INDEX

Sr Description Page No.

No.
1 Abstract 6
2 Introduction 8
3 Literature Survey 10
4 Block Diagram 13
5 Block Diagram 15
Explanation
6 Liquid Level Sensor 21
7 Motor Control Circuit 24
7 PLC Introduction 26
8 PLC Advantages 40
9 PLC Disadvantages 46
10 Solenoid Valve 48
11 PCB Design 54
12 PCB Layout of
Project 58
13 PCB Layout of
Motor Control Circuit 60
14 PLC Programming 62
11 Advantages 65
12 Disadvantages 67
13 Application 69
14 Future Scope 71
15 Cost of Project 73
16 Specifications 77
17 Result and Conclusion 89
17 Bibliography 91
18 Datasheets 93
19 Acknowledgement 130
 ABSTRACT

On our planet earth, 71% of part is occupied by water. Only 2% of water source is
usable and rest of 98% of water is salty water which has no use for human and all
living beings except in sea.

Water, the main source of life. It is the most required, important and individual part
of all living beings. We can not imagine life without water.

Our country India such a populated one is facing such a big problem of water
minimization. If proper precautions are not taken for preserving the most valuable
natural resource then it may lead to an disastrous situation.

This project is based on the theme that water should be controlled to such a level that
it can be utilized with proper use. Due to implementation of this project, water level
can be controlled automatically and hence large amount of water is saved. In future,
India will have not face such problems and there will be a vast progress in the
development of country.
 INTRODUCTION

PLC based Multichannel Automatic Liquid Level measurement aims to control the
level of liquid automatically so that water going waste due to overflow of tanks can be
saved easily.

In this project , Three liquid level sensors are provided for overhead tanks and
source tanks. Those liquid level sensors are low level sensors and high sensors. These
sensors sense the level of liquid and operate relays and serves inputs to Programmable
Logic Controller (PLC). Programmable Logic Controller (PLC) is programmed to
control liquid level and maintain it at specific level in overhead tanks automatically.
BLOCK DIAGRAM
BLOCK DIAGRAM EXPLANATION
SMPS ( Switch Mode Power Supply ) :-
 Electronic Power Supply that incorporates a switching regulator to convert
electrical power efficiently. Like other power supplies, an SMPS transfers power from
a source like the electrical power grid to a load (such as a Personal Computer) while
converting voltage and current characteristics. An SMPS is usually employed to
efficiently provide a regulated output voltage, typically at a level different from the
input voltage.

Unlike a linear power supply, the past transistor of a switching mode supply
continuously switches between low dissipation, full on and full off states, and spends
early little time in the high dissipation transitions (which minimize wasted energy).
Ideally, a switched mode power supply dissipated no power, voltage regulation is
achieved by varying the ratio of to on to off time. In contrast, a linear power supply
regulates the output voltage by continuously dissipating power in the pass transistor.
This higher power conversion efficiency is an important advantage of a switched mode
power supply. Switched mode power supplies may also be substantially smaller and
lighter than a linear power supply due to the smaller transformer size and weight.

LIQUID LEVEL SENSOR :-

The Liquid Level Sensors are the probe type sensors which senses the
level of liquid in tanks. Whenever the liquid level touches the probes, relay coil is
energized. As working voltage of Liquid level Sensor is 12VDC. 12VDC supply is
provided through step down transformer, full-wave rectifier and filter circuit. This
serves as input to PLC. +24 VDC terminal is connected to the common terminal of
relay hence, it gives +24VDC at output which is further connected to the input ports
of PLC.

PROGRAMMABLE LOGIC CONTROLLER :-

Programmable Logic Controller (PLC) is a controller for this project. It has input as
well as output ports. All the Liquid Level Sensors serves as input to PLC. As liquid
level sensors senses the liquid level, relay coil is energized and +24VDC reaches to
PLC through input module. As we have already loaded program in PLC, it gives output
according to user program and hence output devices like indicators, solenoid valves,
pump are controlled through output ports. We are using PC (Personal Computer ) as a
programming device for PLC.

Due to high prices of PLC, it is very important to protect PLC from various abnormal
conditions. Relay Unit is mainly used for over-current, over-heating and short-circuit
protection so that no damage will occur to PLC.

We are using five 24VDC general purpose relay in this relay unit. Four of them are
use for operating solenoid valves and rest of one is used for operating pump.
LIQUID LEVEL SENSOR
 CIRCUIT DIAGRAM

Liquid Level Sensor :

Components of Liquid Level Sensor :-

R1 - 470K Ohm
R2 - 10M Ohm
R3 - 1K Ohm
C1, 2, 3, 4 - 2.2 nF 2.2 kpf/ 222
T1 - BC557 PNP Transistor
D1, 2, 3 - IN4148
LED - 3mm Red.
IC 1 - 4093 Cmos IC
14 Pin IC Socket for IC1
 Rly 1 - 12V /1 CO Relay

Working of Liquid Level Sensor :

The actual circuit of the level sensor is extremely simple. The circuit around N1 forms
an oscillator. If the two sensors are immersed in a conducting solution, C4 will be
charged up via the AC coupling capacitors (C2 and C3) and the diodes so that after a
short time the output of N2 is taken low and the relay is pulled in. The relay can be
used to start a pump for example, which in turn controls the level of the liquid. When
a conductive path between the two sensors no longer exists. C4 discharges via R2 with
the result that the output of N2 goes high and the relay drops out. The Relay turns ON
or OFF only when a contact between the two electrodes due to presence of water.
INTRODUCTION TO PLC
 Programmable Logic Controller :-

A programmable logic controller, which is usually called PLC. More commonly it is

known as programmable controller (PC). It is a electronic device operates on digital signal.
It is designed and developed for industrial applications, hence known as “Industrial
Computer”.

PLC was originally designed to replace relay based logic systems and solid-
state hard-wired control panels. PLC has advantages over relay based system, that they are
easily programmed, more reliable, flexible, relatively inexpensive, and capability to
communicate with field computers. Modern PLC’s are powerful and more

complex.
Programmable logic controllers are used for controlling sequences of events.
Hence they are also known as sequential controllers. For example, in the bottle filling
system it senses the empty bottles, place the bottles at proper position for filling, fill
the bottles at desired locations.
 A PLC is defined by National Electrical Manufacturers Association (NEMA, USA):

“A programmable logic controller is digitally operated electronics system,

designed for use in an industrial environment , which used a programmable
memory for the internal storage of user oriented instructions for implementing
specific functions such as logic, sequencing, timing, counting and arithmetic to
control, through digital or analog inputs and outputs, various types of machines
or processes”.

ELEMENTS OF PLC :-

o The PLC consists of following elements:

Processor (CPU)
Memory
Programming Device
Input Module
Output Module
Power Supply
Power Supply :-
 The power supply converts AC line voltages, to power the electronic circuit in a
programmable controller systems. These power supplies consists of rectifier, filter and
regulated voltages and currents, to supply the correct amount of voltages and current
to the system. The power supply converts 230VAC line voltage into direct current
voltages such as +5 or +-15 or +24V.
The power supply for PLC may be integrated with the processor, memory, and I/O
modules into a single housing, or it might be a separate unit connected to the system
through a cable.

The power supply is designed for the higher temperature and humidity as PLC is used
in industrial environment. It is designed to eliminate the electrical noise present on
AC power or signal lines of industrial plants, so that the noise does not introduce errors
in the control system.
 ADVANTAGES OF PLC

ADVANTAGES OF PLC :-

Industries that exist right now, the presence of PLC is necessary

especially to replace the wiring or cabling systems that previously were used in
controlling a system. By using the PLC will get many benefits which are as
follows:-

Industries that exist right now, the presence of PLC is necessary

especially to replace the wiring or cabling systems that previously were used in
controlling a system. By using the PLC will get many benefits which are as
follows:-

Small size :-

They are usually very compact and do not have large space requirement.

Suitable modular design :

Elements of PLC are in modular form. PLC is designed easily using these
modules.

Rugged construction :
 It is rugged enough to operate in an industrial environment.

Greater reliability :

According to logic in a program, the operations are performed bu it.

Interfacing easy :

The input and output modules are provided for interfacing the input and output
field devices to it.

Ease of programming :

The powerful instructions are provided for programming the PLC. It is

programmed with a minimum time by using these instructions.

Reprogrammed easily :-

It is programmed with a minimum time downtime.

Ability to communication with plant computers, another PLC :-

It communicate with data collection system (plant computer) placed in control

room or field. One PLC can communicate to other.

Relatively inexpensive :-

Relatively inexpensive than hardwired relay control.

Maintenance easier :-

It is modular systems, hence maintained easily and it has self diagnostic

facility.
 Correcting Errors:-

In old days, with wired relay-type panels, any program alterations required
time for rewiring of panels and devices. With PLC control any change in circuit
design or sequence is as simple as retyping the logic. Correcting errors in PLC
is extremely short and cost effective.

Space Efficient:-

Today's Programmable Logic Control memory is getting bigger and bigger

this means that we can generate more and more contacts, coils, timers,
sequencers, counters and so on. We can have thousands of contact timers and
counters in a single PLC. Imagine what it would be like to have so many things
in one panel.

Testing :-

A Programmable Logic Control program can be tested and evaluated in a lab.

The program can be tested, validated and corrected saving very valuable time.

Visual Observation :-

When running a PLC program a visual operation can be seen on the

screen.
Hence troubleshooting a circuit is really quick, easy and simple.

Flexible :-

In the past, each different electronic device controlled by each

controller. Suppose ten machines require ten controllers, but now with only one
tenth PLC machine can be run with each program.
Changes and error correction system easier :-

If one system will be modified or corrected, the change is only done

on the programs contained in computers, in a relatively short time, after that it
downloaded to the PLC. If not using a PLC, for example relays the amendments
made by altering the wiring cables. This course takes a long time.

Number of contacts many :-

Number of contacts held by the PLC on each coil is more than the
contacts held by a relay.

Low cost :-

PLC is capable of simplifying a lot of cabling compared to a relay. So

the price of a PLC at a price cheaper than some fruit relay capable of doing the
wiring for the same amount with a PLC. PLC includes relays, timers, counters,
sequencers, and other functions.

Operating speed :-

PLC operation speed is faster than the relay. Speed PLC scan time is
determined by its in units of milliseconds.

Resistant character test :-

 Solid state devices are more resistant than the relay and test
mechanical or electrical timers. PLC is a solid state device that is more resistant
test.

Simplifies the control system components :-

The PLC also have counters, relays and other components, so it does
not require components such as additional. Use of relays requires counters,
timers or other components as additional equipment.

Documentation :-

Printout of the PLC can be directly obtained and do not need to see the
blueprint of his circuit. Unlike the printout relay circuit cannot be obtained.

Security

Changing the PLC cannot be done unless the PLC is not locked and
programmed. So there is no unauthorized person can change the PLC program
for a PLC is locked.

Can make changes by reprogramming :-

 Since the PLC can be programmed quickly reset the production process
that mixes can be completed. For example part B will be executed but sections
of A is still in the process, the process in section B can be re-programmed in
seconds.

Addition of faster circuits :-

Users can add a circuit controller at any time quickly, without requiring
great effort and cost as in conventional controllers.

DISADVANTAGES OF PLC
 DISADVANTAGES :-

PLC require modules for interfacing of various input and output device.

PLC is designed for relay logic ladder and have difficulty with some smart
devices.

Programming, operation, troubleshooting of PLC, training is required.

The technology is still new :-

Changing the old control system using relay ladder or to a PLC

computer concept is difficult for some people

Bad for the application programs that remain :-

Some applications are applications with a single function. On

application by one function rarely done did not even change at all, so the use of PLC
in applications with a single function will be a waste (cost).

Environmental considerations :-

In a process, the environment may experience a high heat, vibration

direct contact with electrical appliances within the PLC and this event
continuously, thus disrupting the performance of the PLC is not functioning
optimally.

Operating with a fixed circuit :-

 If the circuit in an operation are not changed then the use of more
expensive PLC compared with other control equipment. PLC will be more
effective if the program on the process to be upgraded periodically.

ADVANTAGES
 ADVANTAGES :-

Low power consumption

Simple construction i.e. compact and elegant design.
High efficiency.
Save Water
Save motor from dry running and increase its life.
System is accurate.
Less Maintenance.
Easily installed.
No man power
It gives fast response.
DISADVANTAGES

DISADVANTAGES
Moisture can affect the sensitivity
Cleaning of probes is required due to oxidation problems.
It can not be used for uncovered tanks during rainy season.
APPLICATIONS
 APPLICATIONS

In house-hold tanks.
In difficult to access over head tanks.
In industries for liquid level sensing and controlling.
In hotels, apartments. hospitals, offices, hotels and all commercial
sectors.
In many plants to ensure continuous water supply.
In industries for automation purpose.
In difficult to access over-head tanks.
FUTURE SCOPE
FUTURE SCOPE

PLC Based Automatic Liquid level Controller is a very

popular project. If it is used for commercial purpose in various
industries so many modifications are possible in this circuit.

Wireless operation can be provided.

GSM control can also be provided.
For industrial purpose all advanced version of the circuit is required.
For this SCADA based liquid level controller can also be used.

Timing operation can also be provided by using timer circuits.

We can connect alarm and thus we can get audio indication also,
which is more easier.

We can go by simple hardware circuit also by introducing stainless

steel sensors.

This project can be implemented by using PID Controller.

RESULT AND CONCLUSION
RESULT :-

When water level of Tank 1 is below high level , Solenoid Valve 1 and pump is
operated.

When water level of Tank 2 is below low level, Solenoid Valve 2 and pump is operated
and when it is reached at high level Solenoid 2 gets OFF.

When water level of Tank 3 is below low level, Solenoid Valve 3 and pump is operated
and when it is reached at high level Solenoid 3 gets OFF.

Whenever any solenoid valve is operated, Pump starts .

When all the solenoids are OFF, Pump gets automatically OFF.
Whenever water level of Source Tank goes below it’s high level Solenoid Valve 4
(BMC Valve ) is operated.

Whenever water of source tank is reached below low level, process goes automatically
OFF.

CONCLUSION :-

Water level is controlled automatically without any manual operations.

Operations are controlled by changing program according to our need and
requirements.
BIBLIOGRAPHY