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User Manual
Version 1.0
Water Level controller is used to Fill/Drain the tank, which is depends upon
High/Low level Sensor in Water Tank. If the Tank Low Level Sensor is in OFF condition,
then the Motor (PUMP) starts pumping the water from Reservoir Tank to Process Tank.
When the High Level sensor goes to ON Condition while the water filling in Process Tank.
Then the Motor (PUMP) goes to OFF Condition at that time the Solenoid Valve gets ON.
Then the water drains from the Process tank to Reservoir tank. When it reaches the Low
Level sensor the Solenoid valve gets OFF and then the Pump goes to ON Condition.
Likewise the process repeats continuously.
Water Level Control System is used to operate the Solenoid Valve and Motor based on
Low Level and High Level Sensors Feedback, by using simple Program Logic. But the micro
controller system is very complex to programming and using makes also complexities. Hence
we are choosing PLC are used to control the water level. PLC provides simple detailed
solutions by means of ladder logic program. The CPU combines a microprocessor, an
integrated power supply, input and output circuits. After downloading the program, the CPU
contains the logic required to monitor and control the devices in our application. The CPU
monitors the inputs and changes the outputs according to the logic of our user program.
3. BLOCK DIAGRAM
4. HARDWARE USED
FLOAT SWITCH
SOLENOID VALVE
WIPER PUMP
It is a DC Motor pump, which is used to pump the water from Reservoir Tank
to Process Tank.
5. SPECIFICATION
Float Switch
Wiper Pump
Solenoid Valve
Water Level System having two Tanks like Process Tank and Reservoir Tank. DC
Pump [12V DC] which is connected with a Reservoir Tank. By using the Low Level Sensor
feedback the PLC enables the Output. By using that output we can pump the water to Process
tank from Reservoir tank. When the Low Level Sensor get OFF Condition then the Pump
starts pumping the water up to reaches the High Level sensor. So the Liquid level inside the
tank is increases.
While the water reaches the High Level Sensor then the Pump Goes to OFF
Condition. At the same time the Solenoid valve gets operated in Process tank. Both High
Level and Low Level Float switches are provide the Feedback of 24V DC while sensing.
When the PLC reads the High Level Sensor feedback then it enables another output to
operate the Solenoid Valve. At that same time it cuts the supply to Pump.
Then the Water starts draining from Process Tank to Reservoir Tank, then the High
Level Sensor goes to OFF condition. But the solenoid valve remains ON up to the Low Level
sensor goes to OFF condition. Then the Pump gets ON the water filling in Process Tank.
Likewise the Process Repeats continuously by using PLC.
7. EXPERIMENT SECTION
AIM
APPARATUS REQUIRED
WIRING DIAGRAM
Experimental Procedure :
CONNECTION DIAGRAM :
Connection Procedure :
Connect I1 to HL
Connect I2 to LL
Connect 24V to sensor(float switch) input
Connect Q1 to SV in water level controller
Connect Q2 to Motor in water level controller
From water level controller connect SV to SV in water level stand
From water level controller connect Motor to Motor in water level stand
PROGRAM
PROGRAM EXPLANATION
In Ladder Logic Program, Input I0.0 [I1] is connected to Low Level Sensor and
then the Input I0.1 [I2] is connected to High Level Sensor. Output coil Q0.0 [Q1] is
connected to Solenoid Valve and then the Output Q0.1 [Q2] is connected to Pump.
After run the program, if the Process tank is empty then motor gets ON, due to Low
Level and High Level sensors in OFF Condition. Inputs I1 and I2 are also Normally
Closed – contacts. While Pump gets ON then waters pumping starts from Reservoir Tank
to Process Tank. When the water reaches the Low Level Sensor then the Sensor gets ON.
At that time the Contact I1 [I0.0] goes to Normally Open Contact after that also the
Pump remains ON due to Latch Contact Q1. When the water level reaches the High
Level Sensor then the Sensor gets ON, so the Input I2 [I0.1] goes to Normally Open
Contact. It Cuts the Supply to Output Q1 [Q0.0], so Q1 goes to OFF Condition and Pump
gets OFF Condition.
In draining of Process tank water level, Solenoid Valve gets ON due to both High
Level and Low Level Sensors in On Condition. So in PLC I1 [I0.0] and I2 [I0.1] gets ON
and it enables the Output Q2. While Solenoid Valve in On Condition the water get
draining from Process Tank then the High Level Sensor gets OFF Condition. Then the
Input I2 [I0.1] goes to OFF Condition so the Contact get Normally Open Position but the
Solenoid Valve remains ON Condition due to the Latch Contact Q2. While the water
draining it reaches the Low Level Sensor then the Low Level Sensor goes OFF
Condition. Then the Input I1 [I0.0] goes to OFF Condition so the Contact get Normally
Open Position so it Cuts the Solenoid Valve Supply Q2 [Q0.1] goes to OFF Condition.
Now again the Pump gets ON due to both High Level and Low Level Sensors are in On
Condition. So the Network 1 Program Executes Likewise process going on continuously.
RESULT
Thus the Working of Water Level Controller using PLC was studied.