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Automatic Water Level Control System Using Programmable Logic Controller

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 ISSN: 2714 - 2450
Adeleke University Journal of Engineering and Technology

[AUJET] Vol. 6, No 1, 160 - 166 (2023)

www.aujet.adelekeuniversity.edu.ng

Automatic Water Level Control System Using Programmable Logic Controller

Wasiu Oyediran, ADEDEJI1*, Olakunle, OLUKAYODE2, Seun OYELAMI3, Anthony Olayinka, ADEKOYA4, Kehinde
Adenike, OYEWOLE5, Busayo Sunday, ADEBOYE6 and Gbemileke Abiodun, ABIOYE7.
1Mechanical Engineering Department, Osun State University, Osogbo, Nigeria, wasiu.adedeji@uniosun.edu.ng
2MechanicalEngineering Department, Osun State University, Osogbo, Nigeria, olakunle.kayode@uniosun.edu.ng
3Mechanical Engineering Department, Osun State University, Osogbo, Nigeria, seun.oyelami@uniosun.edu.ng
4Mechatronics Engineering Department, Yaba College of Technology, Lagos, Nigeria, anthony.adekoya@yabatech.edu.ng
5Chemical Engineering Department, Osun State University, Osogbo, Nigeria, Kehinde.fayemiwo@uniosun.edu.ng
6Mechanical Engineering Department, Osun State University, Osogbo, Nigeria, busayo.adeboye@uniosun.edu.ng

7Mechanical Engineering Department, Osun State University, Osogbo, Nigeria, abiodun.abioye@uniosun.edu.ng

*
Corresponding Author: wasiu.adedeji@uniosun.edu.ng

ARTICLE INFO ABSTRACT

Received: April / 2023
Revised: June / 2023
Accepted: June / 2023
Published: June / 2023
Keywords: Automation, PLC,
Float Switch, Ladder Logic,
Water level.
Automation is an essential component of industries as it enhances precision, productivity,
safety, and mitigates potential risks arising from human errors. This paper addresses the
use of MITSUBISHI’S FX1N32MR PLC (Programmable Logic Controllers) and Float
switches to monitor and control the water level in a tank. The PLC receives water level
information as signals from the Upper and lower limit float switches then in turn activates
the appropriate Indicator LEDs and Pump as specified by the ladder logic program running
on the PLC. The goal is to demonstrate a cost effective, affordable and efficient method of
automating water level and consumption in a tank.

1. INTRODUCTION

The management of water resources is a critical issue faced globally today. Water plays a vital role in various sectors, including
agriculture, industry, and domestic usage (Illes et al., 2013). However, the reckless utilization of water has led to considerable wastage
in these sectors. Automation plays a crucial role in minimizing human errors and ensuring continuous monitoring of liquid levels in
tanks. By maintaining an adequate water level, automation systems contribute towards mitigating water wastage and scarcity concerns
effectively (Meher et al., 2019).
A Programmable Logic Controller (PLC) is a computerized device employed for automating mechanical processes (Das et al., 2013).
Its primary function is to transform traditional methods like "Relay Logic" or "Wired Logic" into a specialized programming language
known as "Ladder Logic" to facilitate industrial automation (Bhapkar et al., 2019; Min et al., 2019). Unlike conventional computers,
PLCs are specifically designed to handle multiple input and output configurations, operate within extended temperature ranges,
withstand electrical noise, and remain resilient against vibrations and impacts.
Industrial control systems rely heavily on the PLC, which utilizes digital and analog Input-Output (I/O) modules to establish connections
with various equipment, including sensors and actuators (Imam and Tijani, 2016; Haoqiang 2017). In various industries such as
machining, packaging, material handling, and automated assembly, among others, the PLC has proven to be more cost-effective and
time-efficient compared to alternative control systems (Haque. 2014). The primary goal of this project is to effectively monitor, control,
and analyse the water level within a tank, addressing the water requirements of industrial, commercial, and residential sectors.
In 2013, Cosmina Illes et al. studied water level control system using PLC and Wireless Sensors and outlined a water level control
system. The system utilized a Siemens 24RL PLC and an electric motor-controlled pump. To monitor the water level, wireless sensors
were employed. They concluded that wireless sensor technology together with PLC will pave way for serval automated processes.

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In 2013, Rishabh Das conducted a study on the automation of tank level using PLC and the establishment of HMI through SCADA. The
research involved analysing the level control of a single tank and implementing a control strategy. The study provided valuable insights
into PLC automation for controlling water levels in various tanks. It also shed light on the process of interfacing PLC with HMI using
SCADA and highlighted the necessary input and output components required for connecting with PLC. The system used inductive
proximity sensors to detect level of water due to effect of vibration on existing float switches.
In addition, Ghosh et al. (2008) successfully developed a bottle filling plant utilizing PLC technology (Ghoosh et al., 2008), while Saha
et al. (2012) proposed an efficient PLC-based system for controlling a cement factory (Saha et al., 2012). Cosmina Illes et al., and
Rishabh Das have made considerable efforts in the use of PLCs, wireless sensors, HMI and SCADA to monitor and control the level of
water in the tank. To further reduce the cost required to set up the project, this paper employed cheaper materials without reduction in
quality of operation, thereby beating down the construction cost and still maintaining optimum functionality. Furthermore, the PLC is
programmed in Ladder logic (LD) as opposed to the Function block diagram (FBD) used in aforementioned papers. The ladder logic is
easy to understand and implement compared to FBD. Vibration resistant float switches were employed as an alternative to inductive
proximity sensors used by Rishabh Das et.al

2. METHODOLOGY
2.1 Materials Used

i. FX1N32MR-PLC

This is a 24VDC relay-based programmable logic controller (PLC) made by MITSUBISHI. It is equipped with 16 input and 16 output
digital channels. Each output channel has a maximum load capacity of 2A. Therefore, for heavy loads like pumps that draw more than
2A, a relay card was used to interface them with the PLC's output. The PLC receives input signals from various devices such as float
switches and pushbuttons, processes these signals based on the program running on it, and then sends command signals to the actuators
connected to its output channels. The program is written in ladder logic using GX-Developer software, version 8.
ii. Float switch: The float switch is an electromechanical device utilized for detecting the fluid level in a tank. It operates with two
distinct digital states, namely ON and OFF, corresponding to the upward or downward movement of its mechanical component. When
the water level in the tank reaches the level of the float switch, it causes the switch to rise, resulting in a change of state from ON to OFF
or OFF to ON, depending on the switch configuration (normally open or normally closed). Conversely, when the water level drops
below the switch level, gravity pushes the switch back to its initial position, causing another change of states. By analyzing the signals
generated from these state changes, the PLC can make logical decisions as programmed. The switch has a maximum voltage rating of
220V AC/DC and a brand name TZT.
iii. Pump: The pump is an electromechanical device employed to transfer fluids from a lower position to a higher position. It is important
to note that pumps of different sizes have varying surge currents, which can be nearly twice the operating current. In the context of this
project, a pump with a rating of 24VDC, 3A and 800 L/H flow rate is utilized, with a start-up current of approximately 5A.
iv. Relay Module: The relay module serves as a device for enabling the connection of devices with varying power needs. Typically, a
low-power DC signal is supplied to the input (primary side) of the relay, which then triggers the activation of a high-power DC or AC
signal to operate heavy loads. Additionally, relays can be utilized in situations where a high-power signal is used to drive smaller loads.
The specific relay utilized in this project is rated at 24VDC for the coils (input) and has output ratings of 240VAC or 30VDC, 10A.
Plate 1 below shows various materials used for this project.

(a) (b) (c) (d )

Plate 1: (a)FX1N32MR PLC (b)float Switch (c)DC Pump (d) Relay Module

Table 1 below shows the materials used, symbol used in the ladder program, PLC address assigned and the voltage ratings of the
components.

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Table 1:Ladder Logic Symbols, Assigned PLC Address and Voltage Ratings of Components Used

S/N Components Symbol PLC terminal Ratings

Start Push
1 Button STR Input-X00 24VDC
Stop Push
2 Button STP Input-X01 24VDC
Low level Float
3 Switch FL Input-X02 24VDC
Full Level Float
4 switch FH Input-X03 24VDC
Tank Low
5 Indicator (Red) TL Output-Y00 24VDC
Tank Full
Indicator
6 (Green) TF Output-Y01 24VDC
Pump On
7 Indicator P Output-Y02 24VDC
8 Pump relay R Output-Y03 24VDC
2.2 Method

The ladder logic created is such that when the water level drops below a certain threshold determined by the low level float switch FL,
a red indicator lamp and a pump is activated automatically to replenish the water. While the pump is in operation, a yellow indicator
lamp is ON. When the water level the water level rises to the upper limit determined by the full level float switch FH, the pump, red
lamp and yellow lamp are automatically triggered off while a green indicator lamp is triggered ON. The entire process can be initiated
and stopped by a manual start and stop push buttons, while an emergency button is available to immediately shutdown the entire system
in case of an emergency situation. Due to the high power consumption of the pump (3A), exceeding the maximum output ratings of the
PLC (2A), a relay module was employed to establish a connection between the pump and the PLC. The PLC initiated the activation of
the relay, which, in turn, powered on the pump. The system flow chart, block diagram and circuit diagram arte shown in Figure 2 and
Figure 3 respectively.

Figure 1: Operational Flowchart of Automatic Water Level Control System Using PLC

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Figure 2: Block Diagram and Circuit Diagram

3. RESULTS AND DISCUSSION

The pictorial layout of the system is shown in Figure 3.

Figure 3: Layout of the automatic water level control system

During the simulation of the Ladder logic, the operation was successfully initiated by pressing the start button, and the process was
effectively stopped by pressing the stop button. Additionally, the corresponding indicator LEDs accurately responded to the states of
the upper and lower float switches, providing visual feedback on the water level control system's status. The transitioning of each input
and output devices are described in the simulation stages below;
Stage I: When the system is powered ON, but the Start push button STR is not pressed (N/O contact is logic 0), all output devices (coils)
TL, TH, P and R are OFF (logic 0). Figure 4 shows result of ladder simulation stage 1.

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Figure 4: ladder logic Simulation Stage 1

Stage 2: When the start push button is pressed, the start buffer memory STRM, changes to logic 1. The STRM acts as a latch such that
when the start button de-bounces, the system remains ON. Also, when the start buffer memory STRM is logic 1 and the low level and
high level float switches FL and FH are logic 0 (i.e. No water in the tank), the output coils TL, P and R are set to logic 1 (ON). While
indicator coil TF is logic 0 (OFF). The result of ladder simulation stage 2 is shown in Figure 5 below.

Figure 5:Ladder simulation stage 2

Stage 3: Provided start buffer memory, STRM remains logic 1, when the water level in the tank begins to rise and it rises above low
level float switch FL, but not up to high level float switch FH, FL contact changes to logic 1 while FH contact remains logic 0. Also,
coils TL, P and R remains ON (Logic 1) . Figure 6 shows result of ladder simulation stage 3.

Figure 6: Ladder logic simulation stage 3

Stage 4: Provided start buffer memory, STRM remains logic 1, when the water level rises above both Low and high level float switches
FL and FH, contacts FL and FH changes to logic 1. Output coils TL, P and R are powered OFF (logic 0) While green LED, coil TF is
powered ON (Logic 1). This indicates tank is full. The result of ladder simulation stage 4 is shown in Figure 7 below.

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Figure 7:Ladder logic Simulation Stage 4

Stage 5: Provided start buffer memory, STRM remains logic 1, When the water level in the tank begins to drop and it drops below FH
but still above FL, the contacts FH changes to logic 0 while FL remains logic 1. Also the tank full indicator TF remains ON. Figure 8
shows result of ladder simulation stage 5.

Figure 8: Ladder logic Simulation Stage 5

Stage 6: Provided start buffer memory, STRM remains logic 1, when the water level falls below FL, the contacts FL changes state to
logic 0. Also, coil TF changes state to logic 0. Coils TL, P and R changes state to logic 1. Figure 9 shows result of ladder simulation
stage 6.

Figure 9: Ladder logic simulation Stage 6

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Stage 7: When stop push button is pressed, the start buffer memory changes state from logic 1 to 0 and all coils are set to logic 0. The
result of ladder simulation stage 7 is shown in Figure 10 below.

Figure 10: Ladder logic simulation stage 7

4. CONCLUSION

In conclusion, the use of Programmable Logic Controller (PLC) for water level control systems has proven to be an efficient and effective
solution. Implementing PLC-based automation, the control and management of water levels in tanks and reservoir was achieved with
greater accuracy, reliability, and efficiency. The integration of PLC allows for real-time monitoring, precise control, and automated
actions such as pump activation or shutdown based on predefined water level thresholds. This technology offers advantages such as
reduced water wastage, improved resource management, and enhanced system performance. Overall, water level control using PLCs
provides a cost effective, reliable and automated solution to optimize water usage and prevent unnecessary wastage. A potential future
scope is to expand the project into a comprehensive smart water management system. This could involve incorporating additional sensors
for monitoring water quality, flow rates, and environmental conditions. The system could then optimize water usage, detect leaks or
abnormalities, and provide insights for efficient water resource management. In addition, the project could be further enhanced by
implementing an automatic water filling mechanism. By integrating with water sources, such as pipelines or tanks, the system could
automatically detect low water levels and initiate the filling process. This would eliminate the need for manual intervention and ensure
a constant supply of water, especially in applications where continuous water availability is critical.
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