INTRODUCTION

In industrial settings, technicians rely on HMIs not just to start and stop machines—but to fine-tune processes, check performance, and respond to system feedback. While every HMI is a little different, the core functions are often the same. Now that you know what an HMI is and why it matters, you’ll explore how it actually works through a series of short, hands-on activities. These exercises will introduce key features of the HMI used in class.

TASK

Over the next few pages, you will see "Task" boxes like this. Complete these exercises to become familiar with the HMI you'll use in class.

You will use these skills in future labs.

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LAB MATERIALS

Basic Automation Trainer
Automation Direct HMI
RS232 serial communication cable

Ask an instructor where to find the above items if necessary.

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LAB INSTRUCTIONS

In a manufacturing facility, operators rely on the HMI’s main screen to understand what’s happening at a glance. This screen often shows live system status, access to controls, and navigation to other key areas. Now that you’ve learned how the HMI connects people to machines, this activity will help you explore the main screen of the classroom HMI. You’ll learn how to read and use it the way real operators do in industry.

You should have already powered up and connected an HMI to the CLICK PLC on your Basic Automation Trainer from the previous lab. If not, go back and re-do the previous lab.

PLC Program Indicator

TASK

Check and make sure that there is an indicator in the top-right corner that says "HMI PROGRAM Active", just like what is shown in the photo below.

If it does not say "HMI Program Active", this lab will not work. You will need to go back and do the lab labeled "Download the HMI PLC Program to the PLC".

HMI Main screen with an arrow pointing to HMI Program Active in the top righthand corner

The Main Screen should look similar to the picture above, but there may be a few differences as the program gets updated.

Screen Change Buttons

On the left-hand side and bottom-right, you will see several screen change push buttons. These are used to navigate between the different HMI screens.

Screen change buttons on the HMI: Hourly Counts, Model Change, I/O Screen, Manual Screen, Fault Screen

TASK

Press each Screen Change push button one at a time and take a look at each of the different screens.

INDUSTRY CONNECTION

Many HMIs have multiple screens, which are often reached from the main screen of the HMI.

To get back, press the Main Screen or Exit push buttons on all of the other screens to return to the Main Screen. Exit buttons

Cycle Start Button

The arrow in the photo below is pointing to the "Cycle Start" push button. This button works just like the green push button that is wired into the Basic Automation Trainer.

Main screen of the HMI with an arrow pointing to Cycle Start button

INDUSTRY CONNECTION

Rather than using a button, many machines are run by pushing a button on the HMI. This can help operators ensure that certain tasks have been completed before the machine runs. (You'll learn more about these starting procedures in a future lab.)

Cycle Stop Button

The arrow in the photo below is pointing to the "Cycle Stop" push button. This button does not stop the machine immediately, but it is setup to stop the machine at the end of cycle. The cycle is done after the robot picks and places all three blocks or cylinders.

Main screen of the HMI with an arrow pointing to the cycle stop button

INDUSTRY CONNECTION

Many machines will be damaged if stopped suddenly. Buttons like the "Cycle Stop" button will allow the machine to come to a controlled stop. You'll learn more about controlled stops in a future lab.

Current Model Indicator

The photo below has an arrow pointing to an "Indicator". It is setup to show which model the machine is running.

INDUSTRY CONNECTION

In industry, the same machine is often used to produce different types of products. Models store settings that allow a machine to produce a new product. In some cases, an operator can change the product by changing the model setting on the HMI.

You will learn more about models in a future lab.

Main screen of the HMI with an arrow pointing to the Current Model Indicator

Machine Status Indicator

The photo below has an arrow pointing to a machine status indicator. This indicator can indicate many things like "Machine in Cycle", "Machine Stopped", "Fault Present", "E-Stop Pressed", etc.

Indicators are very valuable tools that can help you efficiently run machines.

INDUSTRY CONNECTION

The indicators on your HMI at work will depend on the machine.

Main screen of the HMI with an arrow pointing to the machine status indicator at the bottom of the screen

Fault Reset Button

Many machines can monitor every aspect of production. When something isn't working correctly, the machine will stop and indicate a fault. After fixing the problem that caused the fault, it is usually necessary to press a the "Fault Reset" push button to clear the fault.

An arrow is pointing to the "Fault Reset" push button on the photo below .

Main screen of the HMI with an arrow pointing to the fault reset button

Robot Button

There may or may not be a "Robot Home" push button visible on the middle-right side of the Main Screen. The "Robot Home" push button "homes" the robot, which sends the robot back to its resting or home position.

INDUSTRY CONNECTION

This button is setup to have conditional visibility, meaning that it is only visible in certain conditions as specified by the PLC and HMI programs. At your job, there may be some settings that have conditional visibility.

Main screen of the HMI with an arrow pointing to the Robot Home button

Identification Number

INDUSTRY CONNECTION

A lot of companies want you to enter some type of identification number so they can know who is running the machines. Some settings will have conditional visibility based on who is signed into the HMI.

The arrow below points to the place to enter an identification number, in this case a badge number.

Main screen of the HMI with an arrow pointing to the Badge Number

TASK

Touch the bottom of the screen where it says "Badge Number."

A numeric entry popup will appear so you can enter your identification number.

Badge Keypad on the HMI

At Bridgerland we don't have badge numbers, but we have Student ID numbers.

TASK

Enter your Student ID number into the numeric entry popup, then press the "ENT" button.

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SUMMARY

You should now be fairly familiar with the functions of the Main Screen.

Navigation to other screens
Cycle start and stop
Fault reset
Machine status
Identification

Feel free to explore all of the buttons again to become confident in navigating through all of the functions of the Main Screen.

If you have questions about the Main Screen, talk with an instructor.