (I/O)
modules are installed that consists of Modbus module, digital I/O module, analog I/O module. In addition, Prosoft configuration
builder and Studio 5000 software are new software to build add on Modbus instruction and ladder diagrams, respectively. The
experiments perform in case study of temperature control by using Proportional–Integral–Derivative (PID) function in the AB
PLC. Wonderware InTouch SCADA software is implemented to monitor the process mimic, trend, and alarm. Moreover, the
technique can support the operators and engineers to make decision for process control and devices diagnostic.
© 2021 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 2021 8th International Conference on Power and Energy Systems Engineering,
CPESE, 2021.

Keywords: PLC; SCADA; Temperature control; WirelessHART; PID; Studio 5000

1. Introduction
Now a day, the development of industrial networks can apply to field devices, controller, and SCADA system.
Their capability to transmit and receive the data are greatly increased. Moreover, industrial Wireless LAN (IWLAN)
has grown significantly. These technologies offer durability and high reliability so they can work continuously
without problems. WirelessHART technology is quite the answer about industrial automation applications has been
described [1]. It is an open standard designed for the device. It detects a connected signal at 4 – 20 mA analog
∗ Corresponding author.
E-mail address: sawai.po@kmitl.ac.th (S. Pongswatd).

https://doi.org/10.1016/j.egyr.2021.11.163
2352-4847/© 2021 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http:
//creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 2021 8th International Conference on Power and Energy Systems
Engineering, CPESE, 2021.
T. Thepmanee, S. Pongswatd, F. Asadi et al. Energy Reports 8 (2022) 934–941

loop and provides a baud rate at 250 kbps. The technology provides a time-synchronized standard and can manage
itself. Channel hopping to avoid signal interference and enable working in conjunction with other wireless networks
that are compatible [2]. Moreover, Practical technique to design and implement the system for remotely monitoring
key performance indicators (KPIs) in operation with SCADA software has been introduced [3]. The technique that
applies a PLC to control process operations and the use of SCADA to monitor status, as well as to display different
values of equipment and to control the process remotely has been proposed [4,5]. Based on the above-mentioned
precautions, the researchers are interested in wireless networking technology, so this research was conducted to
study the functions and use of WirlessHART device by applying it to the temperature control process. Expecting to
gain knowledge and understanding the use of WirelessHART technology in process automation. The engineering
technique for configuration between WirelessHART device, 4–20 mA analog device and AB PLC are described.
In addition, industrial processes that use controllers must integrate a SCADA system. Integration of control and
SCADA available real time monitoring and control. In addition, the operator can achieve many tasks such as safety,
productivity, and quality. The paper presents practical technique to configure and implement the control and SCADA
system. Prosoft configuration builder and Studio 5000 software are built add on instruction and ladder diagrams,
respectively. In addition, AB PLC with Studio 5000 software and Wonderware InTouch software are applied to
implement the control and SCADA integration. The case study of temperature control to confirm the proposed
method that can control and monitor the assigned variable. Moreover, diagnostic data from WirelessHART’s device
can be shown with HMI on SCADA system.

2. Background and related devices

2.1. Field device and controller

Programmable Logic Controller (PLC) is a special computer used to control machinery and processes, such
as control of machinery on the production line of the factory. The Studio 5000 Logix Designer is used for the
programming purpose software of the AB PLC [6]. The compact logix L30ER that is a model of PLC that is a
main controller of this proposed system. It connects to Modbus module, digital I/O modules, analog I/O modules.
The proposed system uses 2 types of field devices that are analog device and WirelessHART device.

2.2. SCADA system

SCADA is a short for Supervisory Control and Data Acquisition. It is a real-time data monitoring and analysis
system used to monitor status and control the operation of various industrial and engineering controls [7]. Function
to calculate and process data from various hardware such as PLC, DCS, RTU then display the data on the screen.
The Wonderwate InTouch program is the most popular SCADA software that was used to create the HMI, trend,
alarm in this work. Moreover, it in order to show the operating state of the temperature control, PV, SV, alarm
status.

2.3. WirelessHART

WirelessHART is a wireless sensor network technology that uses the Highway Addressable Remote Transducer
Protocol (HART). The protocol uses a time mesh architecture that is synchronized, self-organizing and self-healing.
The protocol supports operation in the frequency band of 2.4 GHz ISM. In addition, the technology designs based
on IEEE 802.15.4 [8,9]. The WirelessHART device which is a temperature transmitter receive and sent data from
temperature process to PLC via WirelessHART network.

2.4. PID controller

PID is a control function on PLC that is applied for feedback control system or a closed-loop control system in
which the error value is the difference between the SV and the PV. Compute the controller, trying to reduce the
error value by modulating the input signal of the system. The PID calculation method is based on three variables:
Proportion, Integral, and Derivative. Current error the integral value is determined by the sum of the past errors and
the derivative is determined by the rate of change of the error. The block diagram of the PID controller is shown
in Fig. 1.
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Fig. 1. Block diagram of proposed control loop.

3. WirelessHART installation and configuration

Field device which is temperature transmitter. It is connected to THUM adapter that converts WireHART signal
to WirelessHART. Field device is configured channel = 1, Unit = degree Celsius, Upper Range Value = 100, Lower
Range Value = 0. In addition, THUM adapter is configured to communicate to HART gateway. It configures tag
name = TT 101, network ID = 23481, and joint key. Block diagram and devices of proposed system is shown by
Fig. 2. The temperature transmitter installation and THUM adapter that are configured by 475 Field Communicator
can be shown by Fig. 3(a).

Fig. 2. Block diagram of data flow of proposed system.

Fig. 3(a). Temp. transmitter, THUM adapter, HART gateway and 475 Field Communicator.

The HART technology provides HART Standard EDD PV that supports the device parameters and diagnostic
data such that Primary Variable (PV) is mapped to Device Variable code 0, Secondary Variable (SV) is mapped
to Device Variable code 1, Tertiary Variable (TV) is mapped to Device Variable code 2, and Quaternary Variable
(QV) is mapped to Device Variable code 3. WirelessHART gateway configure screen is shown by Fig. 3(b) that
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Fig. 3(b). WirelessHART gateway configure screen.

Fig. 4. Network architecture of proposed system.

display the parameters such as Name is tag name = TT 101, PV is electronic board temperature = 31.045 DegC.
Moreover, diagnostic data is automatically designed and mapped.

4. Implementation of control and SCADA system

The implementation between control and SCADA system of this work uses Studio 5000 and Wonderware InTouch
software to implement control function and HMI, respectively. The Studio 5000 is a new engineering program from
Rockwell Automation. It is installed on engineering station to create the control procedure with ladder diagram based
on IEC 61131-3 standard then download to AB PLC. Moreover, the proposed technique creates add on instruction
to exchange assigned data between WirelessHART devices and PLC. HMI on operator station in order to display
process mimic, control parameters, process alarm and device diagnostics.
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Fig. 5(a). Block diagram of temperature control system.

4.1. System integration

The proposed system integrates control and SCADA system. AB PLC model L30ER is used as controller which
cooperates with SCADA system on supervisory level. Fig. 4 shows network architecture of proposed system that
consists of 3 levels. Field level focuses on field devices installation and configuration. Temperature transmitter and
power regulator with light bulb are installed and configured as sensor and actuator, respectively. Control level applies
AB PLC with analog I/O module and Modbus module connect to field devices from field level. Process control
start by I/O modules of PLC at control level send CV to power regulator then receives the PV from WirelessHART
gateway. Add on Modbus TCP/PI instruction is built for data transfer from WirelessHART gateway to PLC’s Modbus
module. Control function is PID function that is standard instruction of Studio 5000 software on engineering station.
Control procedure can be shown by block diagram of Fig. 5(a). Moreover, all tag names for process control, process
behavior, and device diagnostics are mapped to HMI on operator station of supervisory level.

4.2. Alarm

Alarm status are proposed to show malfunctions in operation, display alarm values and alarm status. The system
configures 4 values of process alarm that are HighHigh (HiHi), High(Hi), Low(Lo), and LowLow(LoLo). When
PV send value out of configuration value the operator station alerts the abnormal status to operator. Procedure of
alarm alert and alarm status are configured follow Fig. 5(b).
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Fig. 5(b). Block diagram of alarm system.

4.3. Device diagnostic

Field device is a WirelessHART that can be viewed as a remote I/O system. It communicates to a gateway that
collects all of the process and device diagnostics information. In addition, the gateway exchange assigned data with
PLC by tag name mapping. The diagnostic information such as device problems, loop current faults or if a device
needs maintenance alert to operator station. Device diagnostics have an aim of bringing together manufacturing’s
concept and user’s expectation to making use of the capabilities in WirelessHART device diagnostics. The
diagnostics are broken down into failure, off-specification, maintenance, and check function.

5. Experimental results
The proposed system performs with WirelessHART device, AB PLC, InTouch software to implement the system
from field level, control level, and supervisory level, respectively. As a case study start from supervisory level that
select either Manual or Auto mode of PID control. Then, SV send from SCADA to control system that execute SV
and PV with PID function then PLC feed CV to SCR power regulator. Fig. 6(a) shows main screen of SCADA that
has graphic of overall to display mode and setpoint, alarm to show the alarm list, parameter to show assigned HART
parameters, PID for PID tuning, temperature to show the real time temperature from WirelessHART transmitter. In
addition, operator can access to PID tuning screen by click on PID graphic on main screen then the PID Tuning
screen is shown and replaced the overall graphic of main screen. The PID tuning graphic can be shown by Fig. 6(b).
The operator can fill in the PID parameters such as Kp, Ki, Kd for proportional, integral, and derivation action,
respectively. Alarm screen can be shown by Fig. 6(c) that shows alarm list when the value of assigned tag name
over the configuration value (HIHI, HI, LO, LOLO). Fig. 6(d) shows screen of device diagnostics which focuses
on HART parameters. HART parameters such as Primary Variable (TT 101.PV, wihartg.PV), Secondary Variable
(TT 101.SV, wihartg.SV), Tertiary Variable (wihartg.TV), Quaternary Variable (wihartg.QV) mapped and shown on
the screen.

6. Conclusion
In this paper proposed case study of AB PLC by using Modbus module with WirelessHART to temperature
control through SCADA. The proposed systems offered technique to install and configure the AB PLC with Stu-
dio5000, temperature transmitter, and WirelessHART gateway. The proposed technique to build add on instruction
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Fig. 6(a). Main screen of SCADA.

Fig. 6(b). Control parameters and PID tuning screen.

Fig. 6(c). Screen of process alarm.

Fig. 6(d). Screen of device diagnostics.

to transfer all assigned parameter from WirelessHART devices to PLC and SCADA system. Then the parameters of
field devices for process control and devices diagnostic are available to PLC and SCADA system. The results shown
the assigned data and HMI that can display the control parameters, trend graphs, alarm, and diagnostic statuses.
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Moreover, the technique can guideline the system integrator in Thailand to apply the WirelessHART technology
and system integration from different manufacturers of hardware and software.

Declaration of competing interest

The authors declare that they have no known competing financial interests or personal relationships that could
have appeared to influence the work reported in this paper.

Acknowledgments
The software licenses of this work has been supported by Rockwell Automation Thai and Petro Instrument Co.,
Ltd, Thailand. The authors would like to thank Mr. Thanabodee Sukto, Mrs. Wanatpreeya Janprom, Mr. Satana
Ruksaphan for the hardware installation and performing in initial stage of this work.

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