Application: D4-440 PLC and input/output and relay modules wash cars and give change at self-serve car wash Products used: D4-440, D4-16NE3 input module, D4-16TR output module, F1-130DR relay output module Description: Knowing almost nothing about programming, I taught myself enough ladder logic to control a six bay self-serve car wash with a D4-440 PLC and D4-16NE3 input and D4-16TR output modules. The system controls all aspects of the wash, including the choice of service, counting the coins and measuring time. I also added safety features to protect the motors, to watch for low water pressure or no water, and to watch for failure of 3 ph. The PLC also controls the weep system when the temperature drops below 32 degrees and controls the low pressure applications, foam brush, pre-soak and tire cleaner. Depending on the temperature, the system switches winter soap with summer soap in the foam brush. This alone saves a lot of money since freezing only occurs for a few hours a night. A separate bill changer system uses a F1-130DR relay output to read the bill denomination from the bill validator while an electric hopper dispenses change. Submitted by: |
Application: Network of DL405 and DL205 PLCs keep the beer flowing at brewery Products Used: DL440 PLC, DL240 and DL250 PLCs, high speed counter module, analog modules, Ethernet communication modules Description: A network of DL405 and DL205 PLCs monitor and control the delicate process of producing quality beverages at the Ringwood Brewery in England. The Brew House system consists of a D4-450 CPU, 32 digital and 56 analog I/O, high speed counters, an Ethernet link and multiple communications to three touch screen HMIs. The PLC controls chemical dosing, water flowrates and temperatures, and steam boiling controls. In the Tun Room, a DL440 PLC performs fermentation and cooling of fermentation vessels, as well as gycol plant monitoring.The high speed counters, digital and analog I/O supply information to the D4-440 CPU connected to a touch screen operator interface. The cask filling process uses DL240 and DL250 based nodes totaling 128 digital and 8 analog I/O, as well as four high speed counters. Ethernet modules in each PLC provide a network for high-speed exchange of data and control information. A master HMI software package automatically trends and records all temperatures, flows and levels throughout the plant.. All PLCs in the system can also be accessed remotely via dial up networking. Submitted by: |
Application: DL405 performs hot wax transfer management for a corrugated box wax curtain coater Products Used: DL405 PLC, various I/O, DV-1000 operator interface Description: Control system produces a finished paper product intended for coldpack and freezer extremes. Machine production has doubled since the implementation of the DL405 control system! 8 slot backplane includes: 2-16 pt 120v in, 1-16 pt 120v out to control and supervise several motors and valve actuators, 1-8 pt relay to control existing machine entities (from existing machine power), one 16pt simulator card for manual force functions. The unique part of this system is that 2-8pt thermocouple cards are used for level control. It has been found in the industry that this specific wax is very difficult for various industry standard level sensors and devices to detect reliably and consistently. This process includes 7 process tanks, the first being bulk railcar delivery. From bulk storage, the wax is conveyed to various other tanks for temperature conditioning prior to delivery to the curtain. The DL405 dictates the filling of these through the T/C card data. In each tank, we simply installed 2 thermocouple probes, one being much longer than the other. When we see a mean indifference between the two temperatures, we know the tank is low. We also have a probe sampling ambient temperature so we know what type of offset to apply during marginal plant ambient temperatures. The DV-1000 continually and automatically scrolls various machine temperatures and conditions and reports statuses to the operator in English, without any intervention necessary. Submitted by: |
Products Used: D4-450 PLC, D4-16NA, D4-16TA, F4-08AD, F4-08THM, D4-08TR, FA-24PS, LookoutDirect HMI, GH15DN-3-10A, GH15FT-3-00A contactors
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Application: DL405 makes hay whether the sun shines or not Products Used: DL405 and DL305 PLC systems
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Application: DL440 PLC operates and monitors municipal water treatment plant Products Used: DL440 PLC, D4-16TA AC outputs, D4-16NA AC inputs, D4-16TR and F4-08TRS-2 relay outputs Description: This application controls and monitors the operation of a municipal water treatment plant. The software was written using Visual Basic 6.0 for the 20+ MMIs (operator interfaces), and ladder logic was developed using the DirectSOFT programming package. The system allows the operators to control every piece of equipment in the plant. This includes all pumps' lowlift, highlift, backwash, sludge and chemicals. The operator can see and change the dosages for 6 chemicals. The filters can be fully controlled in either auto based on flow, LOH of time or manually. The system has a data logger that logs all needed data at a time selected by the operator. There is also a program that allows laboratory data to be input and compared to online instruments, and that saves the values and deviations to a Microsoft Access database. The system has alarms with criteria editable by the operator. The system can be accessed via modem, the Internet or by direct dialup. Submitted by: |
Application: DL450 PLC controls inline blending system to produce Marine fuel oil Products Used: DL450 PLC, RTD input module, high speed counter module, analog output module, digital I/O, Optimate 1500 Description: The inline blending control system is designed to control the proportioning of gas oil into a stream of Marine fuel oil, not to exceed 380 centistokes in viscosity at a reference temperature of 50°C to the product. The OP1500 operator interface will permit the operator to enter / view the following parameters:
Operational details: During the blending process, the pulse output from the master flowmeter is read, then corrected by the temperature compensator (programmed in the PLC logic) which uses the RTD input as a reference. This results in a modified pulse value which represents the product volumes at base temperatures. The modified pulses are scaled down by a ratio controller (programmed in the PLC logic), then compared with the flow pulses from slave line. Any deviation between the two produces a 4-20mA signal which corrects the slave flow via the slave control valve, using the built-in PID function in the DL450 instruction set. Submitted by: |
Application: DL450 PLC controls a salad washing machine Products Used: D4-450 CPU, various analog and digital I/O
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