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Automation is becoming more prevalent; with little attention from the operator, machines can perform tasks such as performing actions automatically, analyzing, and acquiring data.

This is due to the collaboration of systems such as SCADA and products such as PLCs or HMIs in order to increase productivity, improve safety, and collect all necessary data from the field.

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What is a PLC?

A programmable logic controller (PLC) is a type of industrial computer that can control a single process, a machine system, or even an entire production line.

A PLC is a type of industrial computer that lacks a mouse, keyboard, and monitor. In the general computer, a logical program to control the process is prepared because it is an industrial computer.

The program is then transferred to the PLC via cables. This program is saved in the memory of the PLC. A programming language known as Ladder logic, Statement List, or Functional block diagram is used to create the logical program.

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A programme is designed so that people with an electrical or instrumentation background can easily understand it.

A Programmable Logic Controller is made up of numerous input and output terminals. A PLC monitors the status of switches and sensors via input terminals and sends commands to output devices via output terminals based on this status.

What is SCADA?

SCADA (Supervisory Control and Data Acquisition), as the name implies, primarily performs three functions:

Monitor real-time data in the form of a graphical presentation.

Control industrial processes either locally or remotely.

Obtain both real-time and log data.

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SCADA systems are important in industrial organisations because they help to monitor process data, control processes, and easily detect any issues within the process, reducing downtime.

SCADA, in general, is a software package that aids in the monitoring of the entire plant. The SCADA's basic architecture begins with a Programmable Logic Controller (PLC) or Remote Terminal Units (RTUs).

PLCs and RTUs, as we all know, are microprocessors that communicate with field devices such as valves, pumps, sensors, HMIs, and other end devices. All collected data from end devices is routed through these devices to SCADA computers.

The SCADA software then distributes and displays the data on the monitor to help the operator understand the field condition.

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Interfacing PLC with SCADA:

To connect a PLC to SCADA, we must first establish a proper communication channel or bus. The monitoring PC, which contains SCADA software, must be connected to this communication channel via its communication port.

SCADA software supports a variety of communication protocols, including

MPI/DP

Profibus

Ethernet

OPC, etc.

We must now confirm the PLC protocols. In general, PLC protocols include MPI/DP, Ethernet, Serial Port, and so on.

This is the first step in testing the communication protocols that both the PLC and the SCADA have.

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