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DEBREBREHAN POLY TECHNIC COOLLEG

DEPARTMENT OF ELECTRICAL AND ELECTRONUCS

OCCUPATION FOR : INDUSTRIAL AUTOMATIC CONTROL

AND TECHNOLOGY MANAGMENT

PROJEC TITLE :CONSTRUCTION OF AUTOMATIC WATER

LEVEL CONTROLLER FOR BOTH OVERHEAD AND

UNDERGROUND TANKS

Prepared by

1. Redeat shimels

2. Aster

3. Degnetu T/stadik

4. Asnake Asfaw

5. Tigst Fikre

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ACKNOWLEGEMENTS

We sincerely appreciate my distinguished parents and techers their love

and parental care, my honourable techer in department,all group

members for his tremendous contributions to this work and advice we

gave idea during the course ofthis work, and not forgetting all my

lecturere.

Finally, I appreciate all my course mates, all my friends who have in

oneway or the other contributed immensely to the construction of

thisproject.MayGod bless usall.

ABSTRACT
Automatic water level controller for both overhead and underground
tank is designed to monitor the level of water in a tank. It displays
thelevel of water and when it is at the lowest level; a pump is activat
edautomatically to refill the tank. When the tank is filled to its
maximumcapacity, the pump is automatically de-energized. Several
circuits areput together to ensure proper working of this design, and
the blockdiagram includes the supply unit, the micro-processor unit,
the sensorunit, the display unit and the pump drives unit. The power
unit.is responsible for turning onthe entirecircuit.Some components are
used to setup power unit and they include; a15v stepdown
transformer, a bridge rectifier circuit, a smoothening capacitor and
avoltage regulator IC.The microprocessor (AT89S50) controls
virtuallyall the actions carried out in this design. (AT89S50) is used in
thedesign. The sensor unit is responsible for sensingthe level of water
and transfer the current position of water to the microprocessor.
Thedisplay unit in the circuit is use to physically show the current
positionof water in the tank, the properties of seven segment display
are been used.

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Table Content

CHAPTERONE

1.0 INTRODUCTION-- - - - - - - - -1

1.1 background- - - - - - - - - -2

1.2 aimsandobjective- - - - - - - - -2

1.3 scopeofthestudy- - - - - - - - -3

1.4 constrains-- - - - - - - - - -3

1.5 limitationsoftheproject- - - - - - - -4

CHAPTERTWO

LITERATUREREVIEW

2.0 review- - - - - - - - - - -5

2.1sensors- - - - - - - - - - -6

CHAPTERTHREE

METHODOLOGY

3.00 Project blockdiagram- - - - - - - -7

3.01 MATERIAL LIEST - - - - - - - -

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CHAPTERFOUR

4.0 Overview of the project - - - - - - -11

4.1 Software design--- - - - - - - - - - - - - - - - - - - 12

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4.2 testing-- - -- - -- - - - -- - -- -- - - -- - -- - -- -- 13

4.3 program proceed _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 13

4.4 -CHOICE OF PROGRAMMING LANGUAGE _ _ _ _ _ _ _ 14
4.5 PROGRAME NTRY AND EDITING _ _ _ _ _ _ _ _ 14
4.6 -SYSTEM CONTROL PROGRAM STEPS __ _ _ _ _ _ 15
4.7 -SYSTEM CONTROL PROGRAMSTEPS _ _ _ _ _ _ _ _ 15
CHAPTER FIVE SYSTEM TESTING AND IMPLIMENTATION
TEST PLANAND TEST DATA

5.00 Component test-- - - - - - - -15

5.01 Systemtest- - - - - - - - -

5.02 Transformertest- - - - - - - -

5.03 conclusions- - - - - - - - - -

5.04 Recommendations- - - - - - - -

5. 05 REFFERENCE-- - - - - - - - -

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CHAPTER ONE INTRODUCTIONS

1.0 BACKGROUND

The project “automatic water level control with an automatic

pumpcontrol system” is design to monitor the level of liquid in the tank.

Thesystem has an automatic pumping system attachedtoit soas

torefillthe tank once the liquid gets to the lower threshold, while offing

thepump once the liquid gets to the higher threshold. Sustainability

ofavailable water resource in many reason of the word is now a

dominantissue. This problem is quietly related to poor water allocation,

inefficientuse, and lack of adequate and integrated water management.

Water iscommonly used for agriculture, industry, and domestic

consumption.Therefore, efficient use and water monitoring are potential

constraint for home or office water management system. Moreover, the

commonmethod of level control for home appliance is simply to start the

feedpump at a low level and allow it to run until a higher water level

isreached in the water tank. This water level control, controls monitor

and maintain the water level in the overhead tank and ensures the

continuous flow of water round the clock without the stress of going to

switch the pump ON or OFF there by saving time, energy, water, and

prevent the pump from overworking Besides this, liquid level control

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systems are widely used for monitoring of liquid levels

inreservoirs,silos.Proper monitoring is needed to ensure water

sustainability is actually being reached with disbursement linked to

sensing and automation, such programmatic approach entails

microcontroller based automated water level sensing and controlling

timer IC.

1.1 AIMS AND OBJECTIVES

The goal or objectives of which the designed device is expected

toaccomplish is to build an automatic water level control with

automaticcontrol system. In this project sensors are place at different

level of thetank and with the aid of this sensors, the micro-controller

monitor thelevel of the liquid at any particular point in time, some of the

objectivesare

1. to design anautomatic water monitoring system

2. to incorporate an interactive medium between the end user and

the machine

3. to prevent over labor of the pumping machine and prevent from

getting bad.

4. to avoid wastage ofwater

5. since the demand of electricity is very high, automatic water level

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control saves energy

1.2 SCOPE OF THE PROJECT

The project was design to automatically control the pump which

ensuresconstant reserve of water in the reservoir. The scope of the

design was keep concise and simple to in other not to introduce

unnecessary complexities and render it generally uncomfortable. The

system does nothave attached complex peripheral device which though

impossible for thedetail printable information has been excluded for

reasons of affordability material flow range and less accurate

performances .

well built automatic water pump was use d to achieve this aim, the

automatic water level controller detect and control the water in the tank.

1.3 CONSTRAINS

The biggest setback experienceduring the course of this project

isdifficulties in finding the design of the project, secondlysourcing

ofmaterial and component I used for the project were difficult to find like

pump and buffer for programming

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1.4 LIMITATIONS OF THE PROJECT

It is significant to know that this design is limited to 12v, 5 amps electric

pump and cannot be use to control industrial water pump above 5 amps

BLOCKDIAGRAM OVERVIEW

This project report writing is written is design in such a way that each

chapter is related tothe next asshownbelow

POWERSUPPLY

CONTROL CONTROL DISPLAY

UNITE UNIT

INPUT UNIT

FIG 1.0 BLOCK DIAGRAM OF AUTOMATIC WATER

LEVELCONTROLWITHPUMP

CHAPTERTWO
2.0 REVIEW

An automatic water level control detects the water level in the tank and

also ensures continuous water flow round the clock because of its

automatic, this automatic water control is made up of microcontroller

written in plC programming language this program is burn into an IC

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called AT89S52 With 40 pins. The level measurement consist of

determining the distance from the upper surface of a liquid in a reservoir

or vessel orany arbitrarily chosen mark located above or below this

surface by itselfthe level is not an independent physical quantities

describing the state ofa substance through direct and indirect level, some

examples of direct level measurement are dipstick, the bubbler,

immersion electrode, capacitor type ,liquid level radiation type liquid level

measurement .forinstance the dipstick, it is very simple, the stick being

dipped periodicallythrough a hole and the hole and the immersion mark

is being read off with the aid of the calibrationon the stick.

2.1 SENSORS

Level sens or detect level substance that flow including liquids slurries,

granular materials and powders. Allsubstance that flow to be come

essentially level in their containers (orother physical boundaries)

because of gravity The substance to be measure can beinside a

container or can be in its natural form (e.g. river or lake) . Thelevel

measurement can be either continuous or point value.Continuous level

sensors measure within a specified range and determine the exact

amount of substance in a certain place. Hill point level sensors only

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indicate whether the substance is above or below the sensing

pointgenerally the latter detect levels that are excessively high or low

there are many physical and application of variables that affect selection

of materials

CHAPTERTHREE

3.0 METHODOLOGY

There are many methods of designing an automatic water level control

withs witching device but all these methodologies require human

assistance. In this project an automatic water level control for both

overhead and underground tank with switching device is designed

usingelectronic control to refill the water without human intervention.

Thesystem design was carefully arranged to refill the water tank any

timewater get low to a certain level finally the system automatically

shutdown the water pump by putting the electric pump by off when the

tank is full. The approach used in this work is the modular design

approach the overall design was broken into function block diagrams.

Where each block in the diagram represent asection of the circuit that

carries out a specific function. The system was designed using functional

block diagram this method the circuit is designed to display 3 different

level usingthree sensors to monitor the inflow of water in the tank.

However these displays can be increased and decreasede pending upon

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the level resolution required. This can be done by increasing or

decreasing thenumber of level detector and associated component.

Diodes full-wave rectifier are

used to power the system through a volts battery therectifier output tered using

capacitor C through C3 respectively thefinal design schematic circuit diagram of

the method is shown below inthe figure

rectifier output tered using capacitor C through C3 respectively thefinal design

schematic circuit diagram of the method is shown below inthe figure

Chapter three
Materiyal list for the constraction automatic water level control :
1. FLUID LEVEl DETECT OR SENSORE
2.STEP DOWN TRANSFORMER
3.REPRESENTION DIODE LogicI=ONL
4.BRIDG RECTIFIE ogic
5.RESISTORS Control
6. Capacitor Diod

7. Power supply unit

Relay
8. desplay unit
10k Coil

9.COMMON ANODESEVENSEGMENT DISPLAY

8. LED SEVENSEGMENT DISPLAY NPN

9. THE INPUT INTER FACE DESIGN GND

10. SENSOR PROCEDURE

11. MICROCONTROLLER UNIT

12. FEATURES
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PO3.26PUMPCONTROLSEGMENT

CHAPTERFOUR

SYSTEM IMPLEMENTATION

4.0 Overview of the project

As seen in chapter one, the project consist of six blocks. Which

depictsthe functional parts of the system. In this section, I will like to

makeconceptual design of the design of the system to havein the

detaildesign of the hardware. The design gives an overview on the

function ofthe major block, how they are integrated and the data flow

arrangement.A sensitive automatic detector of water level controller will

switchingdevicecanthedesign processcharacterizedbythefollowing

1. Definitionoftask

2. Requirement

3. Factorthatinfluencechoice

In defining a task, every design comes from an idea or a problem

thatrequire a solution. Questions may be generated on what exactly that

isrequired to be achieved and the feasibility of the ideas as regards to

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theimplementation. If these questions are analyzed critically with

tangiblesolutions to the problem, a development of this idea into a reality

is thenext step. Requirement for design process have to be considered

once anideahasbeenestablish.Theneedtodeterminewhetherornottheidea

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4.1 SOFTWARE DESIGN

Software is computer program, instructions that cause the software,

themachine to do work. Software as whole can be divided into a number

ofcategories base on the type of work done. The two primary software

areoperating software (system software), which controls the working of

thecomputer, application software, which addresses the multitude of task

forwhichpeopleusecomputer.Applicationsoftware,performword
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processing,databasemanagement,andthelike.Twoadditionalcategoriesthat

areeithersystemnor

Applicationsoftware,andlanguagesoftware,whichprovideprogrammerswith

toolstheyneedtowriteprograms.Inadditiontothese task-based categories,

several types of software are describedbasedontheirapplication.

PLANING HARDWARE

BUILDING
THEPROGRA
M COMPILING
SETTINGPROPERTIES

WRITINGCODES

TESTING

4.2 TESTING

After the programs is written ,it was tested, this involve executing the

programs with selected input called test cases, the result whether or

not the program is function in gas desired.

4.3 DEVELOPMENT PROCESS

Inwritingthesoftwareforthisproject,amodularapproachwasemployed. This

made it easier to check for errors and debug the

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program.Threemajortoolswereusedinthedevelopmentprocess;theC51compi

ler was used to translate from the source code into the object code.The

SDCPP was employed to link the program while the PACKIHX did

theconversionfrombinarytohexadecimal.

4.4 CHOICE OF PROGRAMMING LANGUAGE

MyimplementationprogrammingforthisprojectisCprogramminglanguage

reasons being the fact that C combines the element of high-level

language with functionalism of assembly language. C allows

themanipulation of bits, bytes and addresses. Also C codes are

portablewhich means that it is possible to adapt software written for one

type ofcomputertoanother.Nevertheless,aspecialfeatureofCisthatitallows

the direct manipulation ofbite,byte,word and

pointers.Thissuiteittosystemlevelprogrammingwheretheseoperationareco

mmon. C has only 32 key word as compare with Q-basic for IBM

pcwhichcontain159key word

4.5 PROGRAMENTRYANDEDITING

After the design of the software, a text editor is employed to enter

thesource intothe disk file. As noted earlier, thetext editor

alsofunctionsas error correcting in the program. The text editor use is

the CRIMSONtexteditor.

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4.6 COMPILINGAND LINKING

The small device C “compiler” comes with a lot of modules. It dose

thetask of compilation, linking binary to hexadecimal conversion once

thecompilation commandisissuedan objectfile, a hexadecimaland

abinaryfile.

4.7 SYSTEMCONTROLPROGRAMSTEPS

The operation of the micro-controller based water level control system

issummarizedas follows;

1. The display unit display the present level of the water for

example“3”

2. The micro-controller monitor the sensor and open the pump

oncethewaterlevelhasgonetoolow,andthedisplaysystemshows“L”wh

ichmeanslow

CHAPTERFIVE

5.0 SYSTEM TESTING AND INTEGRATION

After the design and implementation phase, the system built has to

betested for durability and effectiveness and also ascertain if there is

needtomodifythedesign.thesystemwasfirstassembledusingbreadboard

.all the component were properly soldered to the oboard from whence

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some test were carried out at various stage .to ensure properfunctioning

of component expected data, the component were testedusing a digital

multimeter (DMM). Resistors were tested to ensure thatthere within the

tolerance value. Faulty resistor were discarded. TheAT78LS05 voltage

regulator, the resulting output was 5.02v which is justa deviation of

0.20v from the expectedresult of 5.00v, the pump wasalso tested

toensure that itwasworkingproperly.

TEST PLANE AND TEST DATA

This chapter entail the overall system testing of integrated design of

voltage measurement device.the testing and integration is done to

ensure that the design is functioning properly as expectedthere

byenabling one or evenintended users for which the project was

targetedfor, appreciate its implementation and equally approaches used

in the designand integration of various modules of the project. however,

this involves checks made to ensure thatall the various unite and

subsystem function adequately also there has to be good interface

existing betweenthe output /input unite subsystem. When the totality of

the modules was integrated together, the system was created and all

module and sections responded to asspec the design through the power

supply delivering into thesystemdesigned.

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COMPONENT TEST

Similar component like resistor were packed together. The other

component include capacitor,switch,transformer,resistor,Diodes(rectifier)

LED, transistor ,voltage regulators etc Reference was made tocolour

codingdata sheet toascertain theexpectedvalueof resistorsused. Each

resistor was tested and the value read and recorded. Also fortransistor

test the DIMM was switched to the diode range. The collector,base,

emitter junctions were tested in the following order. The collector,emitter

and base pins were gotten from the data analysis on power transistor.

TEST FOR TRANSISTORS

Blackprobe Red probe

1sttestonpins collector Base

2ndtestonpins Emitter Base

SYSTEM TEST

The system was powered and operated upon using several possibilities

they include making sure that the pump only start when the water

levelhas gone below the mark, and stops when the water level has

reachmaximum. The seven segment display was also tested to make

surecorrect level was display on the seven segment display screen.

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Thesensorswerealsotested.

TRANSFORMER TEST(stepdown)

Expectedly the transformer was rated220v/12v, 1000mA. from the mains

power supply, the primary coil receives 220v input, the output

wasmeasure to be 16.75v using a DMM. Test data on transformer has it

that the resistance of the primary windings forstep down transformer is

higher than that of the secondary side this was as certained.

OTHER TEST

The bucket used as tank in my project was tested in other to make

surethere was no leakage, the hose or pipe conveying the water from

thelower tank to the upper tank was tested or checked for any kind

ofbreakageorleakage.

PERIMENTEDRESULTVSACTUALRESULT

COMPONENT EXPERIMENTED ACTUAL UNIT TOLERANCES

VALUE VALUE
REGULATOR 5.00 5.02
TRANSFORMER 12Vac @ 13.2 V
240Vac
TRANSISTOR Rbe520 550
Rbc510 548
CAPACITOR 10 10.20
10 10.15

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30 29.82
RESISTOR 1000 1000
2000 2000 5%
220 218
1000 9980

PERFORMANCE EVALUATION

From the table above, it shows that range between the expected

valueand the actual can be tolerated. As a result of this the drift in

expectedvalue has no critical effect on the system design since the result

current range was also exceeded, the operational voltage was not

exceeded.

PACKAGING

After the completion of the work, the circuitry was enclosed in a case

toavoid damage. This is very vitally to the packaging of any electronic

equipment, the enclosure provides protection as well as attraction that

is,it addaesthetic value to the work. The sizes of tank to be used

forpackaging was first of all determined after considering the

followingfactors

1. easy input and removal of water from the tanks

2. positions of the tanks

3. space for future modifications,easy accessibility to circuit board

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4. Easy mobility of the tanks.

BILL OF ENGINEERING MEASURMENT AND EVALUATION To

carry out this project , somethings were put into considerations.

Among those things include the cost of component used for the

construction was the priority.The table below shows the component that

are used in the project construction, the quantity and also the price of

each components

S/N COMPONENT VALUE QUANTITY UNIT BUIK

PRICE

1 TRANSFORME 220V/12V 1 120 120

2 DIODES IN4001

3 CAPACITORS 220035V 1 50 50

10 16v 1 50 50

4 TRANSISTORS C945

5 INTEGRATED 7805 1 80 80

CIRCUITS AT89552 1 450 450

6 RELAY 6v:10amp 1 80 80

7 SEVENSE 1 120 120

GMENT

DISPLAY

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8 POWER 1 40 40

SWITCH

9 VEROBOARD 1 100 100

10 RESISTORS 10KΩ 6 5 60

150Ω 1 5 50

4.7KΩ 5 5 50

10K 5 5 50

variable

11 ACCABLE 3 80 240

12 CASING Knockout 1 500 500

box

13 D.CWATERTR 12v 1 1200 1200

PUMP

14 BUCKETS 2 150 300

LEAD 9 30 270

WATERPIPE 2 80 160

TOTAL 3890

CONCLUSION

Going through the planning, flow process, design and software

implementation, the system has been a tough one,the chapter one to

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four has actually tried as much as possible to explain vividly almost all

(ifnot all) what is involved in the construction of this project. After

thecomplete design of the system, the deviation between the expected

result and the actual result was very close. The performance and

efficiency was beyond expectation and from every ramification the

design of automatic water controller was successful.

PROBLEM SENCOUNTERED

During the course of designing this system there were series of

problems encountered which came on the way of achieving the

desiredgoals of this project. Some parts require re-designing and the

software debugging also created a bit of the problem. After installing the

pump, Inoticed that the bucket was punched there by making water to

leak, thiswas so challenging because it leads to me changing the tank

which affected the budget.

RECOMMENDATIONS

I strongly recommend that government should set up industries

forproduction of basic electronic component locally and establish

researchcenters in each university to enable student have good sound

practical knowledge one ectronics component and their operation

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REFERENCES

Aye,T.S.,&Lwin,Z.M.(2006).Microcontroller Based Electric Expansion

Valve Cwww. ontroller for Air Conditioning Syste, World Academy

of Science, wwww.ering and Technology.Vol.2864.

Belone,S.,&Graw,H.W.(2004).Electronic Circuit Discrete &Integration,

(23rd Www.electronic design and constractin

APPENDIXA:SYSTEMCOMPONENTLIST

1. Dc water pump

2. Lm7805 voltager egulator

3. Veroboard

4. Connectingwire

5. Sevensegment display

6. 240/12v,1000matransformer

7. Solderingiron

8. 30phcapacitor

9. 10uf16vcapacitor

10. Rectifierdiodes

11. 2200uf/25vcapacitor
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