saifalikabi
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Arduino, PLC based SCADA for water treatment plant

Collect analog date by the Arduino send then through Modbus rs485 to PLC and show them on SCADA through Modbus rs232

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Arduino, PLC based SCADA for water treatment plant

Things used in this project

Hardware components

Arduino UNO
Arduino UNO
×1
TIA Portal (WinCC) SCADA software
×1
XGB Ls PLC
×1
XG5000 Ls PLC software
×1
Ultrasonic Sensor - HC-SR04 (Generic)
Ultrasonic Sensor - HC-SR04 (Generic)
×1
Liquid Crystal Display
×1
MAX485 TTL RS485
×1
9V 1A Switching Wall Power Supply
9V 1A Switching Wall Power Supply
×1
RS-232 to USB
×1

Hand tools and fabrication machines

Modbus Master Data Scanner
Arduino IDE
USB Mini

Story

Read more

Schematics

The wiring of the PLC I/O

The mapping of the RS-485 (PLC-Arduino)

The mapping of the RS-232 (PLC-SCADA)

Arduino Board Wiring (as RS485 slave)

Code

ArduinoCode.ino

C/C++
#include <LiquidCrystal.h>
#include <ModbusMaster.h>
#include "dht.h"

#define dht_apin A0 
dht DHT;

#define MAX485_DE      3
#define MAX485_RE_NEG  2
ModbusMaster node;

void preTransmission()
{
  digitalWrite(MAX485_RE_NEG, 1);
  digitalWrite(MAX485_DE, 1);
}

void postTransmission()
{
  digitalWrite(MAX485_RE_NEG, 0);
  digitalWrite(MAX485_DE, 0);
}

#define trigPin1 9
#define echoPin1 8 

#define trigPin2 A4
#define echoPin2 A5


int duration, distance, UltraSensor1, UltraSensor2;

const int rs = 12, en = 11, d4 = 7, d5 = 6, d6 = 5, d7 = 4;
const int tank_level = 24;   //cm
LiquidCrystal lcd(rs, en, d4, d5, d6, d7);

void setup()
{
   lcd.begin(16, 2);
   lcd.clear();

pinMode(echoPin1, INPUT);
pinMode(echoPin2, INPUT);

pinMode(trigPin1, OUTPUT);
pinMode(trigPin2, OUTPUT);
pinMode(MAX485_RE_NEG, OUTPUT);
pinMode(MAX485_DE, OUTPUT);

digitalWrite(MAX485_RE_NEG, 0);
digitalWrite(MAX485_DE, 0);

Serial.begin(9600);

node.begin(1, Serial);

  node.preTransmission(preTransmission);
  node.postTransmission(postTransmission);
}
bool state = true;

void loop() 
{
uint8_t result1 = UltraSensor1;
uint8_t result2 = UltraSensor2;
uint8_t result3 = DHT.temperature;

DHT.read11(dht_apin);

SonarSensor(trigPin1, echoPin1);
UltraSensor1 = distance;
SonarSensor(trigPin2,echoPin2);
UltraSensor2 = distance;

  lcd.clear();
  lcd.setCursor(0, 0);
  lcd.print("L1 ");
  
  lcd.setCursor(3, 0);
  lcd.print(UltraSensor1);

  lcd.setCursor(7, 0);
  lcd.print("L2 ");

  lcd.setCursor(10, 0);
  lcd.print(UltraSensor2);

  lcd.setCursor(0, 1);
  lcd.print("T ");

  lcd.setCursor(2, 1);
  lcd.print(DHT.temperature);

  lcd.setCursor(10, 1);
  lcd.print("RS-485");


result1 = node.writeSingleRegister(0x0000, UltraSensor1);
result2 = node.writeSingleRegister(0x0002, UltraSensor2);
result3 = node.writeSingleRegister(0x0004, DHT.temperature);

delay (50);
}

void SonarSensor(int trigPinSensor,int echoPinSensor)
{
digitalWrite(trigPinSensor, LOW);
delayMicroseconds(2);
digitalWrite(trigPinSensor, HIGH);
delayMicroseconds(10);
digitalWrite(trigPinSensor, LOW);

duration = pulseIn(echoPinSensor, HIGH);
distance= tank_level -((duration * .0343) / 2);


}

TIA Portal SCADA

ActionScript
No preview (download only).

XGB PLC program

ActionScript
No preview (download only).

PLC Logic.docx

BatchFile
No preview (download only).

Arduino Code

C/C++
#include <LiquidCrystal.h>
#include <ModbusMaster.h>
#include "dht.h"
#define dht_apin A0 
dht DHT;
#define MAX485_DE      3
#define MAX485_RE_NEG  2
ModbusMaster node;
void preTransmission()
{
  digitalWrite(MAX485_RE_NEG, 1);
  digitalWrite(MAX485_DE, 1);
}
void postTransmission()
{
  digitalWrite(MAX485_RE_NEG, 0);
  digitalWrite(MAX485_DE, 0);
}
#define trigPin1 9
#define echoPin1 8 
#define trigPin2 A4
#define echoPin2 A5
int duration, distance, UltraSensor1, UltraSensor2;
const int rs = 12, en = 11, d4 = 7, d5 = 6, d6 = 5, d7 = 4;
const int tank_level = 24;   //cm
LiquidCrystal lcd(rs, en, d4, d5, d6, d7);
void setup()
{
   lcd.begin(16, 2);
   lcd.clear();
pinMode(echoPin1, INPUT);
pinMode(echoPin2, INPUT);
pinMode(trigPin1, OUTPUT);
pinMode(trigPin2, OUTPUT);
pinMode(MAX485_RE_NEG, OUTPUT);
pinMode(MAX485_DE, OUTPUT);
digitalWrite(MAX485_RE_NEG, 0);
digitalWrite(MAX485_DE, 0);
Serial.begin(9600);
node.begin(1, Serial);
  node.preTransmission(preTransmission);
  node.postTransmission(postTransmission);
}
bool state = true;
void loop() 
{
uint8_t result1 = UltraSensor1;
uint8_t result2 = UltraSensor2;
uint8_t result3 = DHT.temperature;
DHT.read11(dht_apin);
SonarSensor(trigPin1, echoPin1);
UltraSensor1 = distance;
SonarSensor(trigPin2,echoPin2);
UltraSensor2 = distance;
  lcd.clear();
  lcd.setCursor(0, 0);
  lcd.print("L1 ");
  lcd.setCursor(3, 0);
  lcd.print(UltraSensor1);
  lcd.setCursor(7, 0);
  lcd.print("L2 ");
  lcd.setCursor(10, 0);
  lcd.print(UltraSensor2);
  lcd.setCursor(0, 1);
  lcd.print("T ");
  lcd.setCursor(2, 1);
  lcd.print(DHT.temperature);
  lcd.setCursor(10, 1);
  lcd.print("RS-485");
result1 = node.writeSingleRegister(0x0000, UltraSensor1);
result2 = node.writeSingleRegister(0x0002, UltraSensor2);
result3 = node.writeSingleRegister(0x0004, DHT.temperature);
delay (50);
}
void SonarSensor(int trigPinSensor,int echoPinSensor)
{
digitalWrite(trigPinSensor, LOW);
delayMicroseconds(2);
digitalWrite(trigPinSensor, HIGH);
delayMicroseconds(10);
digitalWrite(trigPinSensor, LOW);
duration = pulseIn(echoPinSensor, HIGH);
distance= tank_level -((duration * .0343) / 2);}

Credits

saifalikabi

saifalikabi

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