A

Project On
WATER CONTORL SYTEM
By
PLC

Submitted by:
Debojyoti Chakroborty

Reg no:MV147967

Date:12.01.2015
Contents
 Introduction
 PLC Description
 System Description
 System Component
 Control Philosophy
 Process flow chart
 Ladder diagram
 Auto CAD design
 General arrangement of control panel
 Legend details
 Single line diagram
 Power circuit of motor
 Control circuit of PLC
 Bill of Material
 Sheet Metal Calculation
 Cost Analysis
 Conclusion
Introduction
A PLC (i.e. Programmable Logic Controller) is an industrial computer that
monitors inputs,make decisions based on its program and control outputs to
automate a process or machine.It was invented to replace the conventional
relay logic circuits for machine and process control.PLC’s are used in many
"Real World" applications. Particularly in the filed of machining,packaging,
material handling, automated assembly or countless other Industries the
application that needs some type of electrical control has a need for a
PLC.Here, we are using a Q series PLC of Mitsubishi company for a water
control system.Because by using PLC, the control system will be more reliable
and cost effective.

PLC Description
Features of Q series PLC:
 I/O range is more than 1024
 Functionality is modularized
 Expansion of racks also
 I/O distribution on network like CC-Link
 Processing time:79 to 34 nSec,QnU:9.5nSec

System Description
A PLC is to control an amusement park water ride. The ride is associated with a
tank of water and splash a tour group. The ride full with tour group is sensed
by ‘cart detect’ limit switch. The water tank is associated with two solenoid
operated valve and corresponding level sensor. The ‘filling valve’,
accompanied by ‘level full sensor’, is at the top end of the water tank whereas
the ‘outlet valve’, accompanied by ‘level empty sensor’, is at the bottom of the
water tank.
System component
1.A cart detect limit switch

2.Two solenoid operated valve(one is filling valve and other is outlet valve)

3.two sensor(one is level full sensor and other is level empty sensor)

4.Three timer

Control philosophy
 The process starts in idle.
 The cart detect limit switch opens the filling valve.
 After a delay of 30 seconds from the opening of the filling valve, the
outlet valve opens.
 When the tanks is full (level full sensor: healthy) the filling valve closes.
 When the tank is empty (level empty sensor: healthy) the outlet valve
closes.
 After a delay of 10 second from the opening of the outlet valve, a water
jet opens.
 After a delay of 2 second, the water jet closes and the process returns to
the ‘idle’ state.
 Ladder Diagram

Program 12/29/2014
Library Name:-
Data Name:MAIN

M0 M1 Y23 Y20
0 Y20 A/S 5
A/S

X0 Y20 X1 Y21
4 Y21 A/S 6 9
A/S

Y21

Y21 T0 M0
9 M0 A/S 10
B/D 0

M0 K300 T0
T0 A/S 17
B/D 11

T0 X2 Y22
17 Y22 A/S 18 21
A/S

Y22

Y22 T1 M1
21 M1 A/S 22
B/D 1

M1 K100 T1
T1 A/S 29
B/D 23

1
Program 12/29/2014
Library Name:-
Data Name:MAIN

T1 T2 Y23
29 Y23 A/S 30
B/D 2

Y23 K20 T2
T2 B/D 31
B/D

37 END

2
 LEGEND DETAILS
Sl.
Tag Material Description Range/Rating Type Make Qty.
No.
Programmable Logic Controller I/P:32 nos;O/P:32 nos Transistor
1 Mitsubishi 1
PLC (CPU)
2 PC -> PLC Communication Port Ethernet E-436709(ETL) Belkin 1
3 PSU Power Supply Unit 6A I/P: 100/240V AC; O/P: 5V DC,6A Mitsubishi 1
I/P: 120/230V AC; O/P:
4 ITRF Isolation Transformer 5VA; CTR-1:1 Gupta Engg. 1
120/230V AC
5 CB1 TPN / FP 63A, Breaking Capacity: 6kA C Curve; Isolator type L&T 1
6 CB2, CB3 DP 10A, Breaking Capacity: 6kA C Curve; Isolator type L&T 2
7 C1 Contactor 10A, 230V AC with (3NO+1NC) Aux. contact Telemecanique 1
8 A Ammeter 0 - 100A Analog, Direct reading; Size: 72 mm2 Meco 1
9 ASS Ammeter Selector Switch 6A 4 position (with Off) Kaycee 1
10 V Voltmeter 0 - 500V Analog; Size: 72 mm2 Meco 1
11 VSS Voltmeter Selector Switch 6A 4 position (with Off) Kaycee 1
12 CF1 - CF10 Control Fuse 2A, 140W with Base mtg. GEC 10
Panel Indicating Lamp;
13 L1 - L7 Red, Green -2 nos. each & 230V AC Filament type Siemens 7
Orange, Yellow, Blue -1 no. each
14 LVR Louver Size: 150 mm² Mesh type Keyman 1
15 EXHF Exhaust fan Size: 4"; 230V AC Ventilation type Rexnord 1
16 CFL Compact Fluroscent Lamp 12W / 230V AC Colour: White Philips 1
17 DLS Door Limit Switch 6A Essen 1
18 TB Terminal Block Size: 2.5 mm² Clip-on type Elmex Bulk
PVC Insulated,
19 Cu. Wires 1100V/660V, 2.5 mm² Finolex 1 coil
Multistranded FRP Flexible
20 Transparent Perspex Sheet 200 mm.(H) × 200 mm.(W) 1.2mm.Thk; Scratch proof Siant-Gobain 1
Hardwares (PVC Channel, DIN
Rail, Nut, Bolt, Screw, Washer,
Cable Tie, Lugs, Rubber Gasket,
21 Various size Various type Reputed Bulk
Ferrules, Groomet, Earthing Stud,
Door Knob, Nameplate, Terminal
Endplate etc.)
[H×W×D]: Fabcon
22 Control Box Wall Mounting; IP-54; 1
500 mm.×500 mm.×300 mm.
Technology
 Control Circuit Of PLC

Scanned by CamScanner
 BILL OF MATERIAL
Sl.
Material Description Range/Rating Type Make Qty.
No.
Programmable Logic Controller I/P:32 nos;O/P:32 nos Transistor
1 Mitsubishi 1
(CPU)
2 PC -> PLC Communication Port Ethernet E-436709(ETL) Belkin 1
3 Power Supply Unit 6A I/P: 100/240V AC; O/P: 5V DC ,6A Mitsubishi 1
I/P: 120/230V AC; O/P:
4 Isolation Transformer 5VA; CTR-1:1 Gupta Engg. 1
120/230V AC
5 TPN / FP 63A, Breaking Capacity: 6kA C Curve; Isolator type L&T 1
6 DP 10A, Breaking Capacity: 6kA C Curve; Isolator type L&T 2
7 Contactor 10A, 230V AC with (3NO+1NC) Aux. contact Telemecanique 1
8 Ammeter 0 - 100A Analog, Direct reading; Size: 72 mm2 Meco 1
9 Ammeter Selector Switch 6A 4 position (with Off) Kaycee 1
10 Voltmeter 0 - 500V Analog; Size: 72 mm2 Meco 1
11 Voltmeter Selector Switch 6A 4 position (with Off) Kaycee 1
12 Control Fuse 2A, 140W with Base mtg. GEC 10
Panel Indicating Lamp;
13 Red, Green -2 nos. each & 230V AC Filament type Siemens 7
Orange, Yellow, Blue -1 no. each
14 Louver Size: 150 mm² Mesh type Keyman 1
15 Exhaust fan Size: 4"; 230V AC Ventilation type Rexnord 1
16 Compact Fluroscent Lamp 12W / 230V AC Colour: White Philips 1
17 Door Limit Switch 6A Essen 1
18 Terminal Block Size: 2.5 mm² Clip-on type Elmex Bulk
PVC Insulated,
19 Cu. Wires 1100V/660V, 2.5 mm² Finolex 1 coil
Multistranded FRP Flexible
20 Transparent Perspex Sheet 200 mm.(H) × 200 mm.(W) 1.2mm.Thk; Scratch proof Siant-Gobain 1
Hardwares (PVC Channel, DIN
Rail, Nut, Bolt, Screw, Washer,
Cable Tie, Lugs, Rubber Gasket,
21 Various size Various type Reputed Bulk
Ferrules, Groomet, Earthing Stud,
Door Knob, Nameplate, Terminal
Endplate etc.)
[H×W×D]: Fabcon
22 Control Box Wall Mounting; IP-54; 1
500 mm.×500 mm.×300 mm.
Technology
 SHEET METAL CALCULATION

Panel Height : 500 mm. = 0.5 m.

Width : 500 mm. = 0.5 m.
Depth : 300 mm. = 0.3 m.
Mounting plate : 350 mm. (H) X 400 mm. (W)
Material of Construction : 2 mm. CRCA, TISCO

Sheet metal required for

A] Cubicle body of the control panel:
= 2[(0.5*0.5)+(0.5*0.3)+(0.3*0.5)] sq.m.
= 2[0.25+0.15+0.15] sq.m.
= 2 * 0.55 sq. m.
= 1.1 sq. m.

B] Mounting plate of the control panel:

= 350 mm. * 400 mm.
= 0.35 m * 0.4 m.
= 0.14 sq. m.

Total Sheet Metal required for control panel [A+B]:

= (1.1+0.14) sq.m. * 16 kg.
[Since, Weight of 2 mm. CRCA: 16 kg/m² ]
= 1.24 sq.m*16 k.g =19.84@ Rs. 180/-
[Cost includes sheet metal cost, transportation, fabrication, painting,
electricity, packing, forwarding, labor charge etc.]
= Rs. 3572/-
Say: Rs. 5000/-
[Rupees Five Thousand only]
 COST ANALYSIS
Sl. Unit Price Total Price
Material Description Range/Rating Type Make Qty.
No. (in Rs.) (in Rs.)
Programmable Logic Controller I/P:32 nos;O/P:32 nos Transistor
1 Mitsubishi 1
(CPU) 31,000.00 31,000.00
2 PC -> PLC Communication Port Ethernet E-436709(ETL) Belkin 1
3 Power Supply Unit 6A I/P: 100/240V AC; O/P: 5V DC ,6A Mitsubishi 1 1,250.00 1,250.00
I/P: 120/230V AC; O/P:
4 Isolation Transformer 5VA; CTR-1:1 Gupta Engg. 1 1,400.00 1,400.00
120/230V AC
5 TPN / FP 63A, Breaking Capacity: 6kA C Curve; Isolator type L&T 1 2,500.00 2,500.00
6 DP 10A, Breaking Capacity: 6kA C Curve; Isolator type L&T 2 450.00 900.00
7 Contactor 10A, 230V AC with (3NO+1NC) Aux. contact Telemecanique 1 500.00 500.00
8 Ammeter 0 - 100A Analog, Direct reading; Size: 72 mm2 Meco 1 650.00 650.00
9 Ammeter Selector Switch 6A 4 position (with Off) Kaycee 1 150.00 150.00
10 Voltmeter 0 - 500V Analog; Size: 72 mm2 Meco 1 650.00 650.00
11 Voltmeter Selector Switch 6A 4 position (with Off) Kaycee 1 150.00 150.00
12 Control Fuse 2A, 140W with Base mtg. GEC 10 25.00 250.00
Panel Indicating Lamp;
13 Red, Green -2 nos. each & 230V AC Filament type Siemens 7 155.00 1,085.00
Orange, Yellow, Blue -1 no. each
14 Louver Size: 150 mm² Mesh type Keyman 1 150.00 150.00
15 Exhaust fan Size: 4"; 230V AC Ventilation type Rexnord 1 350.00 350.00
16 Compact Fluroscent Lamp 12W / 230V AC Colour: White Philips 1 150.00 150.00
17 Door Limit Switch 6A Essen 1 150.00 150.00
18 Terminal Block Size: 2.5 mm² Clip-on type Elmex Bulk 500.00 500.00
PVC Insulated,
19 Cu. Wires 1100V/660V, 2.5 mm² Finolex 1 coil 2,500.00 2,500.00
Multistranded FRP Flexible
20 Transparent Perspex Sheet 200 mm.(H) × 200 mm.(W) 1.2mm.Thk; Scratch proof Siant-Gobain 1 500.00 500.00
Hardwares (PVC Channel, DIN
Rail, Nut, Bolt, Screw, Washer,
Cable Tie, Lugs, Rubber Gasket,
21 Various size Various type Reputed Bulk 2,500.00 2,500.00
Ferrules, Groomet, Earthing Stud,
Door Knob, Nameplate, Terminal
Endplate etc.)
[H×W×D]: Fabcon
22 Control Box Wall Mounting; IP-54; 1 5,000.00 5,000.00
500 mm.×500 mm.×300 mm.
Technology
TOTAL COST: 39,285.00
(Rupees Thirty Nine Thousand Two Hundred & Eightyfive Only.)
Conclusion
We have finished our project successfully by using PLC effectively.PLC reduces
the complex circuitry of the entire control system. We are able to eliminate the
high costs associated with relay-controlled system by using it.Also the entire
control system becomes easy for maintenance and troubleshooting.