Industrial IceMaker Reporting Project

First, great site. Thanks for the help in advance.

Background:
I'm a computer networking guy who knows nothing about industrial equipment, but I am a quick learner.

Project:
Owner would like to be able to monitor industrial equipment (Industrial IceMakers, Conveyour Belts, etc) using a computer. Currently, the electrician has connected some lights on the outside of the icemaker and a video camera that monitors the lights. The owner reviews the video to verify the icemake has come on and gone off at appropriate times (he knows what times the lights should be on/off). So the discussion starts, I research the internet and find out I can connect devices (PLC, PLR) that can have inputs and outputs. The electrician can connect the sensors for me.

Where do I start?
I think I want to monitor contacts for now that are on/off, energized/or not, High/Low, etc. Then I want to write to a file or database. Time, Date, Object, State, etc so that I can run reports for the owner.

The equipment doesnt have any PLC/PLR.

Can you recommend a product to me so I can continue my research.

Thanks

Wow, an excellent first post. I'm sure you will have great help on this project.

Yes, PLCs would be a great help in monitoring the operation of this equipment. Some of the first thing to determine, possibly with the help of the electrician, what type of control voltage is being used in the equipment. Possibly 110VAC or maybe 24VDC. And the On/Off signals ... what type of signal are they? Finally how many signals should be monitored?

As far as communication, Ethernet would probably be the easiest to implement. Can a run be made from a nearby switch? Or would a wireless connection (more expensive for equipment but possibly much easier to install) be more appropriate? Those with more knowledge than I will probably have much better questions.

Once this is established the owner may wish to implement some remote output controls. The PLC would be available for this.

Thanks for the quick reply.

I will check on the voltage but this much I do know. The IceMakers are hugh, industrial strength. One of the stories the electrician told me is they had to bring in power from another Grid. I guess when the IceMaker Blower kicked in the power would dim the lights at near by casinos. He mentioned they use an electrical system that starts only half the motor before starting the other half (Split something).

The IceMaker is real important part with several generators as backup. The company packs and sales shrimp.

We will use Ethernet, this much I can do. We may opt for wireless if needed. In my head I think I would use several PLC's connected to IceMaker and other equipment. Furture plans would be to report on a conveyour belt that dumps shrimp (monitor the hopper, etc).

Hardware

I would look at a system that you can build as needed, like Bernie said Ethernet would be the best way

How many I/O's if there are just a few then I would look at Siemens 1200 or Automation Direct (DL05 with ECOM)

Both would be reasonable cost, both have reasonable HMI's or you can look at a PC based ( Peak HMI)

See here for the 1200
http://www.automation.siemens.com/m...atic-s7-controller/s7-1200/Pages/Default.aspx

See here for the DL05
http://www.automationdirect.com/adc...r)/DirectLogic_05_(Micro_Brick_PLC)/PLC_Units

Peak HMI
http://www.plctrainer.net/Human Machine Interface (PeakHMI).htm

I have sold a lot of trainers to people looking to learn and then take the trainer apart and use it on a project.... maybe another option

Regards!

From the sounds of it you already have a functioning system you just want to monitor. A small AD plc as genius suggested or just some remote I/O blocks might do. As for interfacing to the computer system, you might want to look at an OPC server such as Kepware (http://www.kepware.com) that can read the PLC tags and relay them back to the PC, after that you can program a small database to record the information.

Hey GeniusInTraining -
I checked on the DL05 but am wondering if the ECOM Options Module is true Ethernet? It does'nt seem like it to me.

Is there a low cost PLC that can be programmed with an IP Address and either the PLC generate a log dump to a PC or a server component read the PLC variables over ethernet? Or am I way off. Are there any devices that can do that.

Not sure what you mean by 'real ethernet'

I made and installed a network with DL06's and 05's (about 15 of them)

Using these http://www.automationdirect.com/adc...PLC)/Communications_-a-_Networking/H0-ECOM100

Both the AD and the Siemens 1200 can do it, look at Christoff84's Kepware link this is what I used to go to a RSView 32 package with web server, the customer was very happy... anywhere in the plant they could pull up the production data and see where they were for the days numbers and if they were falling behind

I think I would use the Siemens 1200 if I could make it work but thats just me... I like using the newest on the market and learning them

The Allen Bradley 1100 also has a built in Ethernet port

This is the Kepware that I used http://www.automationdirect.com/adc.../KEPDirect_for_PLCs_(OPC_-a-_DDE)/PC-KEPPLC-3

You may also want to look at this http://www.plctrainer.net/Human%20Machine%20Interface%20(PeakHMI).htm I think we can do it just using the PEAK HMI and this will save you some money in the long run... it also supports the Siemens 1200, I will call the manufacture later today if he does not chime in

So to sum it up... you need to define the project and your funding, you can get a lot of support here for all of the PLC's. You may also just want to call me and we can talk about what you are trying to do....

What manufacturer/model is the icemaker? Most newer ones have built in (or available as an option) communications options already.

I'd consider using the smallest possible PLC if you really need one, and then the Red Lion Datastation to gather the information and present it to a higher level system/monitor.

geniusintraining - my apologies. That is not the product I found and researched. The product you linked to is exactly what I was thinking about.

If the project turns into something the owner is willing to move forward on, I may need to take the suggestion and attend a class.

rdrast - I also looked at and downloaded the RedLion software. I didnt see a driver to talk to the AD-DL05.

I hope to meet with the electrician and find out more about the Industrial IceMaker and the number of inputs and volts.

Thanks again...

This page seems to list the drivers for the AutomationDirect PLCs

I would ask the elctrician to mount some relays parrallel to his lights and use the contacts in a PLC like WAGO (they have internet module so you can do whatever you like with it.