Depending on the process requirement, different levels of control are also addressed - using different devices such as Industrial Process Controllers and PLCs. Whilst addressing some aspects of advanced control theory, this range of products is designed to present the subject with a practical ‘hands on’ approach. Process Control is a fundamental engineering discipline which needs to be studied in many institutions. Clean process fluids of water or air used by appropriate trainers Features
Process Control Level & Flow Process Control Temperature Process Control Level, Flow & Temperature Process Control Pressure Process Control pH Process Control Distributed Control Industrial Process Control PID Control Process Instrumentation Fault Finding Refrigeration & Air Conditioning Process Control Features Ideally suited for Technician and Vocational courses Extendable to cover more complex process control problems Covers a wide range of competencies Industrially relevant processes & components Compact bench-top systems Clean process fluids of water or air used by appropriate trainers Process Control is a fundamental engineering discipline which needs to be studied in many institutions. Process Control depends upon measurement - requiring a detailed under- standing of the relevance, accuracy and different techniques which may be used and applied in open and closed loop systems. The requirement for Process Control is evident not only to maintain quality and efficiency, but also to conserve energy and materials. There are many different processes which need to be controlled including level, flow, temperature, pressure, pH, etc. All these and many more processes can be found in industries such as Petrochemical, Chemical, Pharmaceutical, Brewing, Water and Foods etc. Whilst addressing some aspects of advanced control theory, this range of products is designed to present the subject with a practical ‘hands on’ approach. Depending on the process requirement, different levels of control are also addressed - using different devices such as Industrial Process Controllers and PLCs. Process Control with Feedback’s products involves a wide range of equipment from computer based trainers using industrial control, to conventional fault finding and measurement in order to deliver training applicable to process industries from refrigeration maintenance, to the ‘state of the art’ technology used in oil and gas refining.
Transcript
Process ControlLevel & Flow ProcessControl
Temperature ProcessControl
Level, Flow & TemperatureProcess Control
Pressure Process Control
pH Process Control
Distributed Control
Industrial Process Control
PID Control
Process Instrumentation
Fault Finding
Refrigeration & AirConditioning
Process Control
Features
Ideally suited for Technicianand Vocational courses
Extendable to cover morecomplex process controlproblems
Covers a wide range ofcompetencies
Industrially relevantprocesses & components
Compact bench-topsystems
Clean process fluids ofwater or air used byappropriate trainers
Process Control is a fundamental engineering discipline which needs to bestudied in many institutions.
Process Control depends upon measurement - requiring a detailed under-standing of the relevance, accuracy and different techniques which may beused and applied in open and closed loop systems.
The requirement for Process Control is evident not only to maintain qualityand efficiency, but also to conserve energy and materials. There are manydifferent processes which need to be controlled including level, flow,temperature, pressure, pH, etc. All these and many more processes can befound in industries such as Petrochemical, Chemical, Pharmaceutical,Brewing, Water and Foods etc.
Whilst addressing some aspects of advanced control theory, this range ofproducts is designed to present the subject with a practical ‘hands on’approach.
Depending on the process requirement, different levels of control are alsoaddressed - using different devices such as Industrial Process Controllersand PLCs.
Process Control with Feedback’s products involves a wide range of equipmentfrom computer based trainers using industrial control, to conventional faultfinding and measurement in order to deliver training applicable to processindustries from refrigeration maintenance, to the ‘state of the art’ technologyused in oil and gas refining.
Features
Trainers for Level and Flow,Temperature, Pressure andpH
Uses industry standardProcess Controller, 4-20mAsignals and RS232/RS485serial communication bus
High degree of modularity -easily reconfigurable usingmodern push fittings
Discovery Software
Fully protected by earthleakage circuit breaker
A range of Industrial Process Control Trainers supplied with computer basedlearning material.“Discovery” Software provides real-time control of the processes, on-screensimulation of process monitoring with animated mimic screens, together withtheory, simulation, background information and questions. The free movementbetween screens allows a user-friendly graphical interface. Systems may beconfigured for the study of Level and Flow, Temperature, Pressure and pHcontrol, using a series of units including Process Rigs, Valves, Interfaces,Controllers and a variety of Sensors that measure the process variables.
Software
Procon 38 Series - Process Control
System Benefits
Complete with on-screencourseware, instructionand questions
Provides all required virtualinstrumentation with uniqueDiscovery Software
Introduction to Procon
System interconnections above
Theory -Cycling method of tuning
Three-term controller PID
Discovery Tools 93-400
Software
FeaturesEnables the creation andoverlaying of diagramsUses Microsoft Visio or‘Winwiz’ to to edit diagramsEnables the creation & editingof patching layoutsExisting assignments modifiedor developed new withAssignment BuilderAssignment functionalitycontrolled by AssignmentBuilderAssignments selected andallocated using LaboratoryArchitectScreen presentation modifiedwith Laboratory Architect
Discovery Tools allow full editing of supplied material, together with thecreation of new content and additional assignments.
Modified block diagramusing ‘Winwiz’ andMicrosoft Visio software.In Edit mode, Visio is usedto produce the background(JPG) and Winwiz allowschanges to the monitoringpoints and to thetest probe positions.
Typical Discovery assign-ment with the ‘Tools’ Editmode selected. MicrosoftWord is the default editor.
The look and feel of theuser screens can bepersonalised usingLaboratory Architect andthe ‘skin’ edit file.
Course PresenterProvides students with the means of selecting acourse by name from a list, as in this case AnalogueSignals.
Assignment Buildercontrols assignmentfunctionality, testequipment, test probes,monitor point mappingand board firmware.
Typical assignment patch-ing layout ‘Winwiz’ is usedto modify patching connec-tions (drag & drop) and todraw new connections usingseparate connections.
Laboratory Architect allowsthe tutor to select whichassignments the usermay access.
Discovery Course Manager consists of two sub software applications -Course Designer and Course Presenter.
Discovery Course Manager 93-410
FeaturesProvides tutors with simplecreation or modification ofcoursesIncludes Course Designer forcustomising coursesIncludes Course Presenter -the student interface thatdelivers the coursesAllows Discovery productassignments to be mixedCan be used with a networkby using a shared drive
Course DesignerResources that may be added are: - Documents likeWord or Excel, html or pdf format, multimedia materialand third party programs. Web urls, or locations onlocal intranets. The course window can have severalpages for different sections of a course, such assessions or modules.
External resources folderscan be easily created &resources may then be addedto a folder. Once added, aresource can be used in anynumber of courses.
BenefitsCustomised courses can becreatedAssignments from differentDiscovery products can beintegratedOutside resources can beincluded in the courses-video,audio, additional information etc.
The resulting course window contains resourcesorganised in pages. Clicking on a resource such asVideo Clip or Audio Clip etc. launches it.
Level/Flow Process Control 38-001
The Level/Flow Process Trainer is a single loop system allowing the study ofthe principles of process control, using liquid level and flow rates as themeasured process variables. The system is a completely self-contained, lowpressure flowing water circuit supported on a benchtop-mounted panel, makingit suitable for individual student work or for group demonstrations.
It comprises a dual compartment process tank,linked to a sump tank by manual and solenoidoperated valves. Water is pumped through thesystem, via a variable area flow meter andmotorised control valve. Level is measured inthe process tank. Flow is measured throughan optical pulse flowmeter.The PC Computer & Monitor are not supplied.
Process Interface 38-200The Process Interface is connected tothe system and provides all necessarypower outlets for the Process Trainer,sensors and Process Controller. Itaccepts up to four 4-20mA transmittersignal inputs and allows signal patchingso that different control schemes can bequickly configured. It also provides a4-20mA current source, two current tovoltage converters and a voltage compar-ator with adjustable hysteresis which canbe used to provide a simple 2-statecontrol loop in addition to the maincontroller loop. Protection is providedby a residual current circuit breaker.
Process Controller 38-300The ABB Industrial Process Controllercontained within the Process Controller ismicroprocessor based and is easily con-figured by the user to provide a range ofcontrol functions from 2-state controlto 3-term PID control. It also featureslocal or remote set-point, re-transmissionof set-point or process variable, 4 logicinputs, 4 relay outputs, ramp/soak (profilesequencing) and an autotune facilitywhich can analyse the requirements ofa process and configure the controlparameters for optimum performance.Together with the Process Interface,it provides a simple and convenientmeans of controlling the system.
Required Equipment - supplied with all Procon Training Systems
System with Proportional Control
Procon Level/Flow &Temperature
FeaturesContains a selection of leveland flow sensors & indicators
Flow controlled by linearmotorised control valve
On/Off and proportionalcontrol
P, PI and full PID control withautotune facility
Couples with TemperatureTrainer for dual loop control
Modern push fittings
Water used as the processfluid
Comprehensive lab notesand Discovery Software
Curriculum Coverage
Flow & Level familiarisationand calibration
Interface familiarisation andcalibration
Controller familiarisation andcalibration
Float level transmitter
Pulse flow transmitter
On-Off control
Study of P, PI and PID controlof Level and Flow
Tuning PID controllers
Advanced process control
Process Controller (top) withProcess Interface
Temperature Process Control 38-002
The Temperature Training System is a two loop system, using water as theprocess fluid which allows the study of the principles of process control usingprimary and secondary circuit temperatures as the process variables to becontrolled.Both circuits pass through the heat exchanger and the secondary circuit containsa fan-assisted cooling radiator. Thermistor temperature sensors are located in theinlet and outlet streams of both primary and secondary sides of the heatexchanger and the outlet of the radiator. The primary flow is also monitored.The Trainer can be used with a cold mains water supply through the AuxiliaryTemperature Control Pack 38-480 which is supplied as part of the system.This comprises a motorised control valve, a flow meter and a signal conditioningunit. Alternatively the Temperature Trainer can be connected to the Level & FlowProcess Trainer, which then supplies the cold water circuit. This combinationallows more complex control systems to be investigated.A Forced Air Cooler 38-610 is also available (see overleaf). It accelerates theprocess dynamics using a constant input temperature, allowing a hightemperature differential to be monitored for longer periods.Please note, the PC Computer & Monitor are not supplied with the system.When using either 38-002 and 38-610 with 110V or 120V 50/60Hz supplies,please see note on back page.
Procon Temperature
Features
Temperature monitored inprimary & secondary circuits,flow also monitored
P, PI and PID control withautotune facility
Primary circuit flow controlledby motorised control valve
Primary circuit heater andpump
Secondary circuit fan-assistedcooling radiator
Modern push fittings
Water used as the processfluid.
Operates from mains watersupply using water pressureregulator 38-481
Curriculum Coverage
Temperature familiarisationand calibration
Interface familiarisation andcalibration
Controller familiarisation andcalibration
Pulse flow transmitter
On-Off control
Study of P, PI and PID controlof Temperature and Flow
Manual flow control
Temperature process control
Complex control loops
Dual loop (process) control -using Level/Flow andTemperature Trainers:
Remote Set Point Control
Set Point Ratio Control
Cascade Control
Feedforward Control
Features
Maintains constanttemperature for fluid input
Maintains constanttemperature for fluid input
Enables quick response timesin temperature reduction
Variable speed fan
Variable speed pump
Curriculum Coverage
Familiarisation
Use as a manually controlledcooler
Temperature control by varyingfan speed
Temperature control by varyingpump speed
Temperature control by varyingsecondary flow
Forced Air Cooler 38-610
Optional Equipment for Temperature Process Control 38-002 & 38-003This equipment is designed to be used with the Temperature Trainer, or betweenthe Temperature and Level and Flow Trainers to maintain a constant fluid inputtemperature.
The 38-610 Forced Air Cooling Unit is designed to extend the operating rangeof the Feedback Temperature Control Rig and allow the direct control of itsoperating characteristics.
The 38-610 consists of an electric pump and a fan and radiator unit to cool thecirculating water. The Unit may be initially charged through the header tankwhich should be kept topped up to avoid ingress of air.
There are two signals which may be applied for controlling the degree of cooling.The speed of the fan may be controlled by submitting a 4-20mA current into thetop DIN socket of the control section. The speed of the pump may be similarlyvaried by inputting a 4-20mA signal through the separate adjacent DIN socket.The speed of the pump and fan are then controlled via phase controlled circuitrytaking as its input the 4-20mA signal. Alternatively the fan and the pump maybe set to continuous for full speed operation.
Optional Accessory: Water Pressure Regulator 38-481(required for direct mains operation)
Procon Temperature
FeaturesContains a selection of levelflow and temperature sensorsand indicators
Primary and secondary flowcontrolled by linear motorisedcontrol valves
On/Off and proportionalcontrol
P, PI and full PID control withautotune facility
Can perform dual loopcascade control
Modern push fittings
Water used as the processfluid
Comprehensive lab notesand Discovery Software
Procon Level/Flow &Temperature
Level/Flow & Temperature Process Control 38-003
Curriculum Coverage
Flow and Level familiarisationand calibration
Interface familiarisation andcalibration
Controller familiarisationand calibration
Float level transmitter
Pulse flow transmitter
On-Off control
Study of P, PI and PID controlof Level and Flow
Tuning PID controllers
Advanced process control
Temperature familiarisationand calibration
Interface familiarisation andcalibration
Controller familiarisation andcalibration
Pulse flow transmitter
On-Off control
Study of P, PI and PID controlof Temperature and Flow
Manual flow control
Temperature process control
Complex control loops
Dual loop (process) control -using Level/Flow andTemperature Trainers:
Remote Set Point ControlSet Point Ratio ControlCascade ControlFeedforward Control
Remote set-point facility covering:Setting-up a primary andsecondary controllerSet-point Ratio Control (dualloop)Cascade Control (temperatureand flow)Feedforward Control (flow & flow)
The combined PROCON Level/Flow and Temperature ProcessControl System is self-contained and has all of the features of the individualLevel/Flow and Temperature systems plus Remote Set Point Control.
Remote Set-Point Control can be affected with the PROCON Level/Flow andTemperature Process Control System by using two Process Controllers.The 4-20mA Analogue Remote Set-Point input allows various forms of cascadecontrol to be implemented between linked or interactive control loops.
The process set-point can be Local and Remote or Dual, selected from the frontpanel, or in response to a logic input. When Dual Set-Point is selected thefunction can be ratio or bias action.
A Programmable Logic Controller (PLC) 38-350 is also available. It can be usedwith the Process Interface 38-200 to provide an alternative control method withon/off elements to the standard Process Controller 38-300.
For operation with 110V or 120V 50/60Hz supplies, please see note on back page.
Heat exchange theory
The Pressure Training System is a single loop pneumatic control system.It enables the study of the principles of both pressure regulation of a processand the control of flow in a pressurised system.
The System comprises a low pressure air circuit supported on a panel for useon a benchtop, making it suitable for individual student work or for groupdemonstration.
The Pressure Trainer requires a compressed air supply at a recommendedinput pressure of 40psi. An input filter/drier is used to clean the supplied air.Separately regulated branches provide air for the process and for valve control.
The process branch comprises a regulator, a variable area flow meter, apneumatically operated control valve, an orifice block with changeable orificeplates and both differential and point of measure pressure sensors. The processair flow can be discharged to atmosphere via adjustable diffused outlets.
An air receiver tank can be switched in and out of the circuit. The valve controlbranch comprises a regulator and an electrically operated current to pressureinput converter. This is used to regulate the pneumatic control valve in theprocess line.
The input converter operates from a 4-20mA signal.
Signal conditioning for the sensors is provided by pressure transmitters.The Differential Pressure Transmitter gives a linear differential pressure sensoroutput.
The system is fully equipped with pressure gauges to indicate the pressuresaround the system.
Please note, the PC Computer & Monitor are not supplied with the system.
Optional Accessory: Air Compressor 38-820
Pressure Process Control 38-004
Procon Pressure
Curriculum CoveragePressure safety, familiarisa-tion and calibration
I/P converter and Pneumaticcontrol valve operation
Pneumatic control valve -characteristics at differentpressure ranges
System response and Airreceiver
Principles of Proportioningvalve and proportionalprocess control
Study of P, PI and PID controlof Pressure
Calibration of the differentialpressure sensor & transmitter
Flow control in the Processrig
Features
Safe low pressure operation
Fully gauged for pressureand flow rate
Differential and Gaugepressure sensors
Current controlled (4-20mA)pneumatically operatedcontrol valve
Standard industrialcomponents
Self-sealing outlets formanometer
Safety valves fitted asstandard
Air used as the process fluid
Procon pH
Curriculum Coverage
Introduction, familiarisationand calibration of the pH rig
Interface familiarisationand calibration
Controller familiarisationand calibration
Valve characteristics
Manual control of pH
Open loop response
On/off control of pH
Simple proportional control
Effect of proportional band
Study of proportional andintegral control
Study of proportional andderivative control
Study of proportional, integraland derivative control
Features
All components resistant toagressive fluids
Motorised agitator
Removable pH probe
Industry standard 4-20mAcontrol signals
A precision motorised controlvalve
Four tanks
Modern push fittings
Comprehensive lab notesand Discovery Software
pH Process Control 38-005
The pH Training System is based around the pH Rig and is a self-containededucational platform for teaching pH control.
The System comprises two independently pumped fluid circuits mounted ona robust panel for use on a bench top which allows the study of the principlesof process control using the pH of the mixed effluent and reagent fluids as theprocess variable. The system is suitable for individual student work or forgroup demonstrations.
Effluent and reagent are contained in separate holding tanks prior to beingpumped into the reaction tank where mixing is carried out.
The reaction tank contains an accurate pH probe and agitator. The agitatoris designed to constantly mix the contents of the reaction tank. The pH probeis designed to monitor the pH level of the effluent/reagent mixture and issupplied with a transmitter which produces a standard 4-20mA output signal.
The signal is passed to the Process Controller as the process variable.A precision, motorised control valve is present in the reagent feed to allowaccurate delivery control. The valve is designed to be controlled by standard4-20mA control signals. Total effluent and reagent fluid shut-off capability isprovided by two normally-closed solenoid valves.
A treated fluid tank is provided to facilitate easy disposal of the process fluid.All components have been carefully selected to be resistant to aggressivefluids.
Recommended chemical solutions (customer supplied)Reagent tank: Hydrochloric Acid at 0.05 Mole.Effluent tank: Sodium Hydroxide at 0.05 Mole.
Please note, the PC Computer & Monitor are not supplied with the system.
Distributed Control System 38-009
Process Control
The Feedback Distributed Control System (DCS) trainer is a complete trainingsolution that combines the operations of a leading commercial DCS processmanagement package, namely Emerson’s DeltaV, with an assortment of ourproprietary training rigs.
The training rigs offer a range of processes:
Level and FlowTemperaturePressureForced Air Cooling
These may be operated separately or combined to produce a multi- process,multi-loop system.
The trainer is supplied complete with the PC, software, controller and I/Omodules that are needed to monitor and control the process rigs.
A control cabinet houses the components that provide the interface betweenthe PC and the rigs. The control cabinet is easily connected to the PC and rigsusing the supplied cables.
The valves, transducers and transmitters associated with the training equipmentare standard industrial components that operate using simple 4–20 mA currentloop control, and 24V dc.
The trainer can be used to perform a set of operations that will guide the studentfrom the basics of field components in the process industry to the final controlalgorithms that are used in various applications.
FeaturesTotally self-contained withall power supplies and fluidsources
Industrial control devicesand sensors
PC programmable devices
4-20mA Current Loops
Practicals (hands-onexperience) within eachassignment
Fully developed curriculum
General instructions on howto operate the system
Objectives for eachassignment with suggestionsfor conducting experiments
A graphical user interface
DistributedControl System
(DCS)
Temperature RigLevel & Flow Rig
Pressure Rig Forced Air Cooler
Process Control
Distributed Control System (DCS) Trainer 38-306
The Emerson Delta V Controller contains the following:
1 x Controller
1 x System Power Supply (ac/dc)
2-Wide Power/Controller Carrier
8-Wide I/O Interface Carrier with Carrier Shield Bar
2 x Analog Input Cards: 8 Channels
1 x Analog Output Card: 8 Channels
1 x Discrete Input Card: 8 Channels
1 x Discrete Output Card: 8 Channels
Termination Blocks for each I/O card
FeaturesThe system has the followinggeneral features:
A Windows-based Workstationthat provides a Graphical UserInterface to the processes andSystem configuration functions
The DCS is controlled by anEmerson DeltaV IndustrialControl system
The system includes a PCwith speakers to providegraphical and audible alarms
Allows both continuous andsequential control of theprocesses
Uses Industry-standard4-20mA signals
16 Analogue and 8 Discrete(Digital) inputs
8 Analogue and 8 Discrete(Digital) outputs
Uses a simple interconnectsystem to ease installationand system configuration
The system displays graphicalrepresentations of the testrigs to mimic the processesand to simulate anindustrial environment
The system has two modes:“Design” and “Run”. It ispossible to switch easilybetween these two modes
The Controller and interfacesystem are housed in anindustrial 19” rack
The software provides anintegrated SCADA Environmentwith I/O tags held in a database
The system has a DCS learningenvironment which providesa range of experiments whichhave theory and practicalelements
Process Instrumentation Trainer 38-025
Process Instrumentation
Curriculum Coverage
4-20mA Current Loops
4-20mA Programmable display
Capacitive Level Sensorand Transmitter
Temperature Sensors andTransmitter
Flow Meter and Pulse FlowSensor
Introduction to Control Valves
Pressure Devices
Current to Pressure (I-P)Converter
The Orifice Block
Universal Transmitter
Process Controller
Features
Totally self-contained withall power supplies and fluidsources
Industrial control devicesand sensors
PC programmable devices
Modular and versatile
Allows calibration & testingof process transmitters
4-20mA Current Loops
Mobile wheeled trolley
Fully developed curriculum
PID Controller
Modern process devices are becoming increasinglycomplex and functionally very powerful.
To introduce students to these devices and give them experience in the selectionand utilisation of them Feedback has designed this Process InstrumentationTrainer.
The sensors, actuators and PC programmable devices are all typical industrialunits. The training system has been specifically designed to give studentshands-on experience of setting-up, calibration and use of such devices.
The knowledge gained through the studies of these devices is extended to theirapplication in process control through the use of a dual PID controller 38-541-PC.One of the main features of the controller is that it operates with a PC andprovides system graphing functions, such that responses to system disturbancesand parameter changes can be observed. Data from the system responses,parameter settings etc., is available for export to spreadsheet programs.
Based on a mobile trolley that incorporates all electrical, water (including a waterheater) and air controls, the system provides a totally self-contained unit.
The punched front panel provides a construction area that allows devices to befixed to it via a series of keyhole slots. The instrumentation devices are mountedon robust carriers that allow them to be located and locked onto the front panel.
Optional Accessory: Air Compressor 38-540-AC
For operation with 110V or 120V 50/60Hz supplies, please see note on back page.
Process Controller38-541-PC
Features
A practical process inminiature
Closed and open-loopcontinuous control as wellas two-step control
Fast response times
Thermal time constants andtime transport lag
Easy-to-read metering
TemperatureProcess Control
Process Control Trainer 37-100
Curriculum Coverage
Distance/Velocity Lag
Transfer Lag
Calibration
Two-step Control
Proportional Control
System Response
Frequency Response
The Process Control Trainer comprises a heating element controlled by athyristor circuit which feeds heat into an airstream circulated by an axial fanalong a polypropylene tube. A thermistor detector, which may be placed atone of three points along the tube length, senses the temperature at that point.
The volume of air flow is controlled by varying the speed of the fan via apotentiometer. A change in setting represents a supply side disturbanceand the effects are easily demonstrated.
The detector output is amplified to provide both an indication of the measuredtemperature and a feedback signal for comparison with a set value derivedfrom a separate control. A comparison of these signals generates a deviationsignal which is applied to the heater control circuit such that the controlledcondition is maintained at the desired value. Two step (ON/OFF) andProportional band control is standard.
An external controller is available to enable the operation of compound controlto be investigated. The three term controller module PID150Y providesvariable controls for adjustment of proportional, integral and derivative terms.
An external ±15V, 100mA power supply is required for the PID150Y module.
Capable of being externallycontrolled using ProcessControllers and PLCs
Self contained process
Wide range of easy to applyfaults
Mechanical, electrical & elec-tronic faults can be applied
Fully protected for safety
Comprehensive Instructor’sand Student’s Manuals
Industrial ProcessTrainer
The Industrial Process Trainer has been designed to teach a methodicalapproach to fault diagnosis in industrial processes. The methodologies taughtwithin the system are equally relevant to any student or trainee studying faultdiagnosis.
Faults can be introduced by the instructor via switches concealed behind a lockedcompartment, to which the student does not have access. These switches provideboth short circuits and open circuits and can also switch in or out circuit elementsto simulate a variety of fault conditions. Additional faults can be inserted intothe process through the replacement of working components with faulty ones,e.g. faulty flow switches; faulty relays; faulty solenoid coils and faulty controlvalve electronic circuit board.
The process involves initially filling a header tank with water and then cyclingthe level between a set upper and lower limit, whilst simultaneously creating ademand from the header tank via two on/off solenoid drain valves into a sumptank. Flow is produced by a pump and controlled by relay operated on/offsolenoid valves which control:
the inflow of water to the header tank from the sump tankthe outflow of water from the header tank to the sump tank
The level of water in the header tank is monitored by float switches which openand close at the following points:
Header tank low (nearly empty)Header tank normal operation lower limitHeader tank normal operation upper limitHeader tank overflow
Designed for students studying industrial process maintenance, it can also beused as a process trainer in its own right, using either Industrial ProcessControllers or Programmable Logic Controllers (PLCs).
A PLC interface board 34-252-1 is available for users to develop their ownPLC programs.
Curriculum Coverage
Introduction to the system
Fault finding methodologies
Fault analysis flow charts
Fault finding from circuitdiagrams
Fault identification to LineReplaceable Unit level
Simple electronic faultfinding
Diagnostic tools
Maintenance procedures
Process control techniques
Fault finding processescontrolled from electroniccontrollers
Interfacing to ProgrammableLogic Controllers (PLCs)
Features
A complete ready to usetraining package
Fault diagnosis by logicalelimination
Actual faults produced andnot simulated
Designed for fail-safe operation
Uses environmentally friendlyR134a refrigerant
Fully documented assignments
Refrigeration &Air-conditioning
Curriculum Coverage
Unit performance andoperation
Normal and abnormaloperating pressures
Refrigerant changes of state
Compressor testing andoverhaul
Thermostatic expansion valves
Removal of system contami-nation and plant charging
Electrical components andcontrols
Air conditioning applications
Refrigeration & Air-conditioning Trainer 39-103
This self-contained refrigeration unit uses industrial standard components.The design allows practical instruction to be given on methods of identifyingand correcting faults in industrial systems, in exactly the same way asexperienced in field service conditions.
The system consists of a mobile, floor-standing process unit comprising atwin cylinder semi-hermetic compressor, finned-tube condenser with fan,liquid receiver and forced air evaporator. The Trainer uses environmentallyfriendly R134a refrigerant.
All the above are mounted on a common base-plate for easy access.
Ancillary Equipment
Refrigeration Servicing Package 39-203The Refrigeration Servicing Package contains the additional specialist toolsand measuring instruments required for servicing work on the Air-conditioningtrainer.
Leak Detector 39-202This hand-held leak detector combines high sensitivity to a wide range ofrefrigerations, CFC, HCFC and HFC, with proven reliability. It provides auseful aid to any refrigeration and air-conditioning training programme.Note: The Leak Detector is included in 39-203.
Forced Air Cooler (for use with Procon Temperature 38-002 & 38-003) 38-610
Air Compressor (for use with Procon Pressure 38-004) 38-820
Water Pressure Regulator (for use with Procon Temperature 38-002 & 38-003) 38-481
Air Compressor (for 38 -025) 38 -540 -AC
Proportional, Integral and Derivative Unit (for use with 37 -100) PID150Y
Industrial Process Trainer PLC Interface 34 -252 -1
Refrigeration Servicing Package (for use with the 39 -103) 39 -203
Refrigeration Leak Detector (for use with 39 -103 & included with 39-203) 39 -202
Function Generator FG601
Electronic Wattmeter EW1604
A PC compatible computer with a RS232 interface is required to run the PROCONTrainers and is not supplied with any of the systems.
**
*
* Note: The Process Instrumentation Trainer, 38-025, Temperature Rig, 38-600and Forced Air Cooler, 38-610 operate from 230V ac 50/60Hz supplies. Where110V or 120V ac single supplies exist, an autotransformer is required or theunit can be connected to two phases of a three phase supply producing anominal 230V ac. The 38-025 and 38-600 require supplies with a rating of3kVA minimum whilst the 38-610 requires 250VA.
