PRESSURE CONTROL

TRAINER

Product Code 314A

(With Ethernet communication)

Instruction manual

Contents
1 Description 4 Installation 7 Warranty
2 Specifications 5 Troubleshooting 8 Experiments
3 Packing slip 6 Components used

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Documents to be referred
Following table lists various documents available in PdcSoft CD which needs to be
referred while working with the product.
File name Document description

314A/Im314A.pdf Product Instruction manual & Experiments

WIN7Ethernet/Software Process Software installation guide
Control.pdf
Documents/Theory Process Describes theoretical aspects of process control
Control.pdf study
Documents/Components.pdf Additional details of the components used

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Description

Pressure control trainer is designed for

I/P Converter
understanding the basic principles of
Air Regulator
pressure control. The process set up
consists of pressure vessel fitted with
Air Supply
pneumatic control valve. Pressure
transmitter is used for pressure sensing. Supply Signal
Pressure Pressure
The process parameter (Pressure) is
controlled by microprocessor based Pressure Controller
digital indicating controller which
manipulates pneumatic control valve Set Point
fitted at outlet of pressure tank outlet Tank
through I/P converter. These units along Pressure

with necessary piping are fitted on Pressure

Vent Valve Transmitter
support housing designed for tabletop
N
mounting.
The controller can be connected to
N
computer through Ethernet port for Air Process Tank Control Valve
monitoring the process in SCADA mode. Supply

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Specifications

Product Pressure control trainer

Product code 314A
Type of control SCADA
Control unit Digital indicating controller with Ethernet
communication, Model UT35, Make Yokogawa
Communication Ethernet
Pressure Transmitter Type Two wire, Range 0–5 bar, Output 4–20 mA,
Make Wika
I/P converter Input 4-20mA, Output 3-15 psig, Make Control Air
Control valve Type: Pneumatic; Size: 1/4", Input: 3–15 psig, Air to
close, Characteristics: linear, Make Pneucon
Process tank Pressure vessel, MS
Air filter regulator Range 0-2.5 kg/cm2
Pressure gauge Range 0-2.5 kg/cm2(1No), Range 0-7 kg/cm2(2Nos),
Make Wika
Overall dimensions 550Wx480Dx525H mm
Optional SCADA software package; Compressor

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Packing slip

Box Size W575xD500xH525 mm; Vol:0.15m3 Gross weight: 34 kg

No.1/1 Net weight:21 kg
1 Set up assembly 1 No
2 Piping set (2 Pieces) 1 No
3 Male stud 2Nos 1 No
4 Communication cable 1 No
5 Tool kit 1 No
6 Set of instruction manuals consisting of: 1 No
“PDCSoft” CD (Apex Innovations)
User’s manual Yokogawa
User’s manual reference CD (Yokogawa)

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Installation requirements

Installation requirements
Electric supply
Provide 230 VAC single phase electric supply with proper earthing. (Neutral – Earth
voltage less than 5 VAC)
 5A, three pin socket with switch (1 No.)
Air supply
Clean, oil and moisture free air, pressure 3 Bar, Air consumption 7.0 m3/hr

Computer
IBM compatible with standard configuration with USB port for Hardware lock.
Operating System Windows 7 formatted for NTFS file system
Support table
Size: 800Wx800Dx750H in mm

Installation
 Unpack the box(es) received and ensure that all material is received as per packing
slip (provided in instruction manual). In case of short supply or breakage contact
Apex Innovations / your supplier for further actions.
 Place the set up on table
 Air supply: Ensure that clean and oil free air is received from compressed air
source (compressor / mini compressor) by venting out the air for few minutes.
Then connect air supply to the set up.

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Front view:

Back view:

Commissioning
 Connect electric supply. Switch on Mains.

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 Switch on the compressed air source and adjust the Air regulator to set supply
air pressure at @ 2 kg/cm^2.
 Set the Digital indicating controller to manual mode by pressing the A/M key
and increase output to 100%
 Open the needle valve at the inlet of the pressure tank and adjust the Pressure
relief valve to 2.5 kg/cm^2.
 Decrease output of controller from 100% to 0% in steps of 25%. Check the
pressure on pressure gauge at the output of I/P converter is varying from 15-3
psig and ensure that control valve operates from full close to full open position.
 Switch on the computer and install the software. (Refer “Software Process
Control”)
 Execute the software and ensure correct signals are displayed on computer.
NOTE: Do not disturb the pressure relief valve once set at 2.5 kg/cm2.

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 Troubleshooting

Note: For component specific problems refer components’ manual

Problems Possible causes / remedies
Control valve does  Valve diaphragm leakage/breakage
not operate  Faulty I/P converter
 No output from Controller
I/P converter does  Insufficient supply air pressure
not work  Faulty electrical input signal
 Clogged orifice
No communication  Check communication settings for IP address (Refer
with computer “Software Process control”)

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 Components used

Components Details
Pressure Transmitter Make Keller, Model 21S, Output 4-20mA(2 wire),
Supply 24VDC, Range 0-2.5 bar, Process conn.
1/4"BSP(male), Accuracy +/-1%
Digital indicating Make Yokogawa, Model UT35A (with Ethernet
controller communication)
I/P converter Make Control air inc, Type T500-AC, Input 4-20 mA
DC, output 3-15 psig, end connection 1/4 NPT
Control valve Control Valve , Make pneucon, Type globe 2 way,Model
119, size 1/2"x1/8", Screwed end(F), Body CCS, Trim
SS, Travel 14.3, CV=0.1, Air to CLOSE, Spring range
0.2-1, actuator 12 sq inch.
Air filter regulator Make Airmatic, Model MB10-021-VD-PAP, Range 0-2
Kg/cm^2, Type Relieving
Pressure relief valve Make Airmatic, Range 0-4 kg/cm^2, ¼” BSP
Pressure gauge Make Wika, Dia.2.5", Gly. filled, Brass internals, S.S.
casing, Range 0-2.5 Kg/cm2, 1/4"BSP (M) back
connection
Pressure gauge Make Wika, Dia.2.5", Gly. filled, Brass internals, S.S.
casing, Range 0-7 Kg/cm2, 1/4"BSP (M) back
connection

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 Warranty
This product is warranted for a period of 12 months from the date of supply against
manufacturing defects. You shall inform us in writing any defect in the system
noticed during the warranty period. On receipt of your written notice, Apex at its
option either repairs or replaces the product if proved to be defective as stated
above. You shall not return any part of the system to us before receiving our
confirmation to this effect.
The foregoing warranty shall not apply to defects resulting from:
Buyer/ User shall not have subjected the system to unauthorized alterations/
additions/ modifications.
Unauthorized use of external software/ interfacing.
Unauthorized maintenance by third party not authorized by Apex.
Improper site utilities and/or maintenance.
We do not take any responsibility for accidental injuries caused while working with
the set up.

Apex Innovations Pvt. Ltd.

E9/1, MIDC, Kupwad, Sangli-416436 (Maharashtra) India
Telefax:0233-2644098, 2644398
Email: support @apexinnovations.co.in Web: www.apexinnovations.co.in

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 Experiments
The experiment nos 1 thr 6 are to get feel of the process and PID settings.
Startup Setup:
 Switch on Mains.
 Switch on the compressed air source and adjust the Air regulator to set supply
air pressure at @ 2 kg/cm^2.
Startup software:
 Click on Start|All programs|Wonderware|InTouch|Yes to open InTouch
Appilcation manager.
 Open “Pressure Control Trainer” under InTouch Appplication Manager
 Click “Ignore” under “WindowMaker” for License not available
 Click “Select All” and “OK” under “Windows to Open”
 Click on “Runtime” at Top Right corner under “Intouch- WindowMaker”
 Click “Ignore” under “WindowViewer” for License not available
 Click “OK” under “ WindowViewer” for Demo mode

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1. Study of open loop response (Manual control)
Procedure
 Startup Setup and Startup software as explained before experiment number1.
 Select open loop Experiment (click on “Change Expt.” Button, click on “Change”,
Click on “Open Loop” button.)
 Close the control valve by increasing the controller output to 100%. Note down
steady state process value.
 Apply the step change by 10% to controller output and wait for the process value
to reach the steady state value. Note down the process value.
 Repeat the above step until the controller output reaches to minimum 0%.

Observations
Tabulate the observations as follows
Controller output in % Process Value in %
100
90
80
…
0

 From the above data, note the output required for maintaining the process at
desired set points. (for particular vent valve opening).
 Set the output of the controller to the noted value and at steady state apply the
load change to the process. Load change can be given by slightly varying the vent
valve. Observe new steady state process value.

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2. Study of on/off controller
Procedure
 Startup Setup and Startup software as explained before experiment number1.
 Select “On-Off mode” option for the control from software. (click on “Change
Expt.” Button, click on “Change”, Click on “On-Off mode” button.)
 Change Hystresis value to 1%.(Range 0.1-10%)
 Change the values of the set point and observe the On-Off control operation.

Observations
 Observe that if process value exceeds the set point and increases above the value
of (0.5x Hysteresis), control valve is full open and if process value decreases
below the set point by (0.5 x Hysteresis), the control valve closes fully i.e.
controller operates like On/Off switch.

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3. Study of proportional controller
Procedure
 Startup Setup and Startup software as explained before experiment number1.
 Select P Mode option for control from software. (click on “Change Expt.” Button,
click on “Change”, Click on “P Mode” button.)
 Keep the set point to 60%. Change output mode to Manual. Adjust output value
so as to match the process value with set point and apply this output value as
bias value to the controller. Adjust the proportional band to 50%.
 Switch the controller to Auto mode.
 Apply step change of 10% to set point and observe the response.
 Switch the controller to Manual mode. Decrease proportional band to half of the
previous value & then shift controller to Auto mode. With each decrease, obtain a
new response of the step change. Ensure that the set point changes are around
the same operating point (@ 5-10% only).
 Using trial and error approach, find a value of proportional band so that the
response to a step change has at most one overshoot and one undershoot.
 Set the controller to the settings obtained in the above step and wait for the
system to reach at steady state.

Observations
 Observe steady state error decreases as proportional band decreases.
 Observe the effect of very low proportional band values (system works in
oscillatory mode).
 Observe the response of the system at load change. Load change can be given by
slightly manipulating the vent valve of the tank.
 Study of proportional integral controller

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4. Study of proportional integral controller
Procedure
 Startup Setup and Startup software as explained before experiment number1.
 Select PI Mode option for control from software. (click on “Change Expt.” Button,
click on “Change”, Click on “PI Mode” button.)
 Adjust the process value by changing the output of controller in manual mode to
a particular pressure (set point =60%).
 Set the proportional band estimated from Proportional control (from previous
experiment). Start with derivative time=0 and integral time=1000 sec., which will
cut off the derivative action and widen the effect of integral action.
 Set the set point to desired pressure (@60%). Allow the process to reach at
steady state. Record the steady state error.
 Switch on the controller to manual mode. Reduce the integral time to half of the
previous value. Switch to Auto mode and apply step change to the set point by 2
to 3%. Note the response of the system.
 Using trial and error, find out an integral time, which gives satisfactory response
to the step change in set point.

Observations
 Observe the effect of reducing integral time on offset and on the response of the
process.

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5. Study of proportional derivative controller
Procedure
 Startup Setup and Startup software as explained before experiment number1.
 Initialize Modbus communication on the computer i.e.Start| All programs |
Wonderware FactorySite | IO Servers | Modicon MODBUS
 Execute Programs | Wonderware | InTouch for Pressure control. Select All in
Windows to open and Click “Runtime”.
 Select PD Mode option for control from software. (Click on “Change Expt.”
Button, click on “Change”, Click on “PD Mode” button.)
 Select PD controller. Set the proportional band estimated from Proportional
control (P only). Start with derivative time=0 and integral time=6000 sec., which
will cut off the derivative action and widen the effect of integral action.
 Set the set point to desired pressure (@60%). Allow the process to reach at
steady state. Note the response of the system.
 Switch on the controller to manual mode. Increase the derivative time by 1 sec.
Switch to Auto mode and apply step change to the set point by 2 to 3%. Note the
response of the system.
 Increase the derivative time gradually and observe the process response for step
change.

Observations
 Observe the effect of increasing derivative time. Also note that the process may
show offset as effect of integral action is cut off.

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6. Study of proportional integral derivative controller
Procedure
 Startup Setup and Startup software as explained before experiment number1.
 Select PID Mode option for control from software. (click on “Change Expt.”
Button, click on “Change”, Click on “PID Mode” button.)
 Switch the controller to manual mode.
 Change the proportional band to the value that estimated in proportional
controller. Set integral time and derivative time based on the responses in
previous experiments.
 Change the controller to Auto mode. Apply step change by 2 to 3% to the set
point and observe the response of the process.
 Change the proportional band, integral time, derivative time and observe the
response of the process for step change for each change in setting.

Observations
 Compare the steady state response of the PID controller with P, PI and PD
controller obtained in the previous experiments.

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7. Tuning of controller (Open loop method)
Procedure
 Startup Setup and Startup software as explained before experiment number1.
 Select Process Reaction option for control from software. (Click on “Change
Expt.” Button, click on “Change”, Click on “Process Reaction” button.)
 Adjust controller output, so that the process value is maintained at 60%.
 Start data logging.
 With the controller still in manual mode impose a step change apply a 20 - 30 %
change to controller output. (Open the control valve) Record the step response.
Wait for the steady state.
 Stop data logging.
 Plot the step response (Process reaction curve) from stored data. Find out the
value of slope at the point of inflection and time lag.
 Calculate P I D settings for different modes.
 Select PID Mode option for control from software. (Click on “Change Expt.”
Button, click on “Change”, Click on “PID Mode” button.) Switch on the controller
to manual mode and Keep the set point to 60%. Adjust output value so as to
match the process value to set point.
 Set the PID values obtained from the calculations. Switch on the controller to
Auto mode. Apply the step change & observe the response of the system. Allow
the system to reach steady state.

Observations
(Refer Theory process control for formula.)
 Step change to the system P = Initial output - Final output of the controller.
 Plot the graph of process value Vs Time on a graph paper.
 From process reaction curve:
Slope of the process reaction curve R =
Time lag L=
 Calculate P, PI, PID setting from above values.
 Observe response of the system for different PID settings.

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8. Tuning of controller (Closed loop method)
Procedure
 Startup Setup and Startup software as explained before experiment number1.
 Select Close Loop option for control from software. (Click on “Change Expt.”
Button, click on “Change”, Click on “Close Loop” button.)
 Set the proportional band value to maximum (Say 100). Set the controller to
manual mode and adjust the output so that the process is nearly at set point
(60%).
 Set controller to auto mode and impose step on the process by moving the set
point for a few seconds & then return to its original value (or apply the step
change to the set point of 5%). Wait for some time & observe the response.
 Decrease the proportional band to the half of previous and impose step on the
process as mentioned above. Wait for some time & observe the response.
 Repeat the above procedure and find out correct value of proportional band for
which the system just goes unstable i.e. continuous oscillations are observed in
the output of controller.
 Record the ultimate proportional band and ultimate period from the response.
 Calculate the PID values from the table. Select the PID controller and apply the
parameter values obtained from the above steps. Observe the response of the
process to a step change with these settings.

Observations
 Record the ultimate proportional band (Pbu) and ultimate period (Tu) from above
experiment.
 Calculate PID values by referring theory part for different control actions.
 Observe the process response for these settings.
 Compare the values obtained with open loop response method.

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9. Tuning of controller (Using Auto Tuning method)
Procedure
 Startup Setup and Startup software as explained before experiment number1.
 Select Autotune option for control from software. (Click on “Change Expt.”
Button, click on “Change”, Click on “Autotune” button.)
 Wait Till Autotune is complete. (Blinking of green LED stops).
 Controller automatically finds the PB, IT & DT values.
 Find out PID values at different set points /vent valve positions rates.

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10. To study stability of the system (Bode plot)
Procedure
 Startup Setup and Startup software as explained before experiment number1.
 Select Stability analysis option for control from software. (Click on “Change
Expt.” Button, click on “Change”, Click on “Stability analysis” button.)
 Select function generator to apply the sinusoidal input to the output of the
controller.
 Enter Reference point, Amplitude and Period.
 Observe the sinusoidal output of the controller and sinusoidal response of the
process.
 Log the data for records.
 Change the period and repeat the observation for 3-4 different values of the
period.

Observations
 Form the data file stored note down the
 Observe the output response of the process and note down the output amplitude.
Measure output wave period and note down as T sec. Measure the phase lag x
and note down in sec.
Obs. Input Output Output Lag X Frequency
No. amplitude amplitude Period In sec
A1 % A2 % T in sec

Calculations
 Calculate for each observation
Magnitude ratio as M = A2/A1
Phase angle = (X/T) x 360
Frequency = 1/T cycles / sec.
 Draw the graphs of:
Magnitude Vs frequency on log - log scale
Phase angle Vs frequency on semi-log coordinates.
 Study the graph for stability conditions mentioned in theory.

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