How to Connect a Schneider PLC to a Maple Systems HMI

• Open EcoStruxure Machine Expert Logic Builder 2.6, then select File > New Project
• Select Default Project
• Set the controller to TM241CE40R (Schneider Electric)
• Select the controller firmware version that matches the physical PLC. The example uses 5.5.14.17
• Enter a controller name, such as M241 for this example
• Set the language for SR_Main to Ladder Logic Diagram (LD)
• Enter the project name and choose the folder where the project will be saved
• Select OK

• After the project opens, select the M241 controller in the Applications tree
• Open the Communication Settings tab. The detected controller appears in the communication list
• In the example, the controller is found at:

IP address: 192.168.100.114

Controller: TM241CE40R

Firmware: 5.5.14.17

• Set Connection Mode to IP Address.
• Select Test to verify communication
• Confirm that the controller appears in the device list without a communication error

• Switch from the Applications tree to the Devices tree
• Expand the M241 controller and select: Ethernet_1 (Ethernet Network)
• Under Configured Parameters, select Fixed IP Address and enter the settings shown below:

IP address 192.168.100.114

Subnet mask 255.255.255.0

Gateway address 192.168.100.1 (may not need)

A POU, or Program Organization Unit, contains the PLC program logic.

• Right-click Application (M241: TM241CE40R)
• Select Add Object
• Select POU
• In the Add POU window: Enter a name such as POU
• Select Program as the POU type
• Set the implementation language to Ladder Logic Diagram (LD)

The new POU must be scheduled before the PLC can execute it

• In Ladder, it appears as a Program Call block, not a normal output coil or function block. Schneider refers to this as calling a Program POU from another Program POU

• Open the new POU and enter the variables in the declaration section above the ladder editor.
• The following can be copy and pasted into the program for this project

PROGRAM POU

VAR

// HMI maintained Start/Stop toggle

HMI_RUN_REQUEST AT %MX10.0 : BOOL;

// Internal logic

PUMP_OVERLOAD : BOOL;

FLASH_BIT : BOOL;

// HMI tank-level value

TANK_LEVEL AT %MW0 : INT;

// Physical PLC outputs

PUMP_STARTED : BOOL;

OVERLOAD_OUTPUT : BOOL;

// Flash timers

FLASH_OFF_TIMER : TON;

FLASH_ON_TIMER : TON;

END_VAR

Variable descriptions

HMI_RUN_REQUEST AT %MX10.0 : BOOL;

This Boolean variable receives the maintained Start/Stop command from the Maple Systems HMI. The HMI writes to memory bit %MX10.0.

PUMP_OVERLOAD : BOOL;

This internal Boolean becomes true when the tank level reaches the overload threshold.

FLASH_BIT : BOOL;

This internal bit alternates between true and false to create the flashing alarm signal.

TANK_LEVEL AT %MW0 : INT;

This integer stores the tank-level value. The HMI reads or writes the value through memory word %MW0.

PUMP_STARTED : BOOL;

This Boolean represents the pump-running output or pump-running status.

OVERLOAD_OUTPUT : BOOL;

This Boolean represents the flashing overload output.

FLASH_OFF_TIMER : TON; and FLASH_ON_TIMER : TON;

These are on-delay timer instances used to alternate the alarm output every second.

If PUMP_STARTED and OVERLOAD_OUTPUT control physical terminals, map them to the correct M241 digital outputs in the I/O Mapping window or assign direct output addresses such as %QX0.0 and %QX0.1.

The ladder program contains eight networks.

Network 1: Detect the Pump Overload Condition

Insert a GE, or greater-than-or-equal comparison block.

Configure it as:

• TANK_LEVEL >= 85
• Connect the comparison result to the PUMP_OVERLOAD coil.

This network turns on PUMP_OVERLOAD when the tank level reaches or exceeds 85.

Network 2: Control the Pump-Started Output

Add:

• A normally open HMI_RUN_REQUEST contact.
• A normally closed PUMP_OVERLOAD contact.
• A standard PUMP_STARTED coil.

The pump runs when the HMI run request is active and no overload condition exists. When the tank level reaches 85, PUMP_OVERLOAD opens the interlock and turns the pump output off.

Network 3: Start the Flash-Off Timer

Add:

• A normally open PUMP_OVERLOAD contact.
• A normally closed FLASH_BIT contact.
• A TON block using FLASH_OFF_TIMER.
• Set the preset time to T#1S.

This timer runs while the overload is active and FLASH_BIT is false.

Network 4: Set the Flash Bit

Add:

• A normally open FLASH_OFF_TIMER.Q contact.
• A Set coil for FLASH_BIT.
• After the first timer reaches one second, the network sets FLASH_BIT.

Network 5: Start the Flash-On Timer

Add:

• A normally open PUMP_OVERLOAD contact.
• A normally open FLASH_BIT contact.
• A TON block using FLASH_ON_TIMER.
• Set the preset time to T#1S.

This timer runs while the overload remains active and FLASH_BIT is true.

Network 6: Reset the Flash Bit

Add:

• A normally open FLASH_ON_TIMER.Q contact.
• A Reset coil for FLASH_BIT.

After the second timer reaches one second, it resets FLASH_BIT. This restarts the first timer and creates a repeating one-second on, one-second off sequence.

Network 7: Clear the Flash Bit When the Alarm Clears

Add:

• A normally closed PUMP_OVERLOAD contact.
• A Reset coil for FLASH_BIT.

This network ensures that the flashing sequence resets when the overload condition clears. The next alarm begins from a known off state.

Network 8: Control the Blinking Overload Output

Add:

• A normally open PUMP_OVERLOAD contact.
• A normally open FLASH_BIT contact.
• A standard OVERLOAD_OUTPUT coil.

The overload output turns on only while both the alarm and FLASH_BIT are active. Because FLASH_BIT changes state every second, the physical alarm output flashes.

Before downloading the project, create a boot application so the PLC automatically loads the project whenever power is cycled.

• Select Online from the menu bar
• Click Create Boot Application

Once the project has been built successfully, establish communication with the controller

There are two ways to go online:

• Select Online > Login
• Click the Login button (green arrows) on the toolbar.

Machine Expert compares the project on the computer with the application currently stored in the PLC

If the controller contains a different application, a warning dialog appears stating:

WARNING – UNINTENDED EQUIPMENT OPERATION

This message reminds you that downloading a new application will overwrite the existing PLC program.

Before continuing:

• Verify you are connected to the correct PLC.
• Confirm the controller IP address.
• Confirm the project is intended for that controller.

If user access protection is enabled, the Device User Logon window appears.

Enter the PLC credentials:

User name

Password

Then select OK

After successful authentication, Machine Expert downloads the application to the controller. If security is disabled on the controller, this dialog does not appear.

After the download completes, a Post Configuration Warning may appear indicating that a post configuration is active on the controller.

Review the message and select OK to continue.

If the PLC is in STOP mode after downloading, start the controller by clicking the Run button on the toolbar.

Alternatively:

Online > Operating Mode > Run

Once the PLC begins executing the application:

• The status bar changes from STOP to RUN.
• The RUN indicator turns green.
• The ladder logic executes continuously.
• Inputs, outputs, and timers update in real time.

A green RUN status confirms that the controller is actively scanning the program.

Then verify the program operation. With the controller running, verify that the ladder logic operates as expected.

Launch EBPro and create a new project.

In the New Project window:

• Expand the cMT X Series
• Select cMT2078X / cMT2078X (V2)
• Click OK

Before creating any HMI objects, configure communication with the PLC.

Select:

Home > System Parameters

The System Parameter Settings window opens.

• Add the PLC Driver
• Select New Device/Server
• Expand Schneider Electric
• Select MODBUS TCP/IP
• Click OK

The Device Settings window opens

Configure the communication settings:

Schneider MODBUS TCP/IP

Ethernet

192.168.100.114

502

The default Modbus TCP port is 502, which is supported by the Schneider M241 Modbus Server.

Select Settings if additional Ethernet options need to be modified.

When finished:

Select OK

Verify the Schneider device appears in the device list.

Select OK again to save the System Parameters.

The HMI is now configured to communicate with the PLC over Ethernet using Schneider Modbus TCP/IP.

The Start/Stop button allows the operator to write a maintained run command to the PLC.

Select:

Object > Toggle Switch

Place the switch on the HMI screen.

Open the Toggle Switch properties.

Configure the following:

Device: Schneider MODBUS TCP/IP_1

Address Type: %MX

Address: 10.0

The %MX10.0 memory bit matches the PLC variable:

HMI_RUN_REQUEST AT %MX10.0 : BOOL;

Each time the operator presses the button, the HMI toggles the PLC memory bit ON or OFF.

Next, create an indicator that displays whether the pump is running.

Select:

Object > Bit Lamp

Put the Bit Lamp beside the Start/Stop button.

Configure:

Device: Schneider MODBUS TCP/IP_1

Address Type: %MX

Address: 10.0

The Bit Lamp continuously reads %MX10.0.

When the bit is ON, the lamp indicates the pump run request is active.

When the bit is OFF, the lamp indicates the pump is stopped.

The bar graph displays the current tank level received from the PLC.

Select:

Object > Chart > Bar Graph

Insert a Bar Graph.

Open the Bar Graph properties.

Configure the Read Address

Configure:

Device: Schneider MODBUS TCP/IP_1

Address Type: %MW

Address: 0

Data Type: 16-bit Unsigned

The HMI now reads the PLC word:

TANK_LEVEL AT %MW0 : INT;

Open the Range tab.

Configure:

Minimum 0

Maximum 100

These values match the simulated tank level.

Configure the alarm colors:

Low Limit 0

High Limit 80

Low Color Blue

High Color Red

When the tank level exceeds 85, the upper portion of the bar graph changes to red, providing a visual indication that the tank is approaching the overload threshold.

To display the exact tank level value, insert a Numeric Display.

Select:

Object > Numeric

Place the numeric object below the bar graph.

Configure:

Allow Input: Enabled

Device:: Schneider MODBUS TCP/IP_1

Address Type:: %MW

Address: 0

The numeric display continuously reads %MW0 and displays the current tank level value.

Because Allow Input is enabled, the operator can also type a value directly into the HMI to update the PLC memory word.

To simulate changing tank levels, configure two Set Word buttons.

Select:

Object > Set Word

Create an Increase button.

Configure:

Device: Schneider MODBUS TCP/IP_1

Address Type: %MW

Address: 0

Configure the button attributes:

Set Style: Press and Hold Increment (JOG++)

Increment Value: 5

High Limit: 100

Repeat the process for the decrease button using Press and Hold Decrement (JOG–).

These buttons allow the operator to increase or decrease the simulated tank level in 5-unit increments directly from the HMI.

The HMI alarm activates when the tank level reaches the overload threshold.

Select:

Data/History > Event (Alarm) Log

Create a new alarm by selecting New

Configure the alarm:

Under General

Category: Category 0

Priority: High

Type: Word

Device: Schneider MODBUS TCP/IP_1

Address %MW0

Notification

Configure the notification output:

Enable: Checked

Notification Mode: Set ON

Device: Schneider MODBUS TCP/IP_1

Address: %QX0.5

Configure the alarm condition:

Condition: Greater Than or Equal To

Value: 85

When %MW0 reaches 85, the alarm becomes active and sets output %QX0.5.

Create a second alarm to reset the output after the overload clears.

Select New again

Configure the same read address:

Device: Schneider MODBUS TCP/IP_1

Address: %MW0

Configure the notification:

Notification Mode: Set OFF

Device: Schneider MODBUS TCP/IP_1

Address: %MX10.0

Configure the condition:

Condition: Greater Than or Equal To

Value: 85

With Follow enabled, the notification automatically resets when the alarm condition clears, returning the HMI to its normal operating state.

To provide a visual indication of an overload condition, add a second Bit Lamp that monitors the PLC output controlling the alarm.

Select:

Object > Bit Lamp

Place the Bit Lamp over the alarm beacon image.

Open the Bit Lamp Properties window and configure the following settings:

Mode: Bit Lamp

Device: Schneider MODBUS TCP/IP_1

Address Type: %QX

Address: 0.5

The %QX0.5 output is energized by the PLC whenever the tank level reaches the overload threshold. When the output turns ON, the Bit Lamp illuminates to indicate an active pump overload alarm.

Configure the Blinking Effect

To make the alarm more noticeable, enable the built-in blinking animation.

Under the Blinking section, configure:

Mode: Blinking on state 1

Breaking Time: 1.0 second

This causes the alarm beacon to flash once per second whenever %QX0.5 is ON, providing a clear visual indication that the pump overload condition is active.

To clearly identify the alarm state, configure a text label that appears when the alarm beacon is active.

Open the Label tab in the Bit Lamp Properties window.

Enable Use label, then configure the following settings:

State: 1

Label: OVERLOAD

Font: Arial

Font Size 16

Font Color Red

The label is assigned to State 1, meaning the text OVERLOAD is displayed only when the Bit Lamp is ON. Using a bold red font makes the active alarm condition easy to identify from a distance.

With the blinking animation and label enabled, the alarm beacon flashes and displays OVERLOAD whenever PLC output %QX0.5 is energized, providing operators with an immediate visual indication that a pump overload condition has occurred.

Download the Project

• Select Project > Download (PC → HMI)

• The Download (PC → HMI) window opens.

Configure the download settings:

Download Method: Ethernet

HMI IP Address: 192.168.100.48

Runtime: Enabled

Verify that the HMI IP address matches the address configured on your cMT2078XV2.

Once the connection settings are confirmed, select Download.

EBPro compiles the runtime project and transfers it to the HMI over Ethernet. Depending on the project size and network speed, the download typically completes within a few seconds.

After the download finishes, the HMI automatically starts the runtime application.

If Runtime was enabled during the download, no additional configuration is required. The project immediately begins communicating with the Schneider M241 PLC using the Schneider Modbus TCP/IP driver.

Once the runtime is active, verify that the HMI communicates correctly with the PLC.

With the tank level below the overload threshold, the HMI should display:

• Tank level value updating from %MW0
• Blue tank level bar graph
• Green START/STOP button when the run request is active
• PUMP STARTED status indicator
• Alarm beacon OFF

This confirms that the HMI is successfully reading data from the PLC and displaying the current process status.

Increase the tank level using the on-screen increase button until the value reaches or exceeds 85.

When the overload condition occurs, the HMI automatically updates to display:

• Tank level increasing above the alarm threshold
• Bar graph changing from blue to red
• Alarm beacon flashing
• OVERLOAD label displayed on the beacon
• PUMP OFF status displayed
• Start/Stop button returning to the OFF state

These changes confirm that the PLC logic and HMI are communicating correctly. The PLC detects the overload condition, turns off the pump, energizes the alarm output, and the HMI immediately reflects the new operating state.