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Need help designing a PLC for this agitator / reactor tank process below. Need ladder diagram if anyone is able to do so. Thanks! 1.

Need help designing a PLC for this agitator / reactor tank process below. Need ladder diagram if anyone is able to do so. Thanks!

1. There are two ingredients (A and B) that will be mixed in the reactor tank. Wait for READY signal to be on (when on, it signifies that QA Tank is ready for this batch).

2. To add the fixed amount of ingredient A to the mixing tank, VALVE_A needs to be on. To add the fixed amount of ingredient B to the mixing tank, VALVE_B needs to be on. Both VALVE_A and VALVE_B will be turned on for 10 seconds, then they need to be turned off automatically.

3. When material A is ready to be added, PULSE_A will be on. When material B is ready to be added, PULSE_B will be on. If the PULSE_A for material A (or PULSE_B for material B) is off, the material A cannot be added to the mixing tank even the VALVE_A is turned on.

4. After the materials are fed into the mixing tank, agitate and mix the materials at a high speed (500 rpm) by turning on the motor AGIT_ON_HS for 20 seconds.

5. After that, the agitate motor is then switch for a lower speed (200 rpm) by turning on the motor AGIT_ON_LS for 30 seconds.

6. Once the ingredients A and B are fully mixed at the mixing tank, a HEATER is turned on to raise the temperature. Once the target temperature is reached, a temperature sensor TEMP is used to turn of the heater. At this stage, the temperature of the tank should be kept at 100oC, within +/- 5 oC. A set temperature sensor TEMP is used to detect if the set temperature range is maintained or not. The temperature sensor TEMP is ON if the temperature is maintained within the range of the set temperature 100oC, within +/- 5 oC; otherwise the sensor TEMP is OFF. During this process, if the temperature drops, the heater HEATER should be turned on automatically till the target temperature is reached, while the process continues.

7. After the preset temperature (100oC, within +/- 5 oC) is reached, the ingredient will be kept in the mixing tank for another 40 seconds for agitate.

8. After the agitation and heating, the ingredient is then dumped into the QA Tank by turning on VALVE_OUT for 15 seconds. Once the dump process is completed, a sensor PULSE_OUT will become on.

9. Once all the ingredient has been fully dumped into the QA Tank, the QA Tank will be shipped out by executing a process QA_OUT. The QA_OUT process takes 20 seconds to complete the process.

10. Once the new QA Tank is in position again, the READY signal will be on and the system is ready for next cycle.

11. For every twelve completed finish product QA Tanks shipped out, a quality control sampling process QC_SAMPLE is automatically activated for 20 seconds.

12. For safety measurement, an emergency stop EMERGENCY is added in the system in case of safety emergency.

13. A pilot green light GL1 is turned ON when the QA Tank is in position and ready for the cycle to start.

14. A pilot yellow light YL2 is turned ON to indicate the mixed motor either AGIT_ON_HS or AGIT_ON_LS is on.

15. A pilot red light RL3 is turned ON to indicate the HEATER is turned ON.

16. A pilot blue light BL4 is turned ON when the quality control sampling process QC_SAMPLE is ben activated.

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