PLC Logic Auto-Filling Tank - Free PLC Programming

PLC Logic Auto-Filling Tank - Free PLC Programming Almost in all of the industries Tanks are there for storing up the liquid,chemicals or there are overhead water tank for the water supply in plant.Generally for overhead tank a pump is there for filling of the tank or in other cases also there is a motor/pump for filling purpose of tank. So if the filling of tank is a manual process then a operator has to be employed for the ON and OFF process of the PUMP.

PLC Logic for Auto-Filling of Tank - Free PLC Programming

So, as told above if the process of filling is manual then we have to assign this task to a operator to ON the pump when the Tank empties and OFF the pump when the Tank fills. But in today's scenario all the process are automatic. So today we will discuss the automatic filling of tank and automatic ON-OFF of pump according to tank level. We will build a PLC Logic for this complete application. To write the PLC Program for this process we should understand the logic first.

The PLC Logic will be like following

To monitor the level in tank we can either use a Ultrasonic/Capacitive level sensor which will give analog input to PLC OR we can just put two sensor one at HIGH level and another at LOW level and they will give the signal to PLC for HIGH and LOW level respectively.

When the level will be LOW in tank then the PUMP will start and the filling of tank will start and when the level reaches the HIGH level the PLC will receive the HIGH level signal and the PUMP will stop, so the filling of tank will stop. When again tank empties the PUMP will start on its own and the process continues.

Generally the On and OFF of pump at two levels is a task that requires little intelligence. Suppose the height of tank is 5000cm then the low level should be around 2000cm and high level at 4600 cm. It is done because if for example the low level is set at 300cm hen the PUMP will start at 300 cm and suppose if at the same time the consumption rate increases than the supply of PUMP then the tank will empty. So keep in mind this thing while setting the LOW and HIGH level in Tank.

Well there is no need to install a separate PLC for this small application, as almost all the major industries have the PLC installed so the logic can be built in that existing PLC and thus there will be savings.

PLC Logic Development

Here we will take example of Omron PLC and build the PLC logic using CX-Programmer.

0.0-------------------------------------------------------------- Low level Signal
0.1-------------------------------------------------------------- High Level Signal

100.0 ------------------------------------------------------------ PUMP ON

Here we have build the PLC Programming using the digital Inputs, but the same can using the Ultrasonic/Capacitive Level sensor and taking the Analog input to PLC. You can download the PLC program from Below.

Download PLC Programming logic of Auto Filling Tank.

We have attached both .pdf and .cxp files so that who don't have CX-Programmer software can still view the logic and understand the PLC Logic.

We will also build the PLC logic using the Analog input to PLC, so keep visiting and you can subscribe to Automation Talk for such more PLC Programming examples, SCADA tutorials, VFD applications and HMI Programming.

If you have any doubts regarding this PLC Program then you can write in the comment section below and we will get back to you ASAP. Don't forget to Subscribe to Automation-Talk by Email.

Delta PLC Programming Cable Connection Detail

Delta PLC have a 8 pin minidin female port on the CPU. For the programming of the delta PLC we need a cable which should have one 9 pin D type female port and at the other end 8 pin mini din male port. We will see the programming cable wiring detail of this cable in this post.

Delta PLC Programming Cable - 9 pin D Type Female to 8 pin mini din male

See below diagram for the connection detail.

Delta PLC Programming Cable Connection Detail

Also you can see other programming cables for other PLC also. Keep reading here to get all information related to plc programming and cable details. Subscribe to Automation-Talk by Email.

Using PLC Clock Time in Omron PLC Programming

Almost every plc have the clock function that is we can get the time value in the plc data words. We can synchronize the plc time with the system time at the time of program downloading. PLC stores the value of time , day , Month and year in its internal data words. We already have discussed about the plc internal words.

Reading the Year/Month/Day/Time Value in PLC :-

Many a times while developing the plc logic sometimes it is required to use the time in program to perform a particular function. Also there must be situation when we need to operate a particular device on a Specific date and time. So all these things are possible in PLC , all we need is to find out the plc system words where these values are stored.

Here we will see the example of Omron PLC. One thing we should keep in mind is that the plc must have battery installed so that real time monitoring of Date and Time is possible. In omron PLC there are 4 system words for storing the value of Year,Month,Date,hour,minute and second.

A351 to A354 are the system words in Omron PLC which stores these values. See below for the complete detail.

A351.00 to A351.07 Seconds: 00 to 59
A351.08 to A351.15 Minutes: 00 to 59
A352.00 to A352.07 Hour: 00 to 23
A352.08 to A352.15 Day of the month
A353.00 to A353.07 Month: 01 to 12
A353.08 to A353.15 Year: 00 to 99
A354.00 to A354.07 Day of the week

00: Sunday, 01: Monday, 02: Tuesday, 03: Wednesday 04: Thursday, 05: Friday, 06: Saturday

So by seeing the above values in these system words we can get the exact Date and Time. We can compare the values in these words with our pre-defined DM words and make the plc logic accordingly. Also when we download the program in plc then for the first time we have to synchronize the plc clock with our system clock. See below picture.

Now for example take a situation that we need to operate a particular output to be on 8 pm 20 Dec 2012 and be on afterward. So for this we will use compare instruction and compare the A351 with #0 and A352 with #2020 and A353 with #1212 and when these conditions gets satisfies the output will be on. If you see properly then these condition will be satisfied exactly on 8 pm 20 Dec 2012.

We hope that this plc tutorial will help you to use the plc clock time in developing plc logic . If you still face any problem you can write us in comment section. Also you can subscribe to get all latest updates in plc programming.Subscribe to Automation-Talk by Email.

Keyence KV Studio Software

Keyence is a global name in factory automation, providing advanced sensing & measuring solutions. Including sensors, machine vision systems, bar code readers, measuring instruments & PLCs. It's a Japan based company having global reach. Keyence provide good range of automation controllers, which can be easily programmed using their PLC software called KV Studio. Subscribe to Automation-Talk by Email.

Keyence KV Studio

KV Studio is a PLC software which can be easily programmed and you can download its DEMO version if you want to try it. The latest version of this software is 7. "KV STUDIO" is software for creating ladder programs that combines ease of use and powerful programming processing capabilities.

Features Keyence KV Studio

1. New Unit Editor:

This function is provided for building a system for the KV-5500/5000/3000/1000/700 Series and KV Nano Series. It is used to configure the settings of and assign relays and DM entries on the units of the KV-5500/5000/3000/1000/700
Series and KV Nano Series. You can print unit structure diagrams and lists of settings.

2. Simulator function:

Simulation function is very important for offline testing of PLC program and KV Studio PLC Software also supports it. You can simulate the operation of the ladder program you have created without connecting any KV Series units. This enables you to debug the program you have created and you can also easily perform troubleshooting by conducting continuous scan execution, single scan execution, and single step execution. Reversed step execution is also possible.

2. Monitor function:

You can use the ladder program that you have created to perform online monitoring of the ON/OFF status of contacts in real time. You can display time charts. You can perform online editing.

3. Directly programmable algorithms.

Programming time is significantly reduced by the direct programming algorithm.

Keyence KV Studio features

KV STUDIO Ver. 7 supports the KV series CPU units. Because KV STUDIO Ver. 7 has a function that automatically converts previously created ladder programs when they are read, you can smoothly migrate to the new programming environment.

This software supports PLC's like KV-5500, KV-5000, KV-3000, KV-1000, KV-700/700+M, KV Nano Series*, KV-P16, KV-10/16/24/40.

You can install this software on Windows XP, Windows 2000, Windows Vista, or Windows 7 and equipped with an RS-232C or USB interface.

KV STUDIO Ver. 7 can read the ladder programs for the KZ-300/350 and KZ-A500. When KV STUDIO Ver. 7 reads a ladder program file for the KZ-300/350 (*.ldc) or KZ-A500 (*.ldx), the file is converted into the KV STUDIO file format (*.kpr).

Downloading Keyence KV Studio Software

You can easily download trial version of this software from their official website. You will just have to sign-up and then you can download this software.

Download Keyence KV Studio Software

Note: Do download its user manual before using this software and you can easily learn how to use this software.

Omron HMI Communication With Keyence FA-M3 Series PLC

NV Range of HMI by Omron is capable of communicating with a wide range of PLC. As we already discussed the NV HMI Communication Cable for Panasonic PLC ,Omron HMI Cable Diagram for Allen Bradley PLC , Omron NV HMI Connection with Siemens PLC. Today we will see the step by step procedure for NV HMI Communication with Keyence FA-M3 Series PLC.

RS 232 Communication Between Keyence PLC and Omron NV HMI :-

There are to methods for making a physical connection between HMI & PLC. Either we can connect through Personal Computer Link Module OR Direct Connection to CPU Module. We will see the communication cable diagram for both the types of connections.

||Connecting through a Personal Computer Link Module||

For making this type of connection you need to have the Link Module F3LC11-1N or F3LC11-1F or F3LC12-1F. Make the cable with the following connection diagram.

PLC Side ----------------------------------------------------------------------HMI
Pin 2(RD) -----------------------------------------------------------------Terminal 4(SD)
Pin 3(SD) -----------------------------------------------------------------Terminal 5(RD)
Pin 5(SG) -----------------------------------------------------------------Terminal 8(SG)

Note:- Also short the Pin 4 and 6 , Pin 7 and 8 at the PLC Side.

||Direct Connection to CPU Module||

For this type of communication scheme you will need the KM11-2T Programming Tool Cable. Make the connections as shown below.

PLC Side ----------------------------------------------------------------------HMI
Pin 2(RD) -----------------------------------------------------------------Terminal 5(SD)
Pin 3(SD) -----------------------------------------------------------------Terminal 4(RD)
Pin 5(SG) -----------------------------------------------------------------Terminal 8(SG)

Note:- Also short the Pin 4 and 6 , Pin 7 and 8 at the PLC Side.

Now after making the hardware connection as per your suitability , we have to make some settings both at PLC and HMI side.

|| Settings in NV Designer for Keyence Plc||

NV Designer is the HMI software used to make the screens in NV HMI. Open the NV designer software , Create a New Project and select the proper NV HMI Model which you are using and after that in PLC Type select "Yokogawa FM-M3 Series" and then click Next and select System Memory Area accordingly.

Now we have to define Communication Parameters Both at HMI and PLC side. To set the Communication Parameters in the NV Designer go to PT----NV Configuration and under Communication Parameter Tab select baud Rate as 19200Kbps , Data Bit as 8 , Stop Bit 1 and Parity as None and check sum Enabled.

Also make the following settings in Keyence FA-M3 series PLC:-

Station number--------->> 1
Baud rate--------->> 19,200 bps
Data bits--------->> 8
Stop bits--------->> 1
Parity--------->> None
Checksum--------->> None
End character specification--------->>Enabled
Protection--------->> None

After doing the step by step procedure as told above , you can communicate the NV HMI with keyence PLC easily . Make a sample screen in NV HMI , and test the communication. If you still face any problem then you can write us in comment section. Also you can subscribe to get all latest updates regarding PLC & HMI by subscribing to Automation-Talk by Email.

PLC Programming for Dancing Light - PLC Programming

Many users mailed us for making the PLC program for the dancing light, so here we will see the PLC Logic for making a fancy light decoration system. This PLC program can be used for lighting systems in house or for any festive celebration time. We will see here in detail the logic of PLC programming and the steps involved in making the PLC Program.

PLC Programming for Dancing Light - PLC Programming

Here in this PLC Program we are considering six numbers of LED, 1 start push button, 1 stop push button and 1 selector switch. We will write the PLC program for 2 different mode i.e the LED's will glow in two different pattern.

Recommended Article: Free PLC Software's for Ladder Logic Programming

Mode 1 Pattern of LED Glowing:- While writing this PLC logic we have made the PLC program in such a way that when we will push the Start button then LED 1 will glow, after 1 second LED 2 will glow and again after 1 second LED 3 will glow and so ON and after 6th LED the cycle will start again. The number of LED's can be more as per the need and application.

See the Below table for better understanding.

Time -----------LED1 ------------LED2---------LED3---------LED4--------LED5------------LED6
T=0sec ---------OFF--------------OFF----------OFF----------OFF----------OFF-------------OFF
T=1sec ---------ON --------------OFF----------OFF----------OFF---------OFF-------------OFF
T=2sec ---------ON --------------ON-----------OFF-----------OFF---------OFF-------------OFF
T=3sec ---------ON --------------ON-----------ON------------OFF---------OFF-------------OFF
T=4sec ---------ON --------------ON-----------ON------------ON----------OFF-------------OFF
T=5sec ---------ON --------------ON-----------ON------------ON----------ON--------------OFF
T=5sec ---------ON --------------ON-----------ON------------ON----------ON--------------ON

and then again the cycle resets after every 6 seconds.

Mode 2 Pattern of LED Glowing :-

In the second mode , which will be on when we will select it by selector switch the LED 1 and LED6 will glow first for 1 second then LED 2 and LED 5 will glow and then LED 3 and LED 4 .

See below table for a clear understanding.

Time -----------LED1 ------------LED2---------LED3---------LED4--------LED5------------LED6
T=0sec ---------OFF--------------OFF----------OFF----------OFF----------OFF-------------OFF
T=1sec ---------ON --------------OFF----------OFF----------OFF----------OFF--------------ON
T=2sec ---------ON --------------ON-----------OFF----------OFF----------ON---------------ON
T=3sec ---------ON --------------ON-----------ON------------ON----------ON---------------ON

And then after 3 seconds the cycle resets.

PLC Logic Development for Dancing Light


0.0 --- Start Push Button -- (NO)
0.1 --- Stop Push Button --- (NC)
0.2 --- Selector Switch --- (1 pole)


100.0 ------------- LED 1
100.1 ------------- LED 2
100.2 ------------- LED 3
100.3 ------------- LED 4
100.4 ------------- LED 5
100.5 ------------- LED 6

We have considered only 6 LED here only, however the PLC Programming can be extended for any numbers of LED you want and also the glowing pattern can be changed as you like. If you have some any other pattern in mind and want to make PLC Logic according to that then tell us , we will make for you.

You can download the PLC Program below. We have attached both .pdf and cx-programmer file.

Download PLC Program for Dancing Light.

If you have any queries in ,PLC Programming then write in comment section or want any PLC program related to Dancing Light then tell us we will make it for you.

Also you can subscribe to Automation Talk to receive latest updates for PLC Programming, SCADA Tutorials, HMI Programming, MODBUS and AC Motors. Subscribe to Automation-Talk by Email Now .

Get New Updates

Enter your email address:

Delivered by FeedBurner

Receive all updates via Facebook. Just Click the Like Button Below