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Inst Tools > Blog > PLC Tutorials > Dosing Pump PLC Logic

Dosing Pump PLC Logic

Learn the dosing pump PLC logic with Omron's CX-Programmer for liquid filling through a weight-based dual-tank system.

Last updated: September 30, 2024 12:56 pm
Editorial Staff
PLC Tutorials
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This article discusses the “Loss in Weight Liquid System” often also called liquid filler or dosing pump using CX-Programmer Omron PLC Software. This PLC system is used for the process of filling liquid into a tank with a high level of accuracy. The system features two tanks: one for storage and the other for measuring the liquid. Its operation principle is based on the gradual and measurable weight reduction of the filled storage tank.

Contents
Program ObjectiveSequence-1 is the Tank 1 Filling ProcessSequence-2 is the Tank 2 Filling ProcessSequence-3 is the Drain ProcessPLC IO ListDosing Pump PLC Logic

Program Objective

The PLC program uses 3 buttons:

  1. The PB_START button (0.00) is used to turn ON the system.
  2. The PB_STOP button (0.01) is used to turn OFF the system.
  3. The START_FILL button (0.02) is used to start the filling process on Tank-2.
Loss in Weight Liquid PLC System

The “Loss in Weight Liquid” system has 2 tanks, Tank-1 is used for storage and Tank-2 is used to measure liquid contents. This system will reduce liquid measurably from Tank-1 to Tank-2 and drain the liquid contents from Tank-2.

This system only Starts if the Minimum “Set value” liquid content of Tank-1 has been Set (the value given must not be equal to zero).

Sequence-1 is the Tank 1 Filling Process

The Tank-1 Filling process will be carried out if the Liquid content of Tank-1 is below the Minimum “Set value” limit.

VALVE_1 (100.00) will OPEN first, 2 seconds after that the MOTOR_PUMP (100.01) will be ON and fill liquid into Tank-1.

When the liquid content reaches the Maximum limit (100 liters), MOTOR_PUMP (100.01) will be OFF and VALVE_1 (100.00) will CLOSE.

The Tank-1 Filling process will be carried out again if the Liquid content from Tank-1 is below the Minimum “Set value” limit.

Sequence-2 is the Tank 2 Filling Process

Before the Tank-2 Filling Process is carried out, the Maximum “Set value” limit for the liquid content of Tank-2 must be Set.

The Tank-2 Filling process will only be carried out when the START_FILL (0.02) button is Pressed.

VALVE_2 (100.02) will OPEN to drain liquid from Tank-1 to Tank-2, when Tank-2 has been filled with liquid according to the “Set value” VALVE_2 (100.02) will CLOSE.

Sequence-3 is the Drain Process

2 seconds after the Filling Tank-2 process is complete, the Drain process will be carried out. The Drain process aims to remove the liquid contents from Tank 2.

VALVE_3 (100.03) will OPEN to drain the liquid contents from Tank-2. VALVE_3 (100.03) will CLOSE again when Tank-2 is empty.

Dosing Pump PLC Logic

PLC IO List

CommentInput (I)Output (Q)Memory WordMemory BitsTimer
PB_START0.00    
PB_STOP0.01    
START_FILL0.02    
VALVE_1 100.00   
MOTOR_PUMP 100.01   
VALVE_2 100.02   
VALVE_3 100.03   
TIMER_1    T0000
TIMER_2    T0001
SYSTEM_ON   W0.00 
IR_CUTOFF1   W0.01 
IR_CUTOFF2   W0.02 
IR_VALVE3   W0.03 
SV_TANK1  D0  
PV_TANK1  D1  
SV_TANK2  D10  
PV_TANK2  D11  

Dosing Pump PLC Logic

RUNG 0 (START SYSTEM)

In this Rung, when the memory word SV_TANK1 (D0) is not equal to zero “0” and the PB_START (0.00) button is pressed, the memory bit SYSTEM_ON (W0.00) will be in the HIGH state. Because the KEEP(011) instruction is used, the memory bit SYSTEM_ON (W0.00) will remain in a HIGH state even though PB_START (0.00) button is Released.

The memory bit SYSTEM_ON (W0.00) will become a LOW state if the PB_STOP (0.01) button is Pressed.

Liquid Filling PLC Logic

RUNG 1 (FILLING TANK 1)

When contact NO from memory bit SYSTEM_ON (W0.00) is HIGH state and the value in memory word PV_TANK1 (D1) is less than or equal to SV_TANK1 (D0), then Output VALVE_1 (100.00) will turn ON and Timer TIMER_1 (T0000) will Start counting up to 2 seconds.

After Timer TIMER_1 (T0000) has finished Counting, Output MOTOR_PUMP (100.01) will turn ON. Output VALVE_1 (100.00) will be CLOSED and MOTOR_PUMP (100.01) will be OFF when contact NC from memory bit IR_CUTOFF1 (W0.01) in HIGH state.

RUNG 2 (CUTOFF TANK1)

In this Rung, when the NO contact of memory bit SYSTEM_ON (W0.00) is in a HIGH state and the value in memory word PV_TANK1 (D1) equals “100”, then the Output memory bit IR_CUTOFF1 (W0.01) will be in a HIGH state.

PLC Programming for Liquid Filler

RUNG 3 (FILLING TANK2)

When the NO contact of memory bit SYSTEM_ON (W0.00) is in a HIGH state and the START_FILL (0.02) button is pressed, the Output VALVE_2 (100.02) will OPEN. If the value of memory word PV_TANK2 (D11) is equal to SV_TANK2 (D10), then the Output memory bit IR_CUTOFF2 (W0.02) will be in HIGH state and the Output VALVE_2 (100.02) will be CLOSED due to Interlock.

RUNG 4 (DRAIN)

When the NO contacts of memory bits SYSTEM_ON (W0.00) and IR_CUTOFF2 (W0.02) are in the HIGH state, then memory bit IR_VALVE3 (W0.03) will also be in a HIGH state. Because it uses the KEEP(011) instruction, memory bit IR_VALVE3 (W0.03) will remain in a HIGH state even though the NO contacts of memory bits SYSTEM_ON (W0.00) and IR_CUTOFF2 (W0.02) are in the LOW state.

Memory bit IR_VALVE3 (W0.03) will be in the LOW state if the value of memory word PV_TANK2 (D11) is zero “0”.

Weight-based PLC Logic

RUNG 5 (VALVE 3 ON)

When the NO contact of memory bit IR_VALVE3 (W0.03) is in the HIGH state, Timer TIMER_2 (T0001) will Start counting for 2 seconds. Once Timer TIMER_2 (T0001) finishes counting, Output VALVE_3 (100.03) will turn ON.

Output VALVE_3 (100.03) will turn OFF if the NO contact of memory bit IR_VALVE3 (W0.03) in LOW state.

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