Industrial Process Control Trainers with Discovery software PROCON PROCESS CONTROL TRAINERS

Transcription

1 SYSTEMS Edition 1 I 38S-1 PROCON PROCESS CONTROL TRAINERS Industria Process Contro Trainers with Discovery software Leve & Fow Contro Temperature Contro Pressure Contro SYSTEMS-1 1

2 Temperature Rig Basic Process Rig Pressure Rig Temperature Auxiiary Contro Pack Temperature Sensor Pack Leve Sensor Pack Fow Sensor Pack Pressure Sensor Pack Process Interface Digita Dispay Modue Process Controer Programmabe Logic Controer Data Acquisition Unit RS232 ink Computer + Discovery software packs The Product Range 2 SYSTEMS-1

3 Features Rigs for Leve & Fow, Temperature and Pressure contro. Uses industry standard Process Controer. Uses industry standard 4-20mA signas. Uses industry standard RS485 Seria Communications Bus. High degree of moduarity - easiy reconfigurabe. Discovery software. Fuy protected by Earth Leakage Circuit Breaker. Description The PROCON range of Industria Process Contro Trainers is based on a series of interchangeabe units which aows a buiding bock approach to be adopted. Each Trainer comprises a Process Rig, a Process Interface, a Process Controer and various Sensors. Bench-mounted Process Rigs for Leve and Fow, Temperature and Pressure are offered and each has sensors to measure process variabes. Each sensor is avaiabe as part of a Sensor Pack which incudes a sma transmitter modue. This arrangement iustrates common industria practice, where the transmitter is mounted cose to its sensor and provides a standard 4-20mA output signa. The Process Interface is common to each system. It provides a the necessary power outets for a Process Rig and a interconnections between the sensors and a controer. It forms the centra modue of any system. The Process Controer houses an ABB Kent-Tayor Commander 300 Industria Process Controer which is micro-processor based and easiy configured by the user to provide a range of contro functions from simpe 2-state contro to fu 3- term PID contro. It aso features an autotune faciity which can anayse the requirements of a process and configure contro for optimum performance. A Controer functions can aso be driven from a PC via a standard RS232/ 485 seria ink and the unique Discovery Computer Aided Learning software environment provides rea-time on-screen process monitoring with animated mimic screens and a virtua chart-recorder, together with theory, background information and questions. Optiona additions to the systems incude a Programmabe Logic Controer and a Data Acquisition Unit. These aow the extension of the work possibe on the Process Rigs to incude adder ogic and programming, the deveopment of advanced contro agorithms and the use of advanced process contro techniques such as Fuzzy Logic and Neura Networks to contro the Rigs. The Rigs may be operated separatey, either with or without Discovery software, or the Leve & Fow Rig (the Basic Process Rig) may be connected to the Temperature Rig to form a Dua Loop system. SYSTEMS-1 3

4 PROCON Leve/Fow Process Contro System Features Sef-contained benchtop system. Water used as the process fuid. Contains a seection of eve and fow sensors and indicators. Discovery software provides on-screen instruction and instrumentation. Fow controed by unique ineary profied motorised gate vave. Robust centrifuga pump deivers 5 itre/min. On/Off and proportiona contro. P, PI and fu PID contro with autotune faciity. May be couped to the Temperature Rig for dua oop contro. Description The PROCON Leve/Fow Process Contro System is based around the PROCON Basic Process Rig. This is a singe oop system, using water as the process fuid, which aows study of the principes of process contro using iquid eve and fow rates as the process variabes to be controed. This Contro System incudes: Basic Process Rig. Process Interface. Process Controer. Leve Sensor Pack. Fow Sensor Pack. Digita Dispay Modue. Discovery Software. The system consists of a competey sefcontained, ow pressure fowing water circuit supported on a bench-mounted pane, making it suitabe for individua student work or for group demonstration. The circuit incudes: Sump Tank. Dua-compartment Process Tank. Circuating Pump. Visua indication Fow Meter. Motorised inear fow Gate Vave. 3 Soenoid operated vaves. 4 Manua vaves. Puse fow sensor. Potentiometer Foat eve sensor. On/Off Foat eve switch. 4 SYSTEMS -1

5 The Process Interface is connected to the Basic Process Rig and provides a of the necessary power outets for the Rig, its sensors and the Process Controer. It aso has 4-20mA inputs, a 4-20mA current source, current-to-votage converters and a votage comparator with variabe hysteresis. Protection is provided by a residua current circuit breaker. The Process Controer houses an industry standard ABB Kent-Tayor Commander 300 controer and provides a the input and output faciities required for controing the Rig. It is fuy compatibe with the Process Interface and together they provide a simpe and convenient means of eectricay configuring the system. In combination with the hardware, the Discovery Software provided with the system forms an innovative and motivating deivery method, which enabes a wide range of assignments to be carried out. Background theory, equipment connection and eectrica patching, practica contro, instructions and questions, together with PC-based instrumentation, integrated into the Discovery deivery system, suppy a the instruction and measurement requirements of the assignments. Assignments The Discovery Software assignments provided with the PROCON Leve/Fow Process Contro System are: Introduction to PROCON Fow/Leve Rig Famiiarisation The Centrifuga Pump. The Manua Vaves and the Fow Gauge. The Servo Vave. The Soenoid Vaves. Fow/Leve Rig Caibration A Leve-Voume Correspondence. Fow Meter Caibration. Servo Vave Caibration. Soenoid Vave Caibration. Interface Famiiarisation Circuit Breaker & Circuit Loop Connections. The Servo Vave. The Current-Votage Converters. Interface Caibration Current Source Caibration. Controer Famiiarisation Seria Communication. Navigating the Controer. Using the Controer. Controer Caibration Controer Caibration. Controer Reays. Reading the Controer. Foat Leve Transmitter The Foat Leve Transmitter (FLT). Caibrating the FLT. A Leve Contro Demonstration. Puse Fow Transmitter The Puse Fow Transmitter (PFT). Caibrating the PFT. A Fow Contro Demonstration. On/Off Contro On/Off Pump Contro. On/Off Soenoid Contro. The Foat Switch. Controer On/Off Contro. Proportiona Contro: Leve Simuation. Proportiona Contro of Leve. Proportiona Contro and Offset. Proportiona Band. Proportiona Contro: Fow Servo Proportiona Contro. Proportiona Contro Offset. PI & PID: Leve Contro PI Contro of Leve. Limitations of PI Contro. PID Contro of Leve. PI &PID: Fow Contro PI Contro of Fow. PID Contro of Fow. Tuning PID Controers Zeiger-Nichos Tuning. Sef-Tuning. Process Controer: Advanced Remote Set-Point. Profie Programming. Time Proportioned Output. SYSTEMS -1 5

6 PROCON Temperature Process Contro System Features Dua-circuit benchtop system. Water used as the process fuid. Can be operated from mains water suppy or connected to the PROCON Leve/ Fow Process Contro System. Temperature monitored by five sensors in primary and secondary circuits. Fow aso monitored. Discovery software provides on-screen instruction and instrumentation. Primary circuit fow controed by motorised gate vave. Primary circuit heater and pump. Secondary circuit fan-assisted cooing radiator. P, PI and fu PID contro with autotune faciity. May be couped to the Leve/Fow Rig for dua oop contro. Description The PROCON Temperature Process Contro System is based around the PROCON Temperature Process Rig. This is a two oop system, using water as the process fuid, which aows study of the principes of process contro using primary and secondary circuit temperatures as the process variabes to be controed. This Contro System incudes: Temperature Process Rig. Process Interface. Process Controer. Temperature Sensor Pack. Auxiiary Temperature Contro Pack. Digita Dispay Modue. Discovery Software. The Temperature Process Rig consists of a dua oop, ow pressure, fowing water circuit supported on a bench-mounted pane, making it suitabe for individua student work or for group demonstration. 6 SYSTEMS -1

7 The System incudes: Cosed primary hot water circuit. Eectrica heater. Heat exchanger. 2 Motorised fow vaves. Puse fow sensor. 5 Thermistor temperature sensors. Fan-assisted cooing radiator. Signa conditioning units. The primary circuit oop incudes a heat exchanger through which hot water from an eectricay heated reservoir is continuousy circuated. The secondary circuit aso passes through the heat exchanger and contains a fan-assisted cooing radiator. Thermocoupe temperature sensors are ocated in the inet and outet streams of the heat exchanger. The primary fow rate is aso monitored. The PROCON Temperature Process Contro System may be used on its own, suppied by a cod mains water suppy through the Auxiiary Temperature Contro Pack. This comprises a motorised vave, a fow meter and a signa conditioning unit. Aternativey, the PROCON Temperature Process Contro System may be connected to the Basic Process Rig, which then suppies the cod water circuit. With this combination of rigs more compex contro systems may be investigated. The Process Interface and Process Controer are identica to those used in the PROCON Leve/Fow Process Contro System. Assignments Discovery Software, simiar to that with the PROCON Leve/Fow Process Contro System, is provided and the assignments that can be performed are: Introduction to PROCON Fow/Leve Rig Famiiarisation The Centrifuga Pump. The Manua Vaves and the Fow Gauge. The Servo Vave. The Soenoid Vaves. Fow/Leve Rig Caibration A Leve-Voume Correspondence. Fow Meter Caibration. Servo Vave Caibration. Soenoid Vave Caibration. Interface Famiiarisation Circuit Breaker & Circuit Loop Connections. The Servo Vave. The Current-Votage Converters. Interface Caibration Current Source Caibration. Controer Famiiarisation Seria Communication. Navigating the Controer. Using the Controer. Controer Caibration Controer Caibration. Controer Reays. Reading the Controer. Puse Fow Transmitter The Puse Fow Transmitter (PFT). Caibrating the PFT. A Fow Contro Demonstration. Proportiona Contro: Fow Servo Proportiona Contro. Proportiona Contro Offset. PI &PID: Fow Contro PI Contro of Fow. PID Contro of Fow. Temperature Rig Initiaisation Caibration of the Thermistor Temperature Transmitter. Thermistors. Beeding the Secondary Fow. Temperature Rig Famiiarisation On/Off Heater Contro. Operation of the Heat Exchanger. Operation of the Cooer. Manua Fow contro Simuation. Primary Fow Contro. Secondary Fow Contro. Temperature Process Contro Singe Loop Contro. Industria Process Contro. Automatic On/Off Contro. P, PI, PID Temperature Contro Proportiona Contro of Temperature. PI Contro of Temperature. PID Contro of Temperature. Compex Contro Loops Fow Ratio Contro. Dua Loop Temperature and Fow Contro. Dua Loop Temperature and Leve Contro. SYSTEMS -1 7

8 PROCON Leve/Fow and Temperature Process Contro System Features The combined PROCON Leve/Fow and Temperature Process Contro System has a of the features of the individua Leve/Fow and Temperature systems PLUS: Remote Set Point Contro. Set Point Ratio Contro (Dua Loop). Cascade Contro. Feed-forward Contro. This Contro System incudes: Basic Process Rig. Temperature Process Rig. 2 Process Interfaces. 2 Process Controers. Leve Sensor Pack. 2 Fow Sensor Packs. Temperature Sensor Pack. 2 Digita Dispay Modues. Discovery Software. Assignments The fu set of assignments associated with both the Leve/Fow and the Temperature Process Contro Systems can be performed. In addition the work may be extended with investigations in Remote Set Point Contro, Set Point Ratio Contro (Dua Loop), Cascade Contro and Feed-forward Contro. Remote Set-Point Contro Remote Set-Point Contro can be achieved with the PROCON Leve/Fow and Temperature Process Contro System by using the two Process Controers suppied. The 4-20mA anaogue Remote Set-Point input aows various forms of cascade contro to be impemented between inked or interactive contro oops. The process set-point can be Loca and Remote or Dua, seected from the front pane, or in response to a ogic input. When Dua Set-Point is seected the function can be ratio or bias action. The Remote Set-Point faciity provides the means to study the foowing subject areas: Setting up a primary and secondary controer. Set-point ratio contro (Dua Loop). Cascade Contro (Temperature and Fow). Feed-forward Contro (Fow and Fow). 8 SYSTEMS -1

9 Three schematic diagrams showing how PROCON can be used in experimenta set-ups. 1. Set-point ratio contro (Dua Loop) 2. Cascade Contro (Temperature Contro) 3. Feed-forward Contro (Fow and Fow) SYSTEMS-1 9

10 PROCON Pressure Process Contro System Features Benchtop system. Air used as the process fuid. Fuy gauged for pressure and fow rate. Differentia and gauge Pressure Sensors. Pneumaticay operated contro vave. Standard industria components. The PROCON Pressure Process Contro System is a singe oop pneumatic contro system which aows study of the principes of process contro pressure as the process variabe to be controed. This Contro System incudes: Pressure Process Rig. Process Interface. Process Controer. Pressure Sensor Pack. Digita Dispay Modue. Discovery Software. The Pressure Process Rig consists of a ow pressure air circuit supported on a benchmounted pane, making it suitabe for individua student work or for group demonstration. The circuit incudes: Input suppy fiter/drier. Input converter. Pneumaticay operated contro vave. 2 Reguators. 4 Manua vaves. 6 Gauges. Sight fow meter. Orifice Bock with changeabe Orifice Pates. Differentia Pressure Sensor. Process Pressure Sensor. 27 itre Air Receiver Tank. 20psi Safety Reief Vave. Diffusers. The Pressure Process Rig is suppied with compressed air at a recommended input pressure of 40psi. An input fiter/drier is used to cean the suppied air. Separate reguated branches provide air for the process and for vave contro. The process branch comprises a reguator, a pneumaticay operated contro vave, an orifice bock with changeabe orifice diameters and differentia and process pressure sensors. The process air fow can be discharged to atmosphere via diffusers, or to the air receiver tank. The vave contro branch comprises a reguator and an eectricay operated current to pressure 10 SYSTEMS -1

11 input converter which feeds the contro input of the contro vave. The input converter operates with 4-20mA current. Signa conditioning for the sensors is provided by pressure transmitters. The Differentia Pressure Transmitter incudes a square root extractor circuit to inearise the differentia pressure sensor output. The system is fuy equipped with pressure gauges to indicate the pressures around the system. The Process Interface and Process Controer are identica to those used in the PROCON Leve/Fow Process and Temperature Process Contro Systems. Assignments Discovery Software, simiar to that for the other PROCON Process Contro Systems, is provided and the assignments that can be performed are: Introduction to PROCON Pressure Rig Famiiarisation The Input Converter. The Pneumatic Contro Vave. The Pressure Sensors and Gauges. The Air Receiver. Pressure Rig Caibration Pressure Sensor Caibration. Differentia Pressure Sensor Caibration. Input Converter Caibration. Pneumatic Contro Vave Caibration. Interface Famiiarisation Circuit Breaker & Circuit Loop Connections. The Input Converter. The Current-Votage Converters. Interface Caibration Current Source Caibration. Controer Famiiarisation Seria Communication. Navigating the Controer. Using the Controer. Controer Caibration Controer Caibration. Controer Reays. Reading the Controer. Differentia Pressure Transmitter The Differentia Pressure Transmitter (DPT). Caibrating the DPT. The Square Root Extractor. A Fow Contro Demonstration. Manua Contro Operation of Pneumatic Contro Vave. System Response without Air Receiver. System Response with Air Receiver. Proportiona Contro: Pressure Proportiona Contro of Pressure. Proportiona Contro and Offset. Proportiona Band. Proportiona Contro: Fow Proportiona Contro of Fow. Proportiona Contro and Offset. Proportiona Band. PI & PID: Pressure Contro PI Contro of Pressure. Limitations of PI Contro. PID Contro of Leve. PI & PID: Fow Contro PI Contro of Fow. PID Contro of Fow. Tuning PID Controers Zeiger-Nichos Tuning. Sef-Tuning. Pressure Transmitter The Pressure Transmitter (PT). Caibrating the PT. A Pressure Contro Demonstration. Process Controer: Advanced Remote Set-Point. Profie Programming. Time Proportiona Output. SYSTEMS-1 11

12 Additiona Option Programmabe Logic Controer Features Stand-aone PLC or fuy compatibe with PROCON equipment range. Uses Industria Standard PLC unit. Housed in sturdy meta case. A connections brought out to 4mm sockets. Power suppy incuded. Compete with input simuator bank, variabe 4-20mA current source, current to votage converters and a votage comparator. PLC unit can be programmed in Instruction List or Ladder Logic formats. Suppied with PC-based software for program deveopment. Introductory tutoria guide to PLCs. Hand-hed programmer avaiabe as an option. Description The Programmabe Logic Controer is a fuy functioning industria PLC unit housed in a rugged meta case with a connections brought out to 4mm sockets. The unit is capabe of operating with 24V or 5V ogic signas and can aso accept 4-20mA current oop inputs via the current to votage converters and the votage comparator. A variabe 4-20mA current source with adjustabe span and zero is aso provided. The votage comparator has a variabe hysteresis setting to aow the PLC to contro anaogue events. The Controer is fuy compatibe with the PROCON range of Process Contro Rigs and controers. Program Deveopment Software The unit is suppied with a PC-based program deveopment environment which aows programs to be created in either Instruction ist or Ladder ogic formats. Once deveoped the programs are downoaded to the PLC for execution. The soft-ware has a monitoring faciity which aows the status of the various PLC registers to be dispayed on the PC as the program is running. Programs are stored in an EEPROM in the PLC unit so the program is retained when the unit is switched off. The PLC unit aso has an externay adjustabe timer which, together with the variabe hysteresis contro, is very usefu for contro appications. Appication When used in conjunction with a Process Controer, it is possibe to use the Programmabe Logic Controer with any of the processes incorporating on/off contro eements. The user may create sequences using conventiona adder ogic and demonstrate the programming on the controer itsef, without a process actuay being connected. Together with a Process Rig, Process Interface and Process Controer the foowing subject areas may be studied: Production of Ladder Logic Diagrams for sequence contro and evauation using manua switches and LED s. Sensing and Sequencing contro of the foowing: Basic Process Rig: Contro of the Water Pump. Contro Soenoid Vaves. Basic Process Rig with the Leve Sensor Pack: Sensing the eve in the Process Tank. Contro of the Water Pump. Contro of Soenoid Vaves. Temperature Process Rig: Sensing Temperature. Contro of the Heater. Contro of the Circuating Pump. 12 SYSTEMS -1

13 Additiona Option Data Acquisition Unit Features Fuy featured. Microprocessor based. Inteigent signa conditioning. Spreadsheet pus specia functions. 3 anaogue inputs. 2 digita inputs. 2 anaogue outputs. 2 digita outputs. RS232/485 seria interface. Aows advanced contro methods to be impemented. Description The Data Acquisition Unit gives users the abiity to extend investigations to incude their own contro agorithms, as we as enabing more extensive data capture and instrumentation. At the heart of the Unit is an industria, microprocessor-based, inteigent signa conditioning unit which aows the coection and processing of both anaogue and digita inputs, together with the generation of anaogue and digita outputs. The Unit has 3 anaogue and 2 digita input channes with 2 anaogue and 2 digita output channes. The Data Acquisition Unit is programmed using a PC via its seria interface. Software, manua and seria ead are suppied with the Unit. The software has a fu-featured spread-sheet within it and using standard spreadsheet functions and added specia functions it is possibe to design a vast range of input/output functions for both anaogue and digita signas and a mixture of both. Communications with the PC is by standard RS232 seria ink. An RS485 option is avaiabe. Additiona D-type sockets are provided for mutidrop connection of Process Controers and PLC s for muti-oop distributed process contro. A minimum configuration of one sensor input and a 4-20mA output wi provide users with the abiity to create their own contro agorithms in software and use the PC as a controer. Advanced process contro techniques such as Fuzzy Logic and Neura Networks may be used to contro PROCON systems. The specia functions incude: Outputing anaogue vaues. Interrogating the anaogue inputs. Inputting and outputting digita signas in a variety of formats. A PID function to form 2 standard PID oops. A range of timer functions. PWM output production. Integration of anaogue inputs. A puse function to produce puses in conjunction with the integrator. Setting maximum rate of change of a variabe. Interpoation to produce ook-up tabes. A sampe function. Scaing and cipping. A dispay function. SYSTEMS-1 13

14 PROCON Tender Specifications PROCON Leve/Fow Process Contro System PROCON Temperature Process Contro System PROCON Leve/Fow and Temperature Process Contro System PROCON Pressure Process Contro System Programmabe Logic Controer Data Acquisition Unit A sef-contained, benchtop mounted, Leve and Fow Process Contro trainer using water as the process fuid. The system to contain a Basic Process Rig, a Process Interface, an industry standard Process Controer and Leve and Fow Sensors and Transmitters producing 4-20mA signas. The system to operate with computer aided aboratory software which provides on-screen instruction, contro and instrumentation. Sixteen computer-based assignments are to be provided with the system. A sef-contained, benchtop mounted, Temperature Process Contro trainer using water as the process fuid. The system to contain a Temperature Process Rig, a Process Interface, an industry standard Process Controer and Temperature and Fow Sensors and Transmitters producing 4-20mA signas. The system to operate with computer aided aboratory software which provides on-screen instruction, contro and instrumentation. Sixteen computer-based assignments are to be provided with the system. A sef-contained, benchtop mounted, Leve/Fow and Temperature Process Contro trainer using water as the process fuid. The system to contain a Basic Process Rig, a Temperature Process Rig, two Process Interfaces, two industry standard Process Controers and Leve, Fow and Temperature Sensors and Transmitters producing 4-20mA signas. The system to operate with computer aided aboratory software which provides on-screen instruction, contro and instrumentation. Twenty two computer-based assignments are to be provided with the system. A sef-contained, benchtop mounted, Pressure Process Contro trainer using air as the process fuid. The system to contain a Pressure Process Rig, a Process Interface, an industry standard Process Controer and Pressure Sensors and Transmitters producing 4-20mA signas. The system to operate with computer aided aboratory software which provides on-screen instruction, contro and instrumentation. Sixteen computer-based assignments are to be provided with the system. A stand-aone, robusty packaged unit which is fuy compatibe with the Leve, Fow, Temperature and Pressure Process Contro Systems. The Controer to incude power suppy and use an industria standard PLC unit. To be programmed in Instruction List or Ladder Logic formats and suppied with PC-based software for program deveopment. The Controer to operate with 5V and 24V ogic signas and 4-20mA current oops. A 4-20mA current source with adjustabe span and zero is aso to be incuded. A fuy featured, microprocessor based, inteigent signa conditioning Data Acquisition Unit which is stand-aone and fuy compatibe with the Leve, Fow, Temperature and Pressure Process Contro Systems. To incude 3 anaogue and 2 digita input channes with 2 anaogue and 2 digita output channes. To be suppied with PC based software with both standard spreadsheet and specia contro functions to enabe contro agorithm impementation and advanced process contro techniques. 14 SYSTEMS -1

15 PROCON Process Contro Trainer Product Numbers Listed beow are the product numbers of the constituent parts of the four Process Contro Systems. Each of the systems may be ordered compete, using the composite order numbers given in the heading of the reevant section. However, if you aready have a compatibe controer, interface or measuring equipment you may not need a of the equipment in the systems. In such cases you may order just the equipment that you do require. Pease contact either your oca agent, or Feedback, if you require more information. Equipment in PROCON Leve/Fow Process Contro System Composite Basic Process Rig Process Interface Process Controer Leve Sensor Pack Fow Sensor Pack Digita Dispay Modue Discovery Software Pack Equipment in PROCON Temperature Process Contro System Composite Temperature Process Rig Process Interface Process Controer Temperature Sensor Pack Auxiiary Contro Pack Digita Dispay Modue Discovery Software Pack Equipment in PROCON Leve/Fow and Temperature Process Contro System Composite Basic Process Rig Temperature Process Rig Process Interface (2 off) Process Controer (2 off) Leve Sensor Pack Fow Sensor Pack Temperature Sensor Pack Digita Dispay Modue (2 off) Discovery Software Pack Equipment in PROCON Pressure Process Contro System Composite Pressure Process Rig Process Interface Process Controer Pressure Sensor Pack Digita Dispay Modue Discovery Software Pack Optiona Equipment Programmabe Logic Controer Data Acquisition Unit SYSTEMS-1 15

16 Ordering Information To order any of the PROCON Process Contro Systems simpy quote the tite and number of the System, as given at the start of each section. For further information on these and other equipment in the Contro & Instrumentation range contact Park Road, Crowborough, East Sussex, TN6 2QR, Engand. Teephone: +44(0) Fax: +44 (0) E-mai: Website: Feedback reserves the right to change these specifications without notice. Registered in Engand number A subsidiary of Feedback pc. 16 SYSTEMS -1 Contro & Instrumentaton - I 38-1 Printed in Engand by FI Ltd, Crowborough 0396