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Study and understand the bottle filling and filtering process, as well as, the cleaning and sterilizing process for this brewing operation. Study and understand the existing PLC relay ladder program which controlled this operation. Modify the PLC program residing in an Allen Bradley PLC5 to allow the process to run on non-critical error codes and also improve the error code system to better denote process problems to the operators.

Develop masks to hide noncritical faults from the shut down decision. Build a matrix of conditions to be compared against masked data. Implement the manipulation of the new data arranged in the matrix via calls to new sub operations.

The implementation of the masking procedure allowed the process to continue on faults. With this added feature, down time of the filling line was reduced as well as reduced requirements for maintenance people on that line.

Allen Bradley PLC-5