An introduction to Rockwell Automation's range of machine-level HMI solutions
In this post, I’ll introduce you to Rockwell Automation’s range of machine-level visualization solutions.
After reading this post, you’ll know what Rockwell Automation solutions are available for machine-level HMI applications. You will also be able to pick the best solution for a given application.
If you aren’t familiar with the terms visualization or HMI, then you should probably read this visualization concepts post first. It introduces the concept of visualization in industrial automation and explains some common features of visualization solutions.
Before we dive into the details of Rockwell Automation’s visualization solutions, let’s address the elephant in the room:
Why do people use Rockwell Automation HMI solutions in their machines?
In general, Rockwell Automation software and Allen Bradley hardware is not cheap, so why would someone choose to use Rockwell Automation solutions?
There are two core reasons:
Customers specify Rockwell Automation
If a customer specifies Rockwell Automation, then the OEM building the machine has to use a Rockwell Automation HMI solution. Many US customers have standardize on Rockwell Automation solutions so it is quite common for Rockwell Automation HMI solution to be specified.
They value premier integration.
Rockwell Automation products integrate very well with each other. If you are using a Rockwell Automation PLC, then the easiest HMI to integrate with will be a Rockwell Automation HMI. Different products have different levels of premier integration, but at its core premier integration makes it easier to build HMI applications for a PLC.
Let’s look at what premier integration means in more detail.
If you are building a HMI application for an Allen Bradley PLC using a third-party solution, you generally have to build a tag database to be used by the HMI application. This database basically maps tags in the PLC to tags in the HMI and is an extra component that has to be created and maintained.
Rockwell Automation HMI solutions support direct tag referencing which allows you to read tags directly from the project file or the controller. This eliminates the need to create and maintain a tag database.
Most third-party HMI solutions manage alarms on the HMI. This is fine most of the time, but if the HMI loses connection with the controller some alarm conditions may go undetected.
When using Rockwell Automation HMI solutions, alarms can be handled in the controller. With controller-based alarming, alarm conditions are still recorded when the connection to the HMI is lost and active alarms can be reported to the HMI when the connection is restored.
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Rockwell Automation offers a hug library of pre-defined HMI objects and backing PLC code for common functions and products. These objects are called faceplates.
Faceplates are pre-built, pre-tested, and well-documented objects that allow you to build HMI applications quickly and easily.
For example, there is a faceplate available for PowerFlex drives. This faceplate allows you to control, configure, and troubleshoot a PowerFlex drive through the HMI without writing any code or building anything in the HMI.
Since faceplates are editable, they can be used as provided or as a kicking off point for a custom development.
Faceplates can help to dramatically reduce the amount of time spent engineering, testing, commissioning, and troubleshooting an HMI application.
Faceplates can be downloaded for free from Rockwell Automation’s Sample Code website.
Rockwell Automation offers a DCS for the process industry called PlantPAx. This is a collection of Rockwell Automation products, software, and pre-engineered application code that have been tested and characterized to meet the needs of the process industry.
Using PlantPAx, companies can deliver large process control applications using proven control strategies to deliver rich functionality and known performance.
A key component of the PlantPAx DCS system is Rockwell Automation HMI solutions, so if you want to deploy a PlantPAx system, you will be using Rockwell Automation HMI solutions.
OK, so now that we know why people using Rockwell Automation HMI solutions, let’s look at the machine-level HMI solutions that are available to use.
Remember that a machine-level HMI solution typically controls one machine and is implemented on local hardware. Usually this local hardware is a dedicated HMI terminal, but it may also be an industrial PC.
Rockwell Automation has a range of different machine-level HMI solutions that are suitable for different applications.
Let’s start by looking at the PanelView 5000 HMI solution.
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The PanelView 5000 HMI solution is a modern HMI solution from Rockwell Automation.
PanelView 5000s are programmed with Studio 5000 View Designer. This software is bundled with Studio 5000 Logix Designer, so if you have a Logix Designer license, you don’t need to buy any additional software to program PanelView 5000 HMIs.
PanelView 5000 HMIs have premier integration with Logix 5000 controllers. Out of the box, PanelView 5000 HMIs have built-in diagnostics for Logix 5000 controllers and automatically import alarms from a Logix Designer project. These features make it fast and easy to build HMI applications for Logix 5000 PLCs.
There are some limitations to the PanelView 5000 platform that you should be aware of. Most of these limitations revolve around backwards compatibility.
For example, PanelView 5000 HMIs can only communicate with Logix 5000 controllers running firmware version 27 and later. They also only support ethernet networks and cannot communicate over legacy networks like DeviceNet. This means that PanelView 5000 HMIs are not suitable for applications that require backwards compatibility with older systems.
The PanelView 5000 HMI solution is ideal for anyone who wants to use a modern HMI platform to provide an interface for Logix 5000 control systems and does not have backwards compatibility requirements.
You can learn how to program PanelView 5000 HMIs with our AB-LGX-HMI learning path.
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PanelView Plus is an older HMI solution.
Despite the fact that it is older than the PanelView 5000 solution, PanelView Plus is still an important part of Rockwell Automation’s machine-level HMI portfolio. This is primarily because PanelView Plus HMIs have a massive install base and is the only HIM solution in Rockwell Automation’s portfolio that supports legacy automation networks.
PanelView Plus HMIs are programmed using FactoryTalk View ME, which stands for Machine Edition. This is a paid software product that is purchased separately from the HMI hardware.
There are several version of PanelView Plus HMIs available to buy. These include PanelView Plus 7 Performance, PanelView Plus 7 Standard, PanelView Plus 6, and PanelView Plus 6 Compact.
Generally speaking, the PanelView Plus 7s are lower-cost and built with modern hardware while the PanelView Plus 6s are higher-cost and built with older hardware. Some companies continue to buy PanelView Plus 6s because they have a large install base and can communicate over legacy networks.
Unlike PanelView 5000 HMIs, PanelView Plus HMIs can communicate with third-party controllers but have preferred compatibility with Logix 5000 controllers.
If required, an application developed for a PanelView Plus HMI can be run on a PC.
This is achieved using a piece of software called FactoryTalk View ME station, which provides a runtime for the application on a standard PC.
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Some HMI applications require mobility. That is, the operator needs to be able to walk around the machine while interacting with the HMI.
For these applications, Rockwell Automation offers the MobileView HMI solution.
Its important to note that MobileView HMIs are not wireless - there is a tether that connects back to a control panel. This tether is required to connect the built-in emergency stop back to the control system. So a MobileView HMI is only mobile up to the length of the tether.
Internally, the MobileView HMI has an industrial computer that runs a FactoryTalk View ME Station application which is built using FactoryTalk View Studio ME.
The MobileView HMI solution is ideal for applications that require mobility and safety within a small distance.
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The PanelView 800 HMI solution is a low-cost HMI option, designed for machine builders that want simple functionality at a low price point.
These HMIs are optimized for communicating with Micro800 and MicroLogix PLCs. Although they are optimized for micro-controllers, new versions of the PanelView 800 HMI can communicate with some CompactLogix L1, L2, and L3 PLCs. They cannot communicate with higher-end CompactLogix PLCs or ControlLogix PLCs.
They are programmed using Connected Components Workbench, a free development environment that is also used to program Micro800 PLCs.
The PanelView 800 HMI solution is ideal for small, standalone machines that only require simple HMI functionality.
You can learn how to program PanelView 800 HMIs with our AB CCW HMI learning path.
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FactoryTalk Optix is a brand new HMI platform from Rockwell Automation.
Optix is a modern HMI platform that supports features that are not included in other HMI solutions. For example, Optix applications support multi-user collaboration, integration with version control systems, and can be extended using a scripting language based on C#.
Optix applications can be deployed on Optix HMI panels, industrial PCs, or Edge devices.
The Optix HMI solution is ideal for people who want to use cutting edge technology to develop their HMI applications.
In this post, I explained why companies choose to use Rockwell Automation HMI solutions and introduced you to the various machine-level HMI solutions that are available from Rockwell Automation.
Specifically, I introduced you to;
PanelView 5000 HMIs which are modern HMIs that have tight integration with Logix 5000 controllers.
PanelView Plus HMIs which are older HMIs that can communicate with third-party controllers and support legacy networks.
PanelView 800 HMIs which are low-cost HMIs designed for small, standalone machines.
FactoryTalk Optix which is a modern HMI platform that has cutting edge features and can be deployed to a variety of different devices.
For more information on the features and differences of each HMI platform, check out Rockwell Automation’s Visualization Solutions Selection Guide.
