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

Aug 31, 2022

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Components and supplies

RS-232 to USB

Liquid Crystal Display

XGB Ls PLC

MAX485 TTL RS485

9V 1A Switching Wall Power Supply

TIA Portal (WinCC) SCADA software

XG5000 Ls PLC software

Ultrasonic Sensor - HC-SR04 (Generic)

Arduino UNO

Tools and machines

Modbus Master Data Scanner

USB Mini

Arduino IDE

Project description

Code

PLC Logic.docx

batchfile

1inary file (no preview

inary file (no preview

XGB PLC program

actionscript

1inary file (no preview

inary file (no preview

TIA Portal SCADA

actionscript

1inary file (no preview

inary file (no preview

ArduinoCode.ino

c_cpp

1#include <LiquidCrystal.h>
2#include <ModbusMaster.h>
3#include "dht.h"
4
5#define  dht_apin A0 
6dht DHT;
7
8#define MAX485_DE      3
9#define MAX485_RE_NEG  2
10ModbusMaster node;
11
12void preTransmission()
13{
14  digitalWrite(MAX485_RE_NEG,  1);
15  digitalWrite(MAX485_DE, 1);
16}
17
18void postTransmission()
19{
20  digitalWrite(MAX485_RE_NEG, 0);
21  digitalWrite(MAX485_DE, 0);
22}
23
24#define  trigPin1 9
25#define echoPin1 8 
26
27#define trigPin2 A4
28#define echoPin2  A5
29
30
31int duration, distance, UltraSensor1, UltraSensor2;
32
33const int  rs = 12, en = 11, d4 = 7, d5 = 6, d6 = 5, d7 = 4;
34const int tank_level = 24;   //cm
35LiquidCrystal lcd(rs, en, d4, d5, d6, d7);
36
37void setup()
38{
39   lcd.begin(16, 2);
40   lcd.clear();
41
42pinMode(echoPin1, INPUT);
43pinMode(echoPin2,  INPUT);
44
45pinMode(trigPin1, OUTPUT);
46pinMode(trigPin2, OUTPUT);
47pinMode(MAX485_RE_NEG,  OUTPUT);
48pinMode(MAX485_DE, OUTPUT);
49
50digitalWrite(MAX485_RE_NEG, 0);
51digitalWrite(MAX485_DE,  0);
52
53Serial.begin(9600);
54
55node.begin(1, Serial);
56
57  node.preTransmission(preTransmission);
58  node.postTransmission(postTransmission);
59}
60bool state = true;
61
62void  loop() 
63{
64uint8_t result1 = UltraSensor1;
65uint8_t result2 = UltraSensor2;
66uint8_t  result3 = DHT.temperature;
67
68DHT.read11(dht_apin);
69
70SonarSensor(trigPin1,  echoPin1);
71UltraSensor1 = distance;
72SonarSensor(trigPin2,echoPin2);
73UltraSensor2  = distance;
74
75  lcd.clear();
76  lcd.setCursor(0, 0);
77  lcd.print("L1  ");
78  
79  lcd.setCursor(3, 0);
80  lcd.print(UltraSensor1);
81
82  lcd.setCursor(7,  0);
83  lcd.print("L2 ");
84
85  lcd.setCursor(10, 0);
86  lcd.print(UltraSensor2);
87
88  lcd.setCursor(0, 1);
89  lcd.print("T ");
90
91  lcd.setCursor(2, 1);
92  lcd.print(DHT.temperature);
93
94  lcd.setCursor(10, 1);
95  lcd.print("RS-485");
96
97
98result1  = node.writeSingleRegister(0x0000, UltraSensor1);
99result2 = node.writeSingleRegister(0x0002,  UltraSensor2);
100result3 = node.writeSingleRegister(0x0004, DHT.temperature);
101
102delay  (50);
103}
104
105void SonarSensor(int trigPinSensor,int echoPinSensor)
106{
107digitalWrite(trigPinSensor,  LOW);
108delayMicroseconds(2);
109digitalWrite(trigPinSensor, HIGH);
110delayMicroseconds(10);
111digitalWrite(trigPinSensor,  LOW);
112
113duration = pulseIn(echoPinSensor, HIGH);
114distance= tank_level -((duration  * .0343) / 2);
115
116
117}
118

#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);


}

Arduino Code

c_cpp

1#include <LiquidCrystal.h>
2#include <ModbusMaster.h>
3#include "dht.h"
4#define  dht_apin A0 
5dht DHT;
6#define MAX485_DE      3
7#define MAX485_RE_NEG  2
8ModbusMaster  node;
9void preTransmission()
10{
11  digitalWrite(MAX485_RE_NEG, 1);
12  digitalWrite(MAX485_DE,  1);
13}
14void postTransmission()
15{
16  digitalWrite(MAX485_RE_NEG, 0);
17  digitalWrite(MAX485_DE, 0);
18}
19#define trigPin1 9
20#define echoPin1 8 
21#define  trigPin2 A4
22#define echoPin2 A5
23int duration, distance, UltraSensor1, UltraSensor2;
24const  int rs = 12, en = 11, d4 = 7, d5 = 6, d6 = 5, d7 = 4;
25const int tank_level =  24;   //cm
26LiquidCrystal lcd(rs, en, d4, d5, d6, d7);
27void setup()
28{
29   lcd.begin(16, 2);
30   lcd.clear();
31pinMode(echoPin1, INPUT);
32pinMode(echoPin2,  INPUT);
33pinMode(trigPin1, OUTPUT);
34pinMode(trigPin2, OUTPUT);
35pinMode(MAX485_RE_NEG,  OUTPUT);
36pinMode(MAX485_DE, OUTPUT);
37digitalWrite(MAX485_RE_NEG, 0);
38digitalWrite(MAX485_DE,  0);
39Serial.begin(9600);
40node.begin(1, Serial);
41  node.preTransmission(preTransmission);
42  node.postTransmission(postTransmission);
43}
44bool state = true;
45void loop()  
46{
47uint8_t result1 = UltraSensor1;
48uint8_t result2 = UltraSensor2;
49uint8_t  result3 = DHT.temperature;
50DHT.read11(dht_apin);
51SonarSensor(trigPin1, echoPin1);
52UltraSensor1  = distance;
53SonarSensor(trigPin2,echoPin2);
54UltraSensor2 = distance;
55  lcd.clear();
56  lcd.setCursor(0, 0);
57  lcd.print("L1 ");
58  lcd.setCursor(3, 0);
59  lcd.print(UltraSensor1);
60  lcd.setCursor(7, 0);
61  lcd.print("L2 ");
62  lcd.setCursor(10, 0);
63  lcd.print(UltraSensor2);
64  lcd.setCursor(0, 1);
65  lcd.print("T ");
66  lcd.setCursor(2, 1);
67  lcd.print(DHT.temperature);
68  lcd.setCursor(10, 1);
69  lcd.print("RS-485");
70result1 = node.writeSingleRegister(0x0000,  UltraSensor1);
71result2 = node.writeSingleRegister(0x0002, UltraSensor2);
72result3  = node.writeSingleRegister(0x0004, DHT.temperature);
73delay (50);
74}
75void  SonarSensor(int trigPinSensor,int echoPinSensor)
76{
77digitalWrite(trigPinSensor,  LOW);
78delayMicroseconds(2);
79digitalWrite(trigPinSensor, HIGH);
80delayMicroseconds(10);
81digitalWrite(trigPinSensor,  LOW);
82duration = pulseIn(echoPinSensor, HIGH);
83distance= tank_level -((duration  * .0343) / 2);}
84

#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);}

Downloadable files

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

The wiring of the PLC I/O

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

Arduino Board Wiring (as RS485 slave)

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