PLC/HMI Touchscreen Cont

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PLC-Guy

Well-Known Member
Joined
Dec 12, 2010
Messages
65
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14
Location
Atlanta
Started This Post In Home Brewing Photo Forum
Title Is: PLC/HMI Touchscreen Fermenter Project
The Project Has Developed From That To It Really Belongs Here In The
Automated Brewing Forum.

The Current Status Is Building Up The PLC Electrical Panel Backplane,
Most Wiring Is Completed & Some 120Vac & 24VDC Tested, Will Be
Working Next On The Electrical Schematic/Prints & Wiring Labels.
All Componets Are Isolated w/ Opto-Couplers & Circuit Breakers.

100_1904a.jpg
 
Nice looking build so far, looks like you are one of the few competent panel builders that I have seen. It looks you have a couple solenoid air valves, what are they planned for, air actuated valves like Claudius has on his rig?.
This is the easy part, hardware build, the hard part is the HMI programming with automatic sequencing and control. At least you have HMI software support which makes the task easier than coding your own from scratch which can take a significant amount of time.
 
Purchased 1 For Project For 5500W 23Amp Heater Control
Sold By Amazon.com
ASIN B008DFWTA8
or
Search, ALL DEPARTMENTS,
amico solid state relays

3PH SSR 100Amp Aprox $49.23

100_1903a.jpg
 
Nice looking build so far, looks like you are one of the few competent panel builders that I have seen. It looks you have a couple solenoid air valves, what are they planned for, air actuated valves like Claudius has on his rig?.
This is the easy part, hardware build, the hard part is the HMI programming with automatic sequencing and control. At least you have HMI software support which makes the task easier than coding your own from scratch which can take a significant amount of time.

The SV's Are For Inlet, Drain and C.I.P.
Thank's. I Like Laying a Panel Out Like This, Later On It Takes The
Troubleshooting Pain Away.
I Could Not Imagine The Time Coding From Scratch, Even w/HMI & PLC
Software Takes Alot Of Time From Scratch.
 
A suggestion, lose the automotive ring lugs on the higher current connections and use heavier gauge copper compression lug by T&B or the screw tightened Blackburn models. This is the single greatest cause of SSR problems out there, yes they will connect the wire, but they have to be crimped perfectly and make a perfect connection, which is not likely with most installations. The heavier lugs will carry more current without heating up and causing the SSR to go into thermal lockup, and can be insulated with heat shrink tube. A cheap thermal tattle tail is melt a drop of crayon on the screw head, if it melts and runs during operation you have a thermal problem.
The HMI application for the brew system was built to merge the recipe and control functions into one package, a process that lasted over a year in coding and testing. The brewing system is much more complicated than any other home brewing system, and takes more control and logic to operate safely unattended.
 
Excellent Suggestions, Don't Like Crimping, All Lugs Are Soldered Here and
All Stripped Wire Ends Are Soldered As Well
Will Locate & Install, Thank's Kladue
 
This is the easy part, hardware build, the hard part is the HMI programming with automatic sequencing and control.
It is a pain in the butt and I only programmed the application part.
The program I purchased from Automation Direct to work with there touch panel.
I have always been impressed with your talent.
Cheers,
ClaudiusB
 
Doubled Checked Wiring w/Updating Elec Prints, Have Installed Temp
Labels So Far, Elec Prints Look Good So Next Week Will Do Final Wire
Labels To Cross Reference w/ Elec Prints Line#.
 
You Will See The Print Line#'s On The Left, Wire Labels Will Reference
That ie; 98, 98A, 98B, ect

Draft.jpg
 
From the calibration equipment shown in the photo forum it looks like you are planning on using RTD's with the Rosemount's. You have Rosemount elements?, or are you planning on using the ones sold by Auber.
The 275 communicator and decade box remind me of past calibration work, but we have kept upgrading communicators, software, and calibrators to stay current and meet customers needs in power, petroleum, and high tech.
 
Mixed Bunch, Tri-Clover, Moore, Think 1 Is a Rosemount
Cannot Justify a 375 Communicator For Home Use, Not Going To
Keep a Database, The 268 & 275 Harts Work Fine & Not Bad Priced
On Ebay. The Older Stuff Works Great For Our Appllications & Wallet,
It's Amazing How Older Industrial Technology/Equipement Continues
To Develop Into a Work Of Working Art, Alittle Money & Alot Of Time,
Imagination Can Produce Alot Of Fun & Education.
I Just Like Doing This Type Of Electrical Developement.

Soon I Will Post a Downloadable Semi-Blank Copy Of The Electrical
Schematic That Can Be Edited Under MS-Paint. Poor Mans CAD,
Will Include Various Symbols, Power Supplies, SSR's, ect That If Others Are Interested Will Be Available.
Like Being Able To Locate Wire# to Print & Visa Versa For Quick
Troubleshooting, No Enjoyment From Spaghetti Junction Wiring and
No Prints.

Maybe If Electrical Prints/Symbols Gains Intrest in a jpg Format and
Others As Well (Not Everyone Uses The Same Drawing Creator)
Will email Suggestion Here For For a Up/Downloadable Database Area
Here For Members To Contribute & Use To Assist Other's In Creating
There Own Project Electrical Prints. ie; Choose Your Format, Get
Your Blank Print, Grab Your Componet Symbol(s), Start Creating
On Your PC.
 
My Poor Mans CAD, Microsoft Paint .jpg Format, Cut & Paste
Included Power Supply, SSR's, Circuit Breakers, ect

I Realize Other's Here Might Use Something Else For Drawing Editor(s),
If So, Maybe We Can Ask homebrewtalk To Setup @ Forum Area For
Just This Purpose, Supporting Various Formats For User's To
Upload & Download There Blank Formats w/Symbols They Already Created
If The Intrest Grows.
Hope This Helps Some Of You.

Electrical Sheet-1
http://i41.tinypic.com/1z387s3.jpg


Electrical Sheet-2
http://i39.tinypic.com/2ll1qtg.jpg
 
Almost Ready For Enclosure Cabinet Mounting,
Starting To Clean Up The Wiring Mess,
Also, Upgraded 3PH SSR 100Amp Wiring Lugs/Soldered.

100_1907a.jpg


100_1908a.jpg
 
Is that a MicroLogix 1200? That is what I have. Would love to see you logix program when you get it written. What brand of HMI are you going to use?
 
Yes a MicroLogix-1200 WAR (Dual Comm Ports) w/1762-IF4 4-Channel
Analog Input Card, Processor Has Memory Chip Installed.
The HMI Is a CTC PARKER PS10-2T2-DD3-AD3
Donated From Local Tech College, They Were Running Out Of
Donated Equipement Space & Wanted To Focus On Only Allen Bradley.
The PS10 w/ML-1200 Creates a Great Communication Combination,
The ML1200 Does Not Support BTR/BTW and Is Not Required For PS10 Usage. Once The PLC Is On, Turn On HMI (PLC O:0/0 CR1) The HMI PS10 Will Look For PLC Image Files On Defined Node That Was Setup In HMI Config Menu(s).
Using a RS232 3-Wire Comm Network (Max 50ft) Also Supports
RS/DH485 & 422 (Max 4000ft), If You Go This Route Would Install
Some PC 12Vdc Muffins Fans Inside HMI For Internal Power Supply
& CPU, There Are Already Connections For Pwr, Hard Drives/Floppies.
After Spending Time Figuring The PS10 Out, I Actually Like Them
Better Than The Allen Bradley Panelviews.
For The Program, Have To Finish Panel Backplane, Almost There,
Then Solder/Cable Out Communications, 50% Of PLC Logic Done,
Next Step Is Alot Of TIG Sanitary Welding, Then Bring Complete
System Online & Starting w/C.I.P. Process Finish Step by Step
PLC Logic & Proceed To Fermenting, ect. Going To Be Some Time.
 
Have To Shorten/Solder Comm Cables Next & Install HMI In Top Enclosure,
Top Enclosure Will Not Be Mounted There, Just Sitting Out Of Way.

100_2006a.jpg
 
Wow that's awesome. Looks like my dads electrical workbench. Ham radio and everything.

Dilbert "The Knack" Engineer Video [ame]www.youtube.com/watch?v=60P1xG32Feo[/ame]
One of my favorite short videos.
 
Beautiful. I hope my wiring can match yours! Looks like a lot of $$$ and even more time went into this! Would love to see more of your HMI screens.
 
Couple More

Looking great!

It takes a lot of work to come up with great looking and functional screens.

I use a touch screen only for my remote control room, the brewery is equipped
with two standard 4 line x 20 characters displays.
Those displays do the same thing, run the brewery without graphs.
The touch screen I use is the C-more from Automation Direct.

Menu 06-2013.jpg


Mash Schedules.jpg


FermentHelles-Okto2_Tanks.jpg
 
Claudius,
Really, Really Like Your Pic's, You Really Got It Going On There!
Your a Claudis Marine, Lean Mean Beer Making Machine.
I See Years Worth Of Investments and Dedication, Nothing Less Than
Outstanding Artworkmanship There, Thank's For Sharing It!
 
Excellent work PLC-Guy and ClaudiusB!

My touchscreen only has 320x240 Monochrome capability, but hopefully I can create something as functional as you have!
 
Excellent work PLC-Guy and ClaudiusB!
Thanks

My touchscreen only has 320x240 Monochrome capability, but hopefully I can create something as functional as you have!

You will make great functional displays.
Before the arrival of 6" C-More micro I used the 3" with colored backgrounds for a non brewing project, worked great. Too bad the C-More micro display was not around in 1995, had to use the Optimate series displays.

Cheers,
ClaudiusB

Ready.jpg


Er-Pushed.jpg
 
Been Awhile, Lastest Challenge Was PLC Logic For CIP,
Operator Inputs Values, Rinse Time & CIP Process Time, Total Is
Displayed In The (CIP) Process Time Count-Down Window.

Operator Selects CIP-Mode, Starts Process, Tank-1 Opens Drain SV
And Opens CIP SV, Rinsing Tank-1 Out, After Rinse/Drain Sequence
Has Completed, Drain SV Closes. At This Time Process Count-Down Stops, Waiting For Tank-1 Filling To Operator Inputed Value Level, When Filling Sequence Is Above TK-1 Heating Elements, Tank Heating Starts, (Built In Safety), Tank Has Now Filled, TK-1 Fill Sequence Completed. TK-1 CIP SV Closes.
TK-1 Temp Still Rising Until Reaching Set-Point (Operator Inputed Value),
When Temp PVA (Process Variable-Adjusted) Equals Set-Point,
CIP Process Remaining Time Starts Counting Down.
If The CIP PVA Temp Falls Below Set-Point During Any Of The CIP Process
Remaining Time, PLC Logic Will Restart The Time Over Again Minus Rinse
Time, Will Only Repeat Once, If Repeated, Process Stops, Alerts Operator,
The PLC Logic Assumes There Is a Field Device Failure.
Once Maintenance Has Detected/Corrected Failure(s), CIP Can Be
Attemped/Started Again From The Beginning.

This Logic Should Provide Protection To Ensure a Proper Sterilization
Has Been Performed On This Equipement Without Attempted Operator(s) Manipulation.

It Took Sometime To Reach This Point, So Far All HMI Screens Using
Operator Inputed Values Interact Properly w/PLC Logic When Bench
Testing/Simulating. Also Been Working On Tank-1 NAT/LP-Gas Burner
Construction/Installation. Another Challenge To Support Tank Bottom
Center Drain.

CIP_Mode.jpg


100_2089a.jpg


100_2090a.jpg
 
Good Work Takes Alot Of Your Good Time,
Still Frabricating S/S Special Fittings, ect, Vessel Bottom Cap Installed,
Finally. Purged w/Argon For The Sanitary Welding. Have Some Work
Ahead Frabricating Removable Top Cap w/Seal, ect.
Next Step I Think Should Be Installing The Vessels Legs, Aprox 1.5" S/S
Tubing So I Can Work On The Nat/LP Gas Burner Final Dimension(s).
Hope You All Like The Progress.

100_2164a.JPG


100_2165.jpg


100_2166a.JPG


100_2159a.JPG
 
Looking great!

It takes a lot of work to come up with great looking and functional screens.

I use a touch screen only for my remote control room, the brewery is equipped
with two standard 4 line x 20 characters displays.
Those displays do the same thing, run the brewery without graphs.
The touch screen I use is the C-more from Automation Direct.

You know Automation Direct has took a beating for years about their products but I have always enjoyed working with the C-More line. ( Over 25 installed). If you havent yet check out the C-More Micro HMIs. The a great for breaking into the automation field and have comms for just about any PLC

Sent from a red Solo cup with string connected......
 
Good Work Takes Alot Of Your Good Time,
Great to have you back.
I thought you went to beer heaven:D
It took me over a year to finish my automated Corny keg washer and have almost two years working on the grain processing system.

Hope You All Like The Progress.
Great looking!

Cheers,
ClaudiusB
 
You know Automation Direct has took a beating for years about their products but I have always enjoyed working with the C-More line. ( Over 25 installed). If you havent yet check out the C-More Micro HMIs. The a great for breaking into the automation field and have comms for just about any PLC

Sent from a red Solo cup with string connected......
Most of the PLCs I use for my toy brewery are Automation Direct DL05 and DL06.

Currently I use the C-more and four OP 640 Automation Direct displays.

Cheers,
ClaudiusB
 
I Will Check Them Out, I Believe I Have Ordered Special
Custom PLC/HMI Communication Cables From These Folks.
Thanks
 
Probably Would Have Enjoyed a Zap or Two, But It's All
Been Hard Work & Clean Living So Far. Got To Call The Scrape
Recycler Soon For The 1.5" S/S Legs (Tubing). You Know The
Deal, Working On a Budget Sucks.
Good To Hear From You Claudius, Thank's For The Poke!
Finished Up The Inline 5 Micron Water Filter, Tri-Clamped It All,
Also Finished Up The Heater Element Assy, Twist Locks, Ect,
Found a S/S Pecker Head, Tig'd To The Hoffman Box, Gave
Alot More Room For Big Wires, Hopefully This Weekend Will
Upload The Pic Of That. Have To Frabricate a S/S Heat Shield
For The Gas Valve, Like The Heater Element Box Yet.
The Work Goes On, Like Making It Up As We Going Along.

Found a Great Solution For My 50Amp Service Feed Cable,
Amazon, RV's Power Cords, $102.00 For 30Ft w/Molded Male &
Female Ends, Could Not Make Up Cable Set That Cheap.
Will Use a Stove 50Amp Pigtail, Male Out Of Panel, Lowes.
Till The Next Time Bro!
 
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