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6x2x2 with 4ft tank sump- PLC automated

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6x2x2 with 4ft tank sump- PLC automated

Postby Matt_84 » Thu 09 Jun, 2011 9:18 pm

Well the time is ticking down until i move into my new house (November) and one of the first additions will hopefully be this tank.

I have a little while before i get the tank up and running so I plan on doing things properly.... *shakes head to remove horrible memories of the previous failure* :madface:


System Objectives: Build a sweeeeet tank and automate as much of it as i can using a PLC
System Type: Mixed Reef

Display System: 6'x2'x2' (182.88x60.96x60.96 centimetres for us Australians)

Strike up Date: November sometime.... fingers crossed

Display Lighting: 3 Metal halides, 2 T5 and 4 moon lights (purchased last year and modified for use with PLC)

Stand: Homemade using RC plans
Hood: Maybe

Sump: purchased 4 ft sump from fellow RTAW member

Refugium: nil
Deep Sand Bed:nil

Refugium Lighting: N/A
Chiller: Cooma weather.....

Support systems:

System Water: Artificial Salt Water.

Display Water circulation: closed loop and powerheads

Return Pump: ehiem 1262

Refugium Pump: N/A
Skimmer: Skimz SK252

Evaporation Top Up: Elaborate system thats sure to fail

Chemical Support:

Calcium Addition: Calcium reactor

Alkilinity Addition:

Other Chemical Maintenance: zeovit system

Current Water Chemistry: N/A
Nitrates: nil
Phosphates: nil
Alkalinity:nil
Calcium: nil
Salinity / Specific Gravity: nil
Magnesuim: nil

My big plan is that this PLC I acquired a few months ago will control as much as possible. I'm still learning the ins and outs of it but hopefully i'll be able to control theses things:
Lighting - on/off. and logging hours running so i approximately know when to replace the bulbs.
Auto-top off - using float switches and pump
Dosing
Data gathering
Remote access - so i can check on and adjust things remotely
Alarms - Spill alarms, pump failure alarms,
Auto shut down and notify in case of above alarms

Anyway if you have any ideas or suggestions let me know,

Thanks
Matt
Last edited by Matt_84 on Mon 30 Apr, 2012 2:02 pm, edited 2 times in total.
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby kj52faith » Thu 09 Jun, 2011 10:17 pm

Sounds good. You should put a step by step info on it for us.
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Re: 6x2x2 with 4ft tank sump- Light Modification

Postby Matt_84 » Fri 10 Jun, 2011 7:33 pm

Ok heres the 1st Part of my build,
Modifying the lighting system.
AIM: To enable complete control of the Lighting system to simulate Morning/Day/ afternoon and night and gain valuble experience in programming PLCs

Take one perfectly good light
Image


Rip it apart and install 12V relays
Image

Had a spare pair in my cable so i decided to install some dick smith fans, probably will never get used but they are there if i need them

Image

Re-assemble lights/neaten wiring and hide any "spare" screws.... you probably wont need them anyway
Image
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby Matt_84 » Fri 10 Jun, 2011 7:58 pm

Step 2: Aquire 1 PLC.
I managed to salvage a little fella complete with
16 analog inputs, 16 digital inputs and 24 digital outputs.

Plus this awesome HMI which seems to work but i'm yet to play around with it properly.
Image

Now the programming begins..... :nut:

Programming a PLC is pretty straight forward.. (HAHAHA) sometimes. I acquired the software from work and it doesn't seem to difficult, you just have to break down what you want it to do logically and write a ladder logic file.... simple
I have managed to sort out a few of the outputs but the timer ones are giving me grief at the moment.
I'll post the logic files when i've finished so others can use them and for any ladder logic gurus out there to improve for me :-D
Last edited by Matt_84 on Mon 30 Apr, 2012 2:05 pm, edited 1 time in total.
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby kj52faith » Fri 10 Jun, 2011 10:37 pm

Awesome il probably grab those files of you when my dad builds my plc
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Re: 6x2x2 with 4ft tank sump- Lighting Hours

Postby Matt_84 » Mon 13 Jun, 2011 2:43 pm

Finally got the programming for the lights down. Ended up being easier then i was making it.
Heres a screen shot and a basic run down of the programming for anyone thats interested. For more details just PM me.

Hours need to be tweeked, These hours were just for a test.

Moon Lights : 3am to 5am and then 9pm to 11 pm
fluoros: 5 am to 9 PM
Metal Halide 1:7 am to 2 pm
Metal Halide 2: 10 am to 4 pm
Metal Halide 3: 12 pm to 6 pm

A switch will be installed to allow lights to be manually turned off for maintenance etc

Image
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Re: 6x2x2 with 4ft tank sump- Lights EOL

Postby Matt_84 » Mon 13 Jun, 2011 2:50 pm

To remind me to replace the lights i created these logic files

after 20,000 hours a light will illuminate and remind me to replace the globes. after i replace them i just hit a reset button and it all starts again. It was made difficult because the PLC will only count to 65 hours before it stops so i had to create multiple registers to add up to to the 20,000 hours recommended by the globe manufacturer (will probably decrease this anyway)

Setting up the multiple registers
Image

After hitting the reset button timers are reset to zero
Image
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Re: 6x2x2 with 4ft tank sump- Auto-top off

Postby Matt_84 » Mon 13 Jun, 2011 3:01 pm

ATO system has been modified and is in new design stage.

*Edit - Old ATO plan was unsuitable and too risky
Last edited by Matt_84 on Mon 30 Apr, 2012 2:07 pm, edited 1 time in total.
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby Adam howell » Mon 11 Jul, 2011 11:15 pm

Looks great so far :thumbsup:
Adams&leteisha's 6x2x2 little piece of paradise
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby listen_to_slayer » Thu 06 Oct, 2011 5:23 pm

This is insane! I'm an apprentice sparky, and that PLC looks daunting! I'm guessing you deal with PLC's in your work? Will be good to see this when it all comes to life!! You'd probably been one of the only people in Cooma with a marine system wouldn't you? :P
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby wmackay » Thu 06 Oct, 2011 7:40 pm

This is such a good idea!! Ahh I may have to steal your idea, seeings that I'm a comms and radio tech and I didn't een think to use an old RTU to control
Lights! May have to have a go I think!
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby Matt_84 » Fri 28 Oct, 2011 2:28 pm

listen_to_slayer wrote:This is insane! I'm an apprentice sparky, and that PLC looks daunting! I'm guessing you deal with PLC's in your work? Will be good to see this when it all comes to life!! You'd probably been one of the only people in Cooma with a marine system wouldn't you? :P


Lol I've never touched a PLC in my life, lol so it's been a very steep, very frustrationg learning curve. The kingfisher has a pretty good UI and the documentation has a few examples but most has been trial and error. I'm not sure if anyone else around here has a marine tank though i doubt it.

wmackay wrote:This is such a good idea!! Ahh I may have to steal your idea, seeings that I'm a comms and radio tech and I didn't een think to use an old RTU to control
Lights! May have to have a go I think!


Feel free to steal away :) Maybe you can help me out when i get stuck then :) Good to hear from a fellow comms/radio tech :cheers:
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby wmackay » Fri 28 Oct, 2011 8:00 pm

Haha your one too?! Small world! I got no clue when it comes to programming these things, I'm more a construction kinda guy ha. Wouldn't mind learning but! I am onky apprentice though, I guess it will come with time!
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Re: 6x2x2 with 4ft tank sump- yay the tank... boo the crack

Postby Matt_84 » Mon 13 Feb, 2012 4:09 pm

Well been a while since an update.
New house has been keeping me busy, but I have still been collecting bits and pieces for the tank.
I have about 100kgs of live rock cooking in plastic bins in my new garage fish room :) I picked up the tank from abyss aquariums on the weekend, beautifully built tank. However it didn't survive the journey home :( ended up with a big crack across the bottom. Not sure how this happened as it was sitting on 1inch high density foam and it didn't appear to move the whole way. But it does mean when I get back from my upcoming holiday ill have to drive back up and get it fixed :( stoopid glass.
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby Matt_84 » Mon 30 Apr, 2012 2:26 pm

Things are moving very very slowly. Decidied to renovate my kitchen, remove a wall, seal up a doorway first. My priorities are all mixed up sometimes.
Anyway, i'm getting closer to finishing those projects so I've been making a little time to finally play with the good stuff.

I've been dry fitting some equipment into the sump.
Image

And almost finished cabling the PLC/RTU into my shed rack
Image

Hopefully be picking the tank up again this weekend. :crossfingers: no cracks this time.

Live rock is still cycling away happily in my bins :) a couple of little mushroom thingys have shown up and i'll try and get a picture so i can get an Id on them.

Stand construction will hopefully begin this weekend
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby Matt_84 » Sat 26 May, 2012 3:43 pm

Woo Hoo tank made it home with no cracks this time! :banana:
Image

Image
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby parrdog » Sat 26 May, 2012 4:07 pm

Nice one mate, onward and upward aye :).

Jamie.
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby bubbleboy » Tue 26 Jun, 2012 9:39 am

Hey Matt,
Great to see your still in it and things are comeing alone nicely :clap: :clap:
Let me know if you need anything, i'll be passing you by as per norm :thumbsup:

Cheers
Dave
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby Matt_84 » Tue 26 Jun, 2012 4:20 pm

Hey Dave,
Yeh, things are moving... extremely slow. But at least they're moving in the right direction.
I was wondering if you were going to make the journey down this year. It's alot better this year. Alot more natural snow has fallen and the temps have been cold enough to keep the man-made stuff around longer.
Dont need anything just yet, hopefully it wont be too much longer and i'll finally get this thing wet
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby CoralAddict » Sun 29 Jul, 2012 10:46 pm

What brand of PLC is that, i mainly deal with allen bradley PLC's and planned to use one with a 10 inch monitouch HMI i was given until i found out how hard it was to aquire the software to use it without paying thousands of dollars.lol.

You did well to get one that has 16 analog inputs, have you programmed any of the analogs yet. They are the fun ones to do.

Have you thought about where you are going to get the various probes from, i found most suppliers for the aquarium industry would not tell me if their probes were plc compatable.

Couple of suggestions -
With the right programming, a couple of float switches and the right sump design you could use it to automate water changes.
you can use it to control water temp through heaters and chiller
If you ever change to dimmable lights you could use it to control the dimming

Im sure there is heaps more but thats some of the ones i remember that i was going to do.

looking like a great build so far.

kodey
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby Matt_84 » Fri 03 Aug, 2012 6:14 pm

It's a CSE semaphore Kingfisher.
I've had a bit of a play with the analogs, the PH transmitter worked quite well, had a couple of issues with the temp sensors but think i have that sorted now and I haven't connected my level sensor yet.
The temp sensor probes I got off ebay along with the 4-20ma transmitters. The PH probes are just standard ones i got off an online fish store, the PH 4-20ma transmitters i got of ebay from america. the level sensor was also from the state courtesy of ebay. lol ebay is great.

The water change set-up i have in mind is pretty simple and if it works out i'll post up the plans, if not then i'll pretend it never happened. lol
The power board i have is all wired up with relays and the plc will control:
Lights
Heater
ATO and water change system
Calc reactor
Dosing pumps
Zeo reactor
and a fish feeding system
As well as transmitting all data ( water flow, water spills, temp, PH, Logging - (dosing, feeding, etc..) to my server and my small HMI

I have an analog output card for it that I might try one day for the dimmable lights and possibly a modified heating system.


-------------------------------------------------
List of work to go:
Finish running control cabling to Krone box under house
Sister Joists under floor
drill holes in floor for closed loop pump and CO2 bottle
pour small concrete slab under house to put water change and ATO tanks on
Finish stand and paint

Move everything into house !!!!!!! :bs:
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby indyana1 » Wed 02 Jan, 2013 9:02 am

Im always impressed by you tech guys and what you can DIY. How about some tank shots it must be up and running :poke:

Mick :thumbsup:
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby Matt_84 » Wed 02 Jan, 2013 12:29 pm

lol well the wooden stand I created is now a garage workbench lol
decided to scrap it and make one out of steel. I'm not much of a carpenter lol.
I'm just drawing up some designs then hopefully this week I'll begin the build again. been pretty slack the last few months. longest build ever :(
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby snik66 » Thu 03 Jan, 2013 4:46 pm

Matt_84 wrote:lol well the wooden stand I created is now a garage workbench lol
decided to scrap it and make one out of steel. I'm not much of a carpenter lol.
I'm just drawing up some designs then hopefully this week I'll begin the build again. been pretty slack the last few months. longest build ever :(



bahaha this is gold.. you doing the steel one yourself ? :D
Good luck :thumbsup:
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby Matt_84 » Thu 03 Jan, 2013 5:04 pm

lol I've asked Greg (Meller) very nicely if he wouldn't mind helping me out. :thumbsup:
I'm also not much of a designer/steel worker/welder/... so i'm sure it's not going to be easy but anythings got to be better then the shambles I made of the wooden stand :wall:
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby snik66 » Sat 12 Jan, 2013 12:56 pm

Yeah I think most importantly strength and level other wise your gonig to end up with tank all over your floor!! I'm in the same boat mate don't fell alone :thumbsup:
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby MeLLeR » Sun 13 Jan, 2013 12:11 am

Were getting there Matt. Have set aside time this week to finish up some Sketches. Will try and have some renders ready for you soon ;)
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby Matt_84 » Sun 13 Jan, 2013 1:06 pm

Thanks for that Greg,
I've removed the rear glass panel without too many dramas. Will order the new one this week. Looking forward to getting this thing up and running.
.thanks again Greg!
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby nicktg86 » Wed 10 Apr, 2013 11:41 am

Looks great :clap:
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Re: 6x2x2 with 4ft tank sump- PLC automated

Postby Matt_84 » Thu 20 Jun, 2013 4:25 pm

Decided to use the existing glass and turn it upside down, new weir has been drilled and overflow box has been assembled and drilled.
I found some instructions on the net how to cut glass and after a few attempts on some scrap glass I finally cut the 10mm glass for the overflow box.. very stressful but it worked!

Silicon has finally been cleaned off the tank and the new rear panel will be fitted on Saturday morning, then the overflow box next week hopefully.

The original bean animal holes will now become part of my closed loop system so another pump will be on order soon for that.

The PLC has been moved into another "smaller" cabinet in the shed which will seperate it from my file servers,etc and allow me to install the batteries and solar system to maintain the plc during power outages so it can control the generator and send me alarms if everything fails.

Unfortunately for me, my master stand designer has decided to move states.. lol He has some crazy idea of moving somewhere better then Canberra... as if there is anywhere better :poke: lol
When he settles in I'll be hitting him up for the plans, I've still got alot of pre-work to do before I need them but it's getting closer... hopefully

longest build ever continues..
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