Finally started my PLC aquarium controller build

[Curtie44]

After about a year of late nights on ebay, I have finally gathered up enough components to start my PLC aquarium controller build. Here is what I have so far:

Efector temperature sensor 4-20mA output

Efector level probe for ATO control

I was able to get my hands on a really nice Hoffman box to house all the controls. I had to gut it and redo the layout of the terminal blocks and wireway to suit my needs.

as it was when I got it

Gutted and changed to fit my layout

I'm going to use the digital outputs on the PLC to individually control several outlets. I built this outlet bank out of a Radio Shack project box

One of the thijngs I still need to buy is this peristaltic pump from Omega. I'm going to need 4 or 5 of them in the end. I'll start with one to test it out on the vodka dosing. They make several different ones with different flow rates for $78. http://www.omega.com/ppt/pptsc.asp?ref=FPU100&ttID=FPU100&Nav=

I was also able to pick up an HMI

I threw together a couple of screens that will be displayed on the HMI

Main Screen:

This is the trend screen where I can compare pH and Temp over time, still needs some work:

 

[chubby190]

I have a couple PLCs and ton of relays in the garage. I considered putting together a set up so I could control the temperature, lighting, etc., I eventually decided against it because I remembered how much stuff cost.

Looks like you have a good set up. That touch screen is a nice addition too. How are you plumbing the ATO? From RO/DI to the tank, gravity feed, or a pump?

I've had some bad experiences with SCADA, so I'm weary of doing any of that to my tank--the repercussions of a timer bug could kill your tank. I'm sure you know what you're doing, though. I only know enough to be dangerous.

 

[Curtie44]

The ATO plans are still subject to change but my initial idea was to utilize the 5 gallon Kent doser that I have now. My current manual routine is to top off the Kent doser with RO water that is stored in a 44G brute trash can. I usually have to do this every 2 days. I was thinking I could use the Efector level probe in the Kent doser to control a pump in the 44G Brute. I would have to have a second probe for the Brute so I didn't try to pump water if the Brute was empty.


Basement sump room:

 

[Vancouver Reefr]

Ahhhh i remember my PLC days!!!!! Looking good so far!!! Ive gone to the micro controller route for a bit of a new challenge and im loving it! If your having half as much fun as i am then you in for one hell of a build!!!

VR

 

[Curtie44]

Ahhhh i remember my PLC days!!!!! Looking good so far!!! Ive gone to the micro controller route for a bit of a new challenge and im loving it! If your having half as much fun as i am then you in for one hell of a build!!!

VR

For sure! I'm having a great time designing and laying everything out. I have a ton of wiring in the electrical panel still to do. I only have the analog card done so far. Still have one digital in/out and relay card to do plus the power supply. I need to get a roll of 16AWG blue for all the control wiring before I can continue though.

 

[chubby190]

I'd run a timer for the top-off. In my experience with top off and dosing it's essential. If you program the pump to start when the level falls below x and to stop when it goes above x you're in trouble. There's a lag between the water (or dosing levels) being added and that addition registering. The chemical dosing pumps I've installed usually had an adjustable on time, off time, and then a limit for each action.

One contractor installed a water top-off on a pool system in a facility I managed. His program opened the water valve until the sensor was satisfied with the water level. The problem with this set-up was that the pool could have a 4" higher water level before the sensor was satisfied, there was much flooding in that original plan. I remedied the problem by incorporating a mandatory off period for every on cycle.

 

[Curtie44]

I don't think a timer would work well for my set up. The Efector level probe I have is programmable. It has 4 outputs relative to liquid level (one being an overflow output). Spec sheet says response time is typ. 450 ms, 750 ms max. No worries about lag with those numbers.

 

[chubby190]

I'm not worried about sensor lag, I mean lag between the water being added, and the time it takes to actually arrive at the sensor. If the water is added near the return, then the tank, than finally arrives at the sensor there could be a problem. The whole time the water is flowing and rising in the system there is more water being added behind it. I just meant a timer in the ladder rung that controls that circuit. When your normal low is reached it activates the timer (say 10 seconds) and waits for a default 30 seconds after that to restart the pump. That way the pump isn't on adding water the whole time... Especially with dosing.

I don't mean to lecture a pro, I'm sure you have more experience than me. I'm just offering my experience. With dosing there's a huge lag between what's being added and what the sensors are reading. You also have to account for diffusion in the system before your system decides to add more chemical.

I don't know what kind of experience you have, but I'd look through a CAT controller instruction manual if you haven't designed a dosing system before. They are the off-the-shelf pool and spa controllers.

 

[AcroSteve]

Sweet.

I always sort of dreamed about using a PLC, but did not want to invest that much cash.

Which PLC is that, and tell us how good of a deal you got

Watching with interest.

 

[Curtie44]

I'm not worried about sensor lag, I mean lag between the water being added, and the time it takes to actually arrive at the sensor. If the water is added near the return, then the tank, than finally arrives at the sensor there could be a problem. The whole time the water is flowing and rising in the system there is more water being added behind it. I just meant a timer in the ladder rung that controls that circuit. When your normal low is reached it activates the timer (say 10 seconds) and waits for a default 30 seconds after that to restart the pump. That way the pump isn't on adding water the whole time... Especially with dosing.

I don't mean to lecture a pro, I'm sure you have more experience than me. I'm just offering my experience. With dosing there's a huge lag between what's being added and what the sensors are reading. You also have to account for diffusion in the system before your system decides to add more chemical.

I don't know what kind of experience you have, but I'd look through a CAT controller instruction manual if you haven't designed a dosing system before. They are the off-the-shelf pool and spa controllers.

I see what you are saying but that won't be an issue for my setup. I will have the level probe in the 5 Gallon Kent aqua dose conainer. When the level of the container drops below my setpoint I turn on the pump in the 44 gallon brute trash can to refill the Kent aqua doser. There will be no lag of any kind in a vessel that small, the water will arrive instantly at the sensor. This is strictly for keeping the Kent aqua doser full of RODI water (so I don't have to drag my lazy butt down there every other day to fill it up!). I have the drip rate of the aqua doser set to match the evaporation rate of my system.

Pro? hahaha, that's funny.

 

[Curtie44]

Sweet.

I always sort of dreamed about using a PLC, but did not want to invest that much cash.

Which PLC is that, and tell us how good of a deal you got

Watching with interest.

I'm using a ControlLogix 5555 processor in a 7 sot chassis with 1 ethernet card, 1 analog input card, 1 digital input card, 1 digital output card, and 1 relay output card.

Deal...not really. While I certainly didn't pay list price for any of this stuff it still wasn't cheap. That's why it has taken me so long to finally get all these pieces together. Many, many (over a year) months of frustrating bidding and mostly losing on ebay. Craigslist was a source for some items too. One piece/card at a time. The enclosure and VersaView came off of a piece of decomissioned equipment that was being scrapped. Right place at the right time!

I did get those efector level probes for a steal off ebay though....$27 shipped for 2 of them!! Those babies list for $419 new!!

 

[tahiriqbal]

Tagging along, would like to see the final project finshed with total cost involved!! Like the touch screen concept, how does blue tooth concept sound to you since you can't really place large screen close to the tank and neither close to your hoffman hub?

I hope this project would develop in to something great to meet and suit your needs.

Good luck..

 

[kcress]

I'm surprised that PLC stuff cost you a lot on ePay.

I have some SquareD stuff, analog and digital modules, I over ordered for a job. I decided to ePay them since they cost a small fortune. I check on ePay and see them all listed in multiple sales at about 1/10th what they cost me from SquareD. Depressed I just hung onto them.

Maybe I should find a processor and just use them for my new tank build... Hmmm, You have me interested.

 

[Curtie44]

I got the I/O and power all wired up last night and mounted the sub panel in the box. I would guess the electrical is about 60% complete. I still need to wire up all the relays (still waiting on some of them to arrive), rewire my return pump and run it into the panel, drill and tap my calcium reactor lid to accept a pH probe, plus a ton of other stuff. The cable for my tank pH probe came up about 3 ft. short of reaching the xmitter. The guys at American Marine quickly answered my questions about an extension cable and after a speedy trip to Radio Shack I'm back in business.

pH xmitters:

Raw data coming from the pH and temperature probe:

 

[fd678]

what kind of ph modules are you using? I assume they are 4-20ma output

 

[Curtie44]

what kind of ph modules are you using? I assume they are 4-20ma output

Yes, 4-20mA. From Omega.

 

[stugray]

Curtie44,

Very nice build! Exactly what I would do if I could get this stuff cheap.

With your talk of having to fill your ATO, I thought you'd appreciate this thread:

http://www.reefcentral.com/forums/showthread.php?t=1091726

And for kcress & his SquareD stuff:

Now stick this to the left of the PLC and you have a recent pic:

That timer just gives the Micro-1 a Day/night signal since it doesnt have a RTC.

Stu

 

[fd678]

do you know of any ph controllers that have a 0-5v output?

 

[Curtie44]

Curtie44,

Very nice build! Exactly what I would do if I could get this stuff cheap.

With your talk of having to fill your ATO, I thought you'd appreciate this thread:

http://www.reefcentral.com/forums/showthread.php?t=1091726

And for kcress & his SquareD stuff:

Now stick this to the left of the PLC and you have a recent pic:

That timer just gives the Micro-1 a Day/night signal since it doesnt have a RTC.

Stu

How did I miss this thread??? I may have to rethink how I do my ATO now. Very nice setup Stugray. I'm going to have to go back and take a second look at those liquid level sensors you used. I like the way you made a "sensor tree" as you put it. Since it is attached to the lid you can still move your trash can around by popping it off. Difinitely going to be asking some more questions later.....

 

[Curtie44]

do you know of any ph controllers that have a 0-5v output?

http://www.apcs.net.au/products/premier/ds129413.pdf

http://www.apcs.net.au/products/premier/pht129.html

Looks like these are going to be pretty tough to get here in the states...