Siemens PLC Expert Needed for Dosing System Optimization
Budget: $25 – $50 USD
We are seeking an experienced Siemens PLC developer to assist us in troubleshooting and optimizing our dosing system, which integrates a Badger Meter PFT-4E pulse transmitter paired with industrial turbo meters. We’ve successfully simulated flow rates up to 10 Hz, the maximum capability of our flow meters in AC. However, when connecting to the Badger Meter PFT-4E, we’re encountering inconsistent readings that need to be resolved.
When responding to the post, Provide detailed examples of projects where you’ve successfully troubleshooted inconsistent pulse readings, fine-tuned input filters, or developed autotuning logic for dosing systems. Include the challenges faced, the solutions implemented, and the outcomes achieved.
Primary Task:
Diagnose and Fix Inconsistent Readings: We need a developer to fine-tune the proper input filters or apply other methods to ensure accurate and consistent performance when interfacing the Badger Meter PFT-4E with our Siemens S7-1217 PLCs.
Secondary Task (If Primary Task is Resolved):
Develop Autotuning Logic: We’d like assistance creating logic to autotune the overdosing of our admixtures. Our system does not use analog valves for control (and we have no plans to implement them). Some admixtures pulse at approximately 10 pulses per second, and we need a preemptive solution that trains the system itself to adjust dosing, as our manual reaction time is not fast enough.
Badger Meter PFT-4E Specifications:
Pulse Output: Open-collector NPN transistor (DC current sinking pulse) or switched AC voltage (Triac output).
Maximum Pulse Rate: 10 pulses per second (10 Hz) for AC output; DC output can handle higher rates if scaled.
Pulse Width: Not explicitly specified, but typical for flow meters in this range (e.g., ~50 ms at 10 Hz with 50% duty cycle).
Voltage Compatibility: Supports 24V DC systems (for DC output) or 120V AC (for AC output).
Scaling: Adjustable via internal settings to match the turbo meter’s K-factor (e.g., 17.36 pulses per gallon for a 2-inch turbo meter).
Wiring Configurations:
We have two possible wiring setups for connecting the Badger Meter PFT-4E to the Siemens S7-1217 PLC:
120V AC Configuration:
Pulse from the meter → Weidmuller opto relay (TOS 120VAC/48VDC 0.1A) → PLC high-speed counter capable input.
24V DC Configuration:
Pulse from the meter (open-collector DC output) → Directly to the PLC high-speed counter capable input (e.g., I0.0 on the S7-1217).
The applicant should be comfortable troubleshooting and optimizing either configuration to achieve reliable pulse counting.
Required Skills and Experience:
Extensive Experience with Siemens PLCs: Specifically, the applicant must have hands-on experience with Siemens S7-1217 models.
Expertise in Dosing Systems: We’re seeking someone with a strong background in dosing applications, including troubleshooting and optimization.
Familiarity with Badger Meter Components: Preference will be given to candidates who have worked with Badger Meter flow meters, particularly the PFT-4E, or similar components.
Problem-Solving Skills: Ability to fine-tune input filters or implement alternative methods to ensure reliable pulse counting at frequencies up to 10 Hz.
Wiring Knowledge: Experience with both AC (via opto relays like the Weidmuller TOS 120VAC/48VDC 0.1A) and DC configurations for PLC inputs.
Bonus: Experience developing logic for autotuning dosing systems pulsing at 10 pulses per second.
Key Project Details:
We are using Siemens S7-1217 PLCs exclusively for this system.
Analog valves are not in use, and we will not be adopting them.
The solution must account for admixture pulsing at approximately 10 pulses per second and provide preemptive adjustments due to slow manual reaction times.
The Badger Meter PFT-4E is paired with industrial turbo meters, and the system must handle a maximum pulse rate of 10 Hz in AC mode.
What We’re Looking For:
We need a proactive, experienced professional who can:
Resolve the inconsistent readings from the Badger Meter PFT-4E integration, considering both wiring configurations (120V AC via Weidmuller opto relay or 24V DC direct to PLC).
If successful, collaborate with us to design and implement autotuning logic for admixture overdosing.
When responding to the post, Provide detailed examples of projects where you’ve successfully troubleshooted inconsistent pulse readings, fine-tuned input filters, or developed autotuning logic for dosing systems. Include the challenges faced, the solutions implemented, and the outcomes achieved.
Primary Task:
Diagnose and Fix Inconsistent Readings: We need a developer to fine-tune the proper input filters or apply other methods to ensure accurate and consistent performance when interfacing the Badger Meter PFT-4E with our Siemens S7-1217 PLCs.
Secondary Task (If Primary Task is Resolved):
Develop Autotuning Logic: We’d like assistance creating logic to autotune the overdosing of our admixtures. Our system does not use analog valves for control (and we have no plans to implement them). Some admixtures pulse at approximately 10 pulses per second, and we need a preemptive solution that trains the system itself to adjust dosing, as our manual reaction time is not fast enough.
Badger Meter PFT-4E Specifications:
Pulse Output: Open-collector NPN transistor (DC current sinking pulse) or switched AC voltage (Triac output).
Maximum Pulse Rate: 10 pulses per second (10 Hz) for AC output; DC output can handle higher rates if scaled.
Pulse Width: Not explicitly specified, but typical for flow meters in this range (e.g., ~50 ms at 10 Hz with 50% duty cycle).
Voltage Compatibility: Supports 24V DC systems (for DC output) or 120V AC (for AC output).
Scaling: Adjustable via internal settings to match the turbo meter’s K-factor (e.g., 17.36 pulses per gallon for a 2-inch turbo meter).
Wiring Configurations:
We have two possible wiring setups for connecting the Badger Meter PFT-4E to the Siemens S7-1217 PLC:
120V AC Configuration:
Pulse from the meter → Weidmuller opto relay (TOS 120VAC/48VDC 0.1A) → PLC high-speed counter capable input.
24V DC Configuration:
Pulse from the meter (open-collector DC output) → Directly to the PLC high-speed counter capable input (e.g., I0.0 on the S7-1217).
The applicant should be comfortable troubleshooting and optimizing either configuration to achieve reliable pulse counting.
Required Skills and Experience:
Extensive Experience with Siemens PLCs: Specifically, the applicant must have hands-on experience with Siemens S7-1217 models.
Expertise in Dosing Systems: We’re seeking someone with a strong background in dosing applications, including troubleshooting and optimization.
Familiarity with Badger Meter Components: Preference will be given to candidates who have worked with Badger Meter flow meters, particularly the PFT-4E, or similar components.
Problem-Solving Skills: Ability to fine-tune input filters or implement alternative methods to ensure reliable pulse counting at frequencies up to 10 Hz.
Wiring Knowledge: Experience with both AC (via opto relays like the Weidmuller TOS 120VAC/48VDC 0.1A) and DC configurations for PLC inputs.
Bonus: Experience developing logic for autotuning dosing systems pulsing at 10 pulses per second.
Key Project Details:
We are using Siemens S7-1217 PLCs exclusively for this system.
Analog valves are not in use, and we will not be adopting them.
The solution must account for admixture pulsing at approximately 10 pulses per second and provide preemptive adjustments due to slow manual reaction times.
The Badger Meter PFT-4E is paired with industrial turbo meters, and the system must handle a maximum pulse rate of 10 Hz in AC mode.
What We’re Looking For:
We need a proactive, experienced professional who can:
Resolve the inconsistent readings from the Badger Meter PFT-4E integration, considering both wiring configurations (120V AC via Weidmuller opto relay or 24V DC direct to PLC).
If successful, collaborate with us to design and implement autotuning logic for admixture overdosing.