Operating Manual

Controlled Air Mass and Temperature System with Actuators and Sensors LTR701 08 70 100

Please read the operating instructions thoroughly before using this device. The guarantee and the manufacturers possible liability does not cover defects which are caused by non-observance of these instructions. If this device is passed on to others, than this manual must be, too.

All rights reserved, particularly translations, reprinting and any kind of photomechanical reproduction. 2002 ELWE-Lehrsysteme GmbH, Elwestrae 6, D - 38162 Cremlingen / Schandelah Tel. (05306) 930-0 Fax (05306) 930-210 Printed in Germany by ELWE - Lehrsysteme GmbH

GB
61 08 001.2 18/02

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Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

Operating Manual

Contents
1. 2. 3. 4. 5. 6. 6.1. 6.2. 6.3. 6.4. 6.5. 7. 8. 9. 10. 11. 12. Safety Instructions Specifications Brief description Use as intended Operational controls and their functions Putting into operation Unpacking and setting up Switching on Special safety devices Menu structure (LC display) Description of the RS232 format for the LTR701 Maintenance Care Technical data for the sensors, actuators, signal inputs and outputs Block diagram RS232 interface DAC98 connection page 3 page 4 page 4 page 5 page 5 page 6 pages 6, 7 page 7 page 7 page 7 page 9 page 13 page 13 page 14 page 17 page 19 page 19

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Operating Manual

Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

1.

Safety Instructions

The device must not be put into operation if

it shows any visible damage. it has been dropped. the casing cover is missing. the cable is damaged.

The device must not be used

in damp or wet locations. in locations containing flammable gases, vapours or dust. in hazardous locations.

Avoid
impact, shock and vibration. touching the device and its operational controls with wet hands. the ingress of liquids. overloads and short circuits. heat accumulation due to covered ventilation slots and indicator lamps fire hazard! opening the device when it is connected to power. contacting live parts. touching hot or rotating parts.

Make sure that

a residual-current device has been connected in series the device will only be cleaned when it is off-circuit. only original spare parts are used if repair work has to be carried out.

Only use
plug-in connections with protection against electric shock. undamaged experimental cables. shock-proof equipment.

Electrical working and repairs must only be carried out by our service team or by an authorized
electrical expert.

Changes to the circuit or of any other kind are not permitted.

The ELWE equipment, systems and installations correspond to the harmonised or national standards EN-61010-1, EN-60204 and DIN VDE 0789 depending on the determined use.The protection requirements specified by the law of electromagnetic compatibility (EMC) are fulfilled by the requirements of the harmonised standards EN-50081, EN-50082 and EN-55011. The operator of experimental set-ups is responsible for observing the protection requirements specified by the EMC law. The experiments must be conducted by skilled teachers and trainers.

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Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

Operating Manual

2.

Specifications
230 V 50 ... 60 Hz 100 W 500 VA 0.1 A, slow 0.4 A, slow 2 A, slow Thermostatic switch: 140 C 790 x 260 x 375 14 kg

System voltage: System frequency: Power input of the electronic components: Power input of the heating: Fuse (primary) for the electronic components: Fuse (primary) for the ventilator: Fuse (primary) for the heating: Overheating protection: Dimensions (L x W x H) in mm: Mass:

Inputs: Actuator 1 Actuating signal for ventilator speed: 0 ... 10 V and 4 ... 20 mA Actuator 2 Actuating signal for heater output: 0 ... 10 V and 4 ... 20 mA The actuators can also be manually activated with a rotary adjuster. Outputs: Sensor 1 Throttle angle: Sensor 2 Temperature: Sensor 3 Temperature: Sensor 4 Pressure: Sensor 5 Air mass: PC connection: 0 ... 10 V 0 ... 10 V 0 ... 10 V 0 ... 10 V 0 ... 10 V and 4 ... 20 mA and 4 ... 20 mA and 4 ... 20 mA and 4 ... 20 mA and 4 ... 20 mA

RS232 (serial), 9-pin Sub-D socket

All specifications are subject to change. The specified dimensions and the mass are approximate values.

3.

Brief description

The Controlled Air Mass and Temperature System LTR701 with 5 analog output variables (flow rate, 2 x temperature, pressure and throttle position) and two input variables (ventilator speed and heater output) allows you to determine the features of controlled systems with the controlled variables of temperature, flow rate and pressure and to examine the performance of various controller configurations. When external controllers (industrial controllers or a PC with an appropriate interface) are connected, the following control loop configurations can be set up with the Controlled Air mass and Temperature System LTR701: Simple control loops with: Air mass control, with an uncontrolled air temperature. Air temperature control affecting the heater output, with an uncontrolled air mass. Air temperature control affecting the air mass, with an uncontrolled heater output. Cascade control with: Air temperature as the controlled variable, air mass as the secondary controlled variable adjusted by the heater output. Air temperature as the controlled variable, air mass as the secondary controlled variable adjusted by the heater output. Multi-variable control system: Two independent air mass and temperature control loops, which can be decoupled.

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Operating Manual

Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

4.

Use as intended

The laboratory test LTR701 can be used in experimental set-ups in the field of control engineering for instructions and professional training as described in the operating instructions. The experiments and exercises must correspond to the relevant regulations and must be permanently supervised by authorised teachers and trainers.

5.

Operational controls and their functions

Front panel

Equipment
1 2 3 4 5 6 LC graphic display Adjuster Adjuster Sensor 1 Actuator 1 Actuator 2 Sensor 2 Sensor connection Type K Sensor 3 Sensor connection Type K Sensor 4 Sensor 5 Pushbutton

Function
Display of the operating parameters and values Contrast Select Throttle valve position Ventilator speed Heater output See para. 6.4 description of the menu structure Contrast settings on the LCD Selection of the menu items Measured-value acquisition with the output signal 0 ... 10 V or 4 ... 20 mA Control input with input signal 0 ... 10 V or 4 ... 20 mA Control input with input signal 0 ... 10 V or 4 ... 20 mA Measured-value acquisition with the output signal 0 ... 10 V or 4 ... 20 mA Measured-value acquisition with the output signal 0 ... 10 V or 4 ... 20 mA Measured-value acquisition with the output signal 0 ... 10 V or 4 ... 20 mA Measured-value acquisition with the output signal 0 ... 10 V or 4 ... 20 mA

Temperature

Temperature

9 10 11

Pressure Air mass meter Enter

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Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

Operating Manual

Sensor-actuator unit
12 13 14 15 16

17 20

18

19

Equipment
12 13 14 15 16 Rotary adjuster Air inlet Measuring tube Sensor inputs Air mass meter

Function
Throttle position

Controlled system Temperature sensor type K see Specifications

Optional
17 18 19 20 Ventilator Operators panel and electronic analysis unit Rocker switch Sub-D socket, 9-pin Power ON/OFF switch RS232 interface on the side on the rear

6.
6.1

Putting into operation

Unpacking and setting up Unpacking

When the Controlled Air mass and Temperature System LTR701is unpacked, all the parts must be checked for damage (visual inspection) or completeness (according to the confirmation of order and the delivery note). Immediately report possible damage in transit to the transport company and to us. Late complaints cannot be accepted for compensation.

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Operating Manual

Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

Setting up Before setting up the equipment, please check if your system supplies a voltage of 230 V / 50 60 Hz. When choosing the location for your equipment, observe the following points: Select a location where the equipment is not subject to varying outside temperature. Especially avoid direct sun light and direct heat, e.g. from a heater, because this may have an effect on the measured values and controlled variables. When operated, the input and output air flow must not be disturbed (e.g. by covering it with a hand) in order not to affect the measured values and controlled variables.

6.2

Switching on

The equipment is switched on with the rocker switch (19) on the right side. When switched on, the equipment conducts a self test and initialises itself. When the initialisation phase is terminated, the equipment can be operated according to the required control-loop design. With the aid of the LC display you can read the basic settings and the actual measured values and change the parameter settings for the controlled system (also see paragraph 6.4). The two actuators ventilator speed and heating power can be manually selected with the rotary switch (see para. 6.4 for conditions). The actuator variables can also be changed in the off position via the signal levels (0 10 V or 4 20 mA) which are connected to 4-mm safety sockets. The standardised measured values for the sensors run to 4-mm safety sockets.

6.3

Special safety devices

The heater is protected against overheating by means of a thermostatic switch ( = 140 C). In addition, the current flow is monitored. The heater can only be operated when 10% of the ventilator power has been reached. When the ventilator power is less than 10%, the heater switched off.

Warning! The casing of the controlled system and the air flowing out can get hot. Do not touch it when the system is in use.

6.4

Menu structure (LC display)

When the controlled air mass and temperature system is switched on, the following message is displayed on the monitor:

Zukunft durch Ausbildung LTR 701 0870100 ELWE Lehrsysteme GmbH Elwestr.6 38162 Cremlingen www.elwe.com Only use under supervision 529151A0 V0.46 18.12.2001

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Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

Operating Manual

At this point the value for the pressure sensor signal is measured and stored as an (analog) reference point (zero). Later on the measured value is subtracted from the test results to compensate for the varying air pressure and a drift over time of the pressure sensor. Press the Enter button to change to the operating mode Bar graph. In this mode the operator controls on the front panel of the equipment for the motor and heating power are active. When a valid RS232 string is received (see Description of the RS232 Format), the control is transferred to the RS232 interface. When the transfer is cancelled, the last values for the motor and heating power remain valid. The control can only be retransferred to the operator controls on the front panel when valid RS232 strings have not been received for a while and after switching into the main menu and back to Bar graph mode. The main menu contains the following items: Screen normal/invers Brightness Bargraph 2 channel y/t writer Temperature range 0..100 C Temperature range 20..120 C Speaker on/off

With Screen normal / invers you can select normal or inverted display of the monitor contents. A star (*) indicates the selected mode. Press the button to get to the menu Brightness. Select Brightness 0..15 Linearity is poor Press key when ready

It allows you to adjust the brightness of the display independently from the contrast. The supply voltage of the voltage converter for the fluorescent lamp is internally controlled in 16 grades. The required value is adjusted with the selector and converted by pressing the Enter button. In the menu Bar graph the values for the : throttle valve position, motor power, heating power, temperature sensor 1, temperature sensor 2, pressure sensor and air mass meter

are illustrated as a bar graph and as a numerical value. Use the Enter button to get back to the main menu. With menu item 2 channel y/t writer you get into the following submenu: Select channel 1 Select channel 2 Grid on/off y/t writer

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Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

With Select channel 1 and 2" you can select one of the following sensors Throttle valve Motor Heating t1 t2 Air mass meter Pressure

With Grid on/off a grid is inserted in the graphic. The grid scale is 2 s/DIV. The on/off mode is indicated with a star. In the y/t writer mode a paper writer is simulated. The paper feed is 5 pixel/second. In the main menu the variable temperature range can be selected with Temperature range 0 ... 100 C or Temperature range 20 ... 120 C

The selected temperature range is indicated with a star. When the selected temperature range is 20 ... 120 C, 20 C are directly subtracted at the sensor. The 20 C are added again by the software in the LTR701. The voltage outputs 0 ... 10 V and the current outputs 4/20 mA have a phase angle of 20. The loud speakers are switched on and off in the menu item Speaker on/off When it is switched on, it is indicated with a star. The brightness selected with the menu item Brightness, the operating modes Screen normal/invers, Speaker on/off, Temperature_range und Grid_on and the sensor settings selected for the y/t writer mode are permanently stored in an EEPROM.

6.5

Description of the RS232 format for the LTR791

When the Bar graph menu is activated, the LTR701 transmits a 42 byte string 10 x per second via the RS232 interface. The baud rate has a fixed setting of 9600 baud. The string consecutively transmits the values for the position of the throttle (0 ... 100.0), the motor power (0 ... 100.0%), the heating power (0 ... 100.0%), temperature 1 (0 ... 102.3 C) or (20 ... 120.0 C) depending on the selected temperature, temperature 2 (0 ... 102.3 C) or (20 ... 120.0 C) depending on the selected temperature, the pressure sensor (0 ... 500 N/m) and the air mass meter (0 ... 120.0 kg/h).

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Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

Operating Manual

An example:: D 89.6M 39.9H 19.2t 38.4t 29.2p 8Q 45.5 It means: throttle position motor power heating power temperature 1 temperature 2 pressure air mass = 89.6 = 39.9% = 19.2% = 38.4 C = 29.2 C = 8 N/m = 45.5 kg/h

The individual 42 bytes of the string are: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. Letter D for throttle Three-digit number of the throttle angle or space Two-digit number for the throttle valve or space One digit number for the throttle angle or space Point Tenth of the throttle angle Letter M for the motor Three-digit number foir the motor power in % or space Two-digit number for the motor power or space One-digit number for the motor power or space Point Tenth of the motor power Letter H for heating Three-digit number for the heating power in % or space Two-digit number for the heating power or space One-digit number for the heating power or space Point Tenth of the heating power Letter t for temperature Three-digit number for the temperature of sensor 1 or space Two-digit number for the temperature of sensor 1 or space One-digit number for the temperature of sensor 1 or space Point Tenth of the temperature of sensor 1 Letter t for temperature Three-digit number for the temperature of sensor 2 or space Two-digit number for the temperature of sensor 2 or space One-digit number for the temperature of sensor 2 or space Point Tenth of the temperature of sensor 2 Letter p for pressure Four-digit number for the pressure on the pressure sensor or space Three-digit number for the pressure on the pressure sensor or space Two-digit number for the pressure on the pressure sensor or space One-digit number for the pressure on the pressure sensor or space Letter Q for quantity (air mass) Three-digit number for the air mass or space Two-digit number for the air mass or space One-digit number for the air mass or space Point Tenth of the air mass CHR$ (13) CR/LF

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Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

11

The characters received via the RS232 interface can be converted into variable values with the following lines in a basic program: A(1) = 4.95 * VAL(MID$(B$, 2, 5)) A(2) = 4.48 * VAL(MID$(B$, 8, 5)) A(3) = 4.48 * VAL(MID$(B$, 14, 5)) A(4) = 3.73 * VAL(MID$(B$, 20, 5)) A(5) = 3.73 * VAL(MID$(B$, 26, 5)) A(6) = .896 * VAL(MID$(B$, 32, 5)) A(7) = 1.49 * VAL(MID$(B$, 37, 5)) The characters received via the RS232 interface are contained in a B$ string. For example, the numerical value for the throttle position (A(1) = ...) is cut out with the MID$ function, 5 characters long and beginning with the 2nd character. It is converted into a numerical value with the VAL function. By multiplying it by the numerical value of 4.95 it is adapted to the graphic.

The LTR701 can receive a string of 9600 byte via the RS232 interface. It controls the motor or the heating power When a valid string is received, the control of the motor and the heating power is transferred to the RS232 interface. The control can be retransferred to the potentiometers and the voltage/current inputs by changing to the main menu and back to the Bar graph mode. A valid string for the control of the motor or heating power has the following feature: 1. 2. 3. 4. 5. Letter M or H Any number of spaces One-digit, two-digit or three-digit number without point NO!!! space CHR$(13)

The transfer can be achieved in a Q-basic program with the following 2 lines: PRINT #1, M; STR$ (motor) PRINT #1, H; STR$ (heating) The variables motor and heating must contain an integer value of 0 ... 999. Transmissions containing other characters than M, H 0...9" spaces and CR are not valid and do not change the actual value. The reduction to values from 0 ... 999, which means a lack of 1000", is not a restriction, because the motor/heating power was set internally with an 8-bit PWM. The following Q-basic program is only used to demonstrate the RS232 interface. It can be started from the instruction line or with Windows 3x, 9x with the following batch: QBASIC /RUN C:\LTR701\LTRrs232

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Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

Operating Manual

REM QBASIS program to demonstrate steering LTR701 via RS232 REM Heizung <=> Heating SCREEN 12: WINDOW (0, 0)-(639, 479): CLS PRINT 18.12.2001" PRINT This is just a demo to demonstrate steering LTR701 via RS232" PRINT Connect LTR701 and computer via RS232 cable PRINT Select COM (1/2) WHILE (KOM <> 1) AND (KOM <> 2) KOM = VAL(INKEY$) WEND CLS PRINT M => Motor+ m => Motor- H => Heating+ h => Heating- ; PRINT Space => Exit program COLOR 9: PRINT Throttle flap ; COLOR 10: PRINT Motor ; COLOR 11: PRINT Heating ; COLOR 12: PRINT t1 ; COLOR 13: PRINT t2 ; COLOR 14: PRINT Pressure ; COLOR 15: PRINT Air mass meter FOR N = 1 TO 7: B(N) = 0: NEXT N X = 0: Motor = 0: Heizung = 0 IF KOM = 1 THEN OPEN COM1:9600,N,8,1,CD0,CS0,DS0,OP0,RS,TB256,RB256" FOR RANDOM AS #1 IF KOM = 2 THEN OPEN COM2:9600,N,8,1,CD0,CS0,DS0,OP0,RS,TB256,RB256" FOR RANDOM AS #1 WHILE I$ <> I$ = INKEY$ IF I$ = m THEN Motor = Motor - 10: IF Motor < 0 THEN Motor = 0 IF I$ = M THEN Motor = Motor + 10: IF Motor > 990 THEN Motor = 990 IF I$ = h THEN Heizung = Heizung - 10: IF Heizung < 0 THEN Heizung = 0 IF I$ = H THEN Heizung = Heizung + 10: IF Heizung > 990 THEN Heizung = 990 IF X = 0 THEN LINE (0, 0)-(639, 447), 7, BF IF LOC(1) <> 0 THEN A$ = (INPUT$(1, #1)) IF A$ <> CHR$(13) THEN B$ = B$ + A$ ELSE A(1) = 4.95 * VAL(MID$(B$, 2, 5)) A(2) = 4.48 * VAL(MID$(B$, 8, 5)) A(3) = 4.48 * VAL(MID$(B$, 14, 5)) A(4) = 3.73 * VAL(MID$(B$, 20, 5)) A(5) = 3.73 * VAL(MID$(B$, 26, 5)) A(6) = .896 * VAL(MID$(B$, 32, 5)) A(7) = 1.49 * VAL(MID$(B$, 37, 5)) FOR N = 1 TO 7 IF A(N) > 447 THEN A(N) = 447 LINE (X, A(N))-(X, B(N)), 8 + N B(N) = A(N) NEXT N B$ = X = X + 1: IF X = 640 THEN X = 0 PRINT #1, M; STR$(Motor) PRINT #1, H; STR$(Heizung)

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END IF END IF WEND PRINT #1, M0": PRINT #1, H0" SYSTEM

Monitor example

7.

Maintenance

The device is generally maintenance-free. Frequently remove the dust from the air inlets and outlets.

8.

Care

Warning! Before cleaning, disconnect the device from the voltage supply. Use a soft, dry cloth to clean the unit. In case of stubbom dirt, moisten the cloth with a soap solution or mild detergent. Dry the device by wiping it with a soft cloth. Never use alcohol, paint thinners, petrol or cloths treated with chemicals for cleaning, because it might damage the surface of the unit and harm the environment.

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Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

Operating Manual

9.

Technical data for the sensors, actuators and signal inputs and outputs
Input Actuator 1 Ventilator speed Input Actuator input 0 ... 10 V 4 ... 20 mA Power 0 ... 100% 0 ... 100% Increase 10% / V 6.25% / mA

Input Actuator 2 Heating power Input Actuator input 0 ... 10 V 4 ... 20 mA

Note:

Power 0 ... 100% 0 ... 100%

Increase 10% / V 6.25% / mA

In the case of the actuators the inputs build the maximum values. For the inputs 0 ... 10 V, 4 ... 20 mA and the adjuster the maximum is built and used as a manipulated variable.

Output Sensor 1 Throttle position Output Output 0 ... 10 V 4 ... 20 mA Angle 0 ... 100 0 ... 100 Increase 10 / V 6.25 / mA

Output Sensor 2 Temperature sensor type K Output Output 0 ... 10 V 4 ... 20 mA Temperature in C 0 ... 100 (20 ... 120) 0 ... 100 (20 ... 120) Increase 10 / V 6.25 / mA

Output Sensor 3 Temperature sensor type K Output Output 0 ... 10 V 4 ... 20 mA Temperature in C 0 ... 100 (20 ... 120) 0 ... 100 (20 ... 120) Increase 10 / V 6.25/ mA

Output Sensor 4 Air pressure Output Output 0 ... 10 V 4 ... 20 mA Conversion of pressure units: Pressure p in mbar 0 ... 10 mbar 0 ... 10 mbar Increase 1 mbar / V 1.6 mbar / mA

1 bar = 1000 mbar = 100000 N/m2 = 105 Pascal 1 mbar = 100 N/m2 = 100 Pascal

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Output Sensor 5 Air mass meter Output Output 0 ... 10 V 4 ... 20 mA

Note:

Mass in kg/h 0 ... 120 kg/h 0 ... 120 kg/h

Increase see characteristic see characteristic

Always add 4 mA to the current inputs and subtract 4 mA from the current outputs. When a temperature range of 20 ... 120 C is set, the outputs have a phase angle of 20 C. Example: The voltage on the sensor output is 4.0 V. The measured value is 40 C. In the measuring range of 20 ... 120 C the measured value of 40 C + 20 C forms a basic value of 60 C. The internal software regards the basic value. The display indicates the correct value. Tolerances for the sensor outputs: 10% of the final measure value

Data sheets Air mass sensor The air mass sensor is supplied with 12 V and supplies a voltage of 0 ... 5 V on its output. The voltage value of 0 ... 5 V for the air mass sensor is gained by the factor 2 and is available at the signal output 0 ... 10 V. On the output 4/20 mA 0 V 4 mA and 10 V 20 mA. The voltage/air mass characteristic for the air mass sensor is very non-linear.

The LC display does not illustrate the voltage of the sensor, but the respective air mass in kg/h. The voltage/air mass characteristic is simulated and linearised with 35 supports in the micro-controller of the LTR701.

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Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

Operating Manual

Temperature sensor Type K Thermocouple sensor Thermal e.m.f. Type K 40 mV/K ELWE art. no. 08 70 110 (wire sensor, twisted) ELWE art. no. 08 70 111 (liquid-flow sensor, V4A tube) Ni-CrNi 0 C = 0.0 mV T90 = 0,3 s T90 = 3 s

Response rate

U in mV

Temperature in C

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10. Block diagram

Drosselklappe throttle
Winkelangular Potentiometer potentiometer

Mechanischer design Mechanical Aufbau

Heizung heating

NiCr-NiNiCr-Nidifferential measuring measuring NiCr-NiNiCr-NiDifferenzpressure sensor probe 2 probe 1 Mesonde 1 Mesonde 2 drucksensor

Optional optional air Luftmassenmass sensor sensor

Ventilator ventilator
P

Meorifice blende

LC-Display

Mikroprozessor-Steuerung Micro-Processor Control

U I U I Drosselklappe

throttle

Ventilator ventilator intern

internal

U II U extern external

Heizung heating intern

internal

U I U I extern external

U I U I Temperatur 1 temperature 1

U I U I Temperatur 2 temperature 2

U I U I Druck pressure

RS232

RS232

U II U Luftmasse

air mass

Stellglied actuator

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Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

Operating Manual

Controlled air mass and temperature system LTR 701

Power supply Contrast

Enter

Ventilator Select

Actuator 1

8-channel ADC

Heating

Actuator 2

Sensor 1

Sensor 2

Sensor 3

Sensor 4 Pressure

Sensor 5 Air mass

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11. RS232 interface

To connect a PC use a standard cable (1:1 wiring, 9-pin connector and 9-pin socket) for the RS232 interface. If your PC is equipped with a 25-pin connector for the serial interface, use a respective common adapter. Do not use a common modem cable with a twisted wiring.
9-pin Sub-D connector 9-pin Sub-D socket PC-Connector (DAC98) Pin no.
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

12. Connection DAC98

The PC plug-in card DAC98 (art. no. 08 90 200) is available for the analysis and the simulation of the controlled air mass and temperature system LTR701. With the PC plug-in card and the program MCON (art. no. 08 81 700) the LTR701 is operated via the PC. Pin configuration PC plug-in card DAC98 LTR701
PC-Connector (DAC98) Pin no.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Warning:

Pin name
CHA0 CHB0 CHA1 CHB1 CHA2 CHB2 CHA3 CHB3 DIN0 DIN1 DIN2 DIN3 nc nc AGND AIN0 AIN1 /CHA0 /CHB0 /CHA1 /CHB1 /CHA2 /CHB2 /CHA3 /CHB3 n. c. n. c. n. c. n. c. n. c. n. c. n. c. n. c. n. c. n. c. n. c. n. c. n. c. n. c.

Configuration

Pin name
DIN4 DIN5 DIN6 DIN7 nc AGND AIN2 AIN3 Dout0 Dout1 Dout2 Dout3 Dout4 Dout5 Dout6 Dout7 DGND DGND AIN6 AIN7 Timer/Clk Aout0 Aout1 AIN4 AIN5 n. c. n. c. n. c. n. c. n. c.

Configuration

Analog earth Sensor 3, temperature 2 0 ... 10 V Sensor 4, air pressure, 0 ... 10 V n. c. n. c. n. c. n. c. n. c. n. c. n. c. n. c. n. c. n. c. Analog earth Analog earth n. c. Actuator 1, ventilator speed 0 ... 10 V Actuator 2, heating power 0 ... 10 V Sensor 5, air mass 0 ... 10 V Analog earth

Analog earth Sensor 1, throttle position 0 ... 10 V Sensor 2, temperature 1 0 ... 10 V n. c. n. c. n. c. n. c. n. c. n. c. n. c. n. c.

All the unused inputs must be connected to the analog earth.

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Controlled Air Mass and Temperature System with Actuators and Sensors LTR701

Operating Manual

Adapter for the connection of controlled air mass and temperature system LTR701 to the DAC98

The adapter consists of a connection cable with eight 4-mm safety connectors (LTR701) and a 50-pin Sub-D socket (DAC98). Connect the Sub-D socket to the PC plug-in card DAC98. To avoid contacting problems, screw fix the Sub-D socket. The 4-mm safety connectors are connected to the 4-mm safety sockets on the LTR701 as marked.
Note: The adapter is not necessary when the LTR701 is fitted with the option Connection to DAC98" (50-pin Sub-D socket). A corresponding connection cable is available.

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LTR701 Controlled air and temperature system

Control for Laboratory Experiment LTR701

Updated: 12-April-2002

Control of the LTR701

LTR701 Controlled air and temperature system

Contents
1 Possible experiments ............................................................................................................................................1 1.1 1.2 1.3 Contents and aims of the experiments ..........................................................................................................1 Basic theories ...............................................................................................................................................1 Testing methods............................................................................................................................................6 Identification of the static and dynamic properties of the controlled systems.......................................6 Controlled air flow system................................................................................................................6 Controlled air temperature system ..................................................................................................11 Examination of the control loop properties ........................................................................................16 Simple air pressure control loop .....................................................................................................16 Simple air temperature control loop ...............................................................................................18 Cascade control ..............................................................................................................................22

1.3.1 1.3.1.1 1.3.1.2 1.3.2 1.3.2.1 1.3.2.2 1.3.2.3

Control of the LTR701

LTR701 Controlled air and temperature system

Possible experiments

1 Possible experiments
1.1 Contents and aim of the experiments
The controlled air and temperature system LTR701 with two measurable output variables (pressure/flow rate and temperature) and two input variables (speed of the fans and power of the heater) allows you to determine the properties of controlled systems, in which the controlled variables are the temperature and the pressure or the flow, and to examine the performance of different controller structures. The manually adjustable angle of the throttle can, for example be applied as an external interference signal. As will be demonstrated below, the structures of a pressure or flow rate control only differ by an additional static characteristic element (or measuring element), so that both types of control loop will be examined in the same paragraph below. When external controllers (industrial controller or PC) are connected, the following control loop structures can be set up with the controlled air and temperature system LTR701: Simple control loops: Air pressure/flow rate control, the temperature is not controlled, Air temperature control with an effect on the heat output, the flow rate is not controlled, Air temperature control with an effect on the flow rate, the heat output is not controlled.

Cascade control systems: Air temperature as controlled variable, air pressure/flow rate as cascade controlled variable by adjusting the heat output, Air temperature as controlled variable, air pressure/flow rate as cascade controlled variable by adjusting the air flow.

Multi-variable control system: Two independent air pressure/flow rate and temperature control loops. Decoupling is possible.

1.2 Basic theories

Two different methods are used to mathematically describe the static and dynamic properties of the controlled service: the theoretical and the experimental formation of models. The theoretical formation of models describes the balancing equations for the transport of a compressible medium in a pipe when thermal energy is selectively applied. If, for reasons of simplification, we assume laminar flow conditions, the result would be a partial differential equation to describe the local distribution of pressure and temperature. It would still be a problem to determine the coefficient of this partial differential equation.

Possible experiments

LTR701 Controlled air and temperature system

Therefore it seems to be appropriate to use the much easier method of experimental analysis. All the inputs of the controlled system are successively energised in steps and the reaction of the controlled system is measured as a step response on its outputs. Then each step response is described with a mathematical model, whose step response corresponds well with the measured response. In the simplest case, the mathematical model is a first-order timedelay element, whose characteristic variables, amplification and time constant can be directly read off the measured step response. Additional time delays can then easily be described with a lag element. The transfer function of such a model would be:

G ( s ) = e Tt s

k 1 + Ts T and the dead time Tt .

with the gain factor k , the time constants

Due to the non-linearity of the described controlled system, the input and output signals are displayed as deviations from previously determined operating points. Accordingly determined transfer functions only apply to this area of operation. The approach for the measured step responses leads to the following structure for the controlled system:

Figure 1.

Block diagram for controlled pressure and temperature systems.

u M describes the manipulated variable for the motor of the fan, u H the manipulated variable for the heater and
the manually adjustable angle of the throttle valve as an interference signal. The output variables which are measured via the respective sensors are the pressure p at the end of the pipe and the air temperature on one of the four possible measuring points. The measured pressure will additionally be filtered via a first-order time-delay element (VZ1, realised in the PC program). As illustrated further below, Pmeas is preferably used for the measurement of step responses or control loop performances instead of the directly measured pressure. The respective blocks in between can, for example, be described with the following transfer functions:

LTR701 Controlled air and temperature system

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G1 ( s ) = G 2 (s ) =

p 0,425 = e 0,24s or uM 2,4 s+1 0,368 = e 0,7s p 8,35 s +1 0,485 = e 0,8 s uH 12,6s + 1 0,543 = e 0,3 s uH 3,3s + 1 G 4 (s) =

G1(s ) = e 0,24 s

0,425 0,4 s + 1

withoutVZ1

G 3(SENSOR 3 ) = G 3(SENSOR 2 ) = G 4 (s ) =

p 0,03 = or 2,1s + 1

0,03 0,1s + 1

withoutVZ1

The transfer functions illustrated above are exemplary results for the analysis of step responses, whose details are described in the paragraphs below. They only apply to a certain type of the controlled air and temperature system LTR701. With other types the parameters may greatly deviate due to inevitable tolerances. The effect of the ambient temperature as an additional external input or turbulence has been ignored. The same applies to the heating or cooling of the inner pipe, which will be seen as a temperature drift in long-term measurements. As mentioned at the beginning of this section, due to the variety of input and output variables it is possible to use different controller designs for the present laboratory test. Some examples will be examined below. Figure 2 shows a block diagram for a controlled temperature system with an uncontrolled air flow rate.

Figure 2. Block diagram for a temperature control loop

Possible experiments

LTR701 Controlled air and temperature system

Figure 3 shows a block diagram for a flow rate control loop with uncontrolled air temperature.

Figure 3. Block diagram for a flow rate control loop The following two figures 4 and 5 illustrate block diagrams for different types of cascade control systems. In both cases the temperature is the controlled variable of the external control loop (master controller GR1 ), whereas the flow rate is the controlled variable of the cascade control loop (follower controller G R 2 ). In the first version (figure 4), the heater output is affected by the actuating signal of the follower controller, whereas the fan is supplied with a fixed manipulated variable.

Figure 4: Block diagram of the cascade control for the temperature (control of the heater)

LTR701 Controlled air and temperature system

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In the second version (figure 5) the fan speed is affected by the actuating signal of the follower controller, whereas the heater is supplied with a fixed manipulated variable.

Figure 5: Block diagram of the cascade control for the temperature (control of the fan)

Possible experiments

LTR701 Controlled air and temperature system

1.3 Testing methods

The exemplary diagrams illustrated in the following paragraphs, which show the patterns of different control loops, have been established with the universal controller program MCON from amira GmbH.

1.3.1 Identification of the statistic and dynamic properties of the controlled systems.
To identify the transfer functions of the individual controlled systems the step responses are measured as mentioned in the previous section. A square-wave generator used as a signal source and a storage oscilloscope or recorder for the signal input is sufficient to conduct the measurements. Both devices must have a signal range of 0-10 V or 4-20 mA. To set up the mentioned control loop structures up to 2 analog or digital controllers with the respective signal inputs/outputs must be additionally available. Alternatively, the external devices, such as the signal generator, the recorder and the controllers can be replaced by a PC with suitable analog inputs and outputs and a program for the control and for recording measured values.

1.3.1.1 Controlled air flow system

The statistical property of the controlled air flow system can be described with a statistic characteristic curve according to:

Q = f (u M ) ,
with:

Q - air flow [ m3/h ], u M - control signal for the fan speed [V or mA or %].

In the laboratory test, the air pressure instead of the air flow rate is measured with an aperture plate and a pressure transducer. The pressure in the pipe generated by the air flow on the aperture is compared with the atmospheric pressure, which is assumed constant. As is widely known, the air flow on the aperture only depends upon the air pressure via a static root characteristic. If it is possible to determine the parameters of this characteristic in a single measurement (e.g. with the optimum air mass sensor), the pressure control can be replaced by an air flow control by simulating this characteristic in the controller input of the pressure measurement. To measure the static and dynamic properties of the controller air system square-wave signals must be applied to the inputs for the fan speed ( u M ) and the throttle ( ), whose effect on the air pressure can be measured on the pressure transducer. The following figure 6 shows the block structure used in the MCON to measure the effect of the fan speed on the air pressure.

LTR701 Controlled air and temperature system

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Figure 6: MCON work sheet to measure the step response (fan -> air pressure) The right part of the above work sheet (simulation file LTRPRESS.SIM) shows the actuation of the fan speed. A square-wave generator directly supplies its output signal (5V +/-1V, period of 20s) to the channel 0 on the digitalanalog converter, which itself must be connected to the socket (ACTUATOR 1) to activate the fan speed. A constant value of 4 V is subtracted from the square-wave signal to obtain an improved display in the plot diagram. The left part of the above work sheet shows the air pressure measurement. The measuring socket (SENSOR 4) on the pressure sensor is connected to the channel 3 on the analog-digital converter, whose measured values can be directly displayed on an indicating instrument, an oscilloscope figure and in the plot diagram. The measured value is also filtered via a first-order time-delay element (amplification of 1.0, time constant of 2 s) and displayed like the direct measured value. The additional filtering of the measured air pressure value is necessary, because the air flow turbulence in the pipe cause corresponding air pressure variations, since a graphic analysis of the step response would not be possible practically. The simulator parameters adjusted in the program represent a measuring time of 40s for a period of 10ms for the scanning rate as well as the rate for storing the measured values. The very small value for the rate of the measured value storage has been selected to be able to display the relatively low dead time in the step response. Figure 7 below shows the test result as a plot diagram.

Possible experiments

LTR701 Controlled air and temperature system

MCON - Measuring
2.00 1.50 1.00 0.50 0.00 0.00 20.00 Time[s] Pressure Pressure VZ1 Fan output

MCON V1.4 LTRPRESS.SIM 05.03.02 11.38

Figure 7: Plot diagram of the step response (fan -> air pressure) The MCON zoom function is used to graphically analyse the step response. The resulting image is illustrated below:

MCON - Measuring
1.75 1.50 Pressure Pressure VZ1 Fan output

63%
1.25

0,85V

1.00 0.75 0.50 10.00

T=2,4s Time[s]

20.00

MCON V1.4 LTRPRESS.SIM 05.03.02 11.38

Figure 8. Enlarged detail of the step response (fan at 5V -> air pressure) The manually added lines for the initial and final values of the Pressure VZ1 indicate a change of 0.85V (on the MCON, the Y axis always represents Volt). The line at 63% of the change intersects the step response at an interval from the value of the time constant of T=2.4s. The delayed increase of the step response compared to the input response at 10s (see figure 7) is caused by a short dead time of approx. 0.24s. Therefore, the gain and the transfer function is:

G1(s ) = e 0,24 s

0,425 with uM0 = 5V 2,4s + 1

LTR701 Controlled air and temperature system

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The transfer function includes the dynamic properties of the components connected in series, such as the amplifier, the fan, the pipe, the pressure sensor and the additional VZ1 element. Without the additional VZ1 element the time constant is approx. 0.4s. This transfer function also only applies to an operating point of 5V (or 50%) for the fan speed. To demonstrate the dependence on the operating point, the experiment is repeated with a square-wave generator with an adjustment of +/-1V and an offset of 1 V (DC component), i.e. an operating point of 1V. Figure 9 below shows an enlarged detail of the test result.

MCON - Measuring
0.30 0.23 0.15 Pressure Pressure VZ1 Fan output

0,16V

0.08 0.00 10.00 Time[s] 20.00

MCON V1.4 LTRPRESS.SIM PRESS001.PLT 05.03.02 11.05

T=2,6s Figure 9. Enlarged detail of the step response (fan at 1V -> air pressure) When analysed as above, the transfer function is G1(s) = e 0,5 s 0,08 2,6s + 1 with uM0 = 1V

Compared with the transfer function for the operating point u M 0 = 5V , the value for the dead time has doubled and the gain factor has decreased significantly with a similar time constant. The changes are caused by the significantly lower velocity of the air flow, which is also clear when you look at the low turbulence of the directly measured air pressure. To determine the (turbulence) transfer function between the throttle valve position and the air pressure, a squarewave signal must be applied to the throttle valve. Since this cannot be done due to a lack of technical possibilities, the adjustment must be carried out manually. Figure 10 shows the block structure used in the MCON (simulation file LTRPRESF.SIM) to measure the effect of the throttle valve movement on the air pressure when the fan speed is constant. The fan is constantly controlled with 5V, the air pressure is measured with the additional VZ1 element and the throttle valve position (SENSOR 1) is also recorded with channel 0 on the A/D converter.

Possible experiments

LTR701 Controlled air and temperature system

Figure 10. MCON work sheet to measure the step response (throttle valve -> air pressure) Figure 11 shows the test result of a manually activated (jump) throttle valve movement from OPEN CLOSED and back from CLOSED OPEN.

MCON - Measuring
7.50 6.00 4.50 3.00 1.50 0.00 0.00 20.00 Time[s] MCON V1.4 LTRPRESF.SIM PRESF001.PLT 06.03.02 14.52 Pressure VZ1 Fan output Flap

Figure 11. Plot diagram of the step response (throttle valve -> air pressure) The diagram shows that the position of the throttle valve has almost changed abruptly (OPEN=9V or = 90 , CLOSED=0V or = 0 ). The effect of this change on the air pressure is relatively low. Again, a more accurate analysis can only be achieved with an enlarged detail (see figure 12).

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MCON - Measuring
1.20 1.13 Pressure VZ1 Fan output Flap

0,3V

1.05 0.97 0.90 0.82 15.00 Time[s] 22.50 MCON V1.4 LTRPRESF.SIM PRESF001.PLT 06.03.02 14.52

T=2,1s Figure 12. Enlarged detail of the step response (throttle valve -> air pressure) When the diagram is analysed as described above, the transfer function is

G4 ( s ) =

p 0,03 = 2,1s + 1

A further dead time cannot be seen with the present resolution and due to the fact that the throttle valve position has not exactly changed abruptly. Again, the transfer function only applies to an operating point of 5V (or 50%) for the fan speed. A definition of the operating point for the throttle valve position is not necessary, because only the binary states OPEN or CLOSED are being used, and not the state half open.

1.3.1.2 Controlled air temperature system

To measure the static and dynamic properties of the controlled air temperature system, square-wave signals must be applied to the inputs for the heater output ( u H ) and the fan speed ( u M ) or the throttle valve ( ). Their effect on the air temperature is measured with a temperature sensor. As shown above in the block diagram in figure 1, the effect of the heater output on the air temperature can only be measured directly, whereas the two other input variables for the fan speed and the throttle valve position only act indirectly through the air pressure. This fact must be taken into consideration when determining the transfer function G2 . Furthermore, the controlled air and temperature system LTR701 contains 2 temperature sensors (one with and one without a handle) with different time constants. The sensors can be plugged in at 4 different measuring points along the pipe. Generally, up to 16 different transfer functions can be determined. To simplify matters, the following definition applies to all the temperature measurements below: The temperature sensor without a handle is plugged into the first measuring point on the beginning of the pipe (near the fan) and is connected to the input of SENSOR 2" (indicated with t1 on the display).

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LTR701 Controlled air and temperature system

The temperature sensor with a handle is plugged into the forth measuring point at the end of the pipe (near the orifice plate) and is connected to the input of SENSOR 3" (indicated with t2 on the display). The operating instructions of the controlled air and temperature system LTR701 show that the voltage range from 0...10V can be assigned to the temperature range from 0...100C or 20...120C at the temperature sensor inputs. The last assignment applies to all the temperature measurements below. Finally, when selecting the heater output, it must be taken into consideration that a temperature limit of approx. 140C must not be exceeded and that the value for the fan speed must not fall below 10%, otherwise the heater will be automatically switched off. Figure 13 below shows the block structure used in the MCON to measure the effect of the heater output on the air temperature when the fan speed is constant.

Figure 13. MCON work sheet to measure the step response (heater -> air temperature) The top right corner of the figure above (simulation file LTRTEMP.SIM) shows the constant control of the fan speed. The output signal, which is accessed on the potentiometer (5V ), is directly applied to channel 0 on the D/A converter, which itself must be connected to socket ACTUATOR 1 to control the fan speed. The control of the fan speed is transferred to the plot diagram. Below it, the blocks for the control of the heater output are indicated. The output signal from a square-wave generator (3V +/-1V, period of 100s) is directly applied to channel 1 on the D/A converter, which itself must be connected to socket ACTUATOR 2 to control the heater output. Finally, a

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constant value of 0V, in this case, is deducted from the square-wave signal to obtain an improved display in the plot diagram. The left part of the figure above indicates the air pressure measurement and, below it, the two air temperature measurements. The measuring socket for the pressure sensor is connected to channel 3 on the A/D converter, whose measured value is filtered through a first-order time-delay element (gain: 1.0, time constant: 2 s) before it is displayed. The temperature sensors must be located as decribed in the definitions mentioned above, SENSOR 2 must be connected to channel 1 on the A/D converter and SENSOR 3 to channel 2 on the A/D converter. Both measured values are displayed and transferred to the plot diagram. The simulator parameters set in the program represent an integration period of 120s for a period of 10ms for the scan rate and of 100ms for the rate of storing the measured values. Figures 14 and 15 below indicate the test result as a plot diagram or as its enlarged detail.

MCON - Measuring
4.50 3.75 3.00 2.25 1.50 0.00 50.00 Time[s] 100.00 MCON V1.4 LTRTEMP.SIM TEMP01.PLT 02.04.02 12.57 Fan control Temperature (2) Temperature (3) Heating control

Figure 14. Plot diagram of the step response (heater -> air temperature)

MCON - Measuring
4.00 3.50 3.00 2.50 Fan control Temperature (2) Temperature (3) Heating control

0,97V

2.00 60.00 80.00 Time[s] 100.00 MCON V1.4 LTRTEMP.SIM TEMP01.PLT 02.04.02 12.57

T=12,6s Figure 15. Enlarged detail of the step response (heater -> air temperature)

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LTR701 Controlled air and temperature system

As expected, the sensor without a handle mounted near the heater indicates a higher temperature and a faster response. It also shows the turbulence in the air flow mentioned above. The diagram only indicates the graphical analysis of the step response for the sensor with a handle (measuring point: end of the pipe, connection to SENSOR 3). The same applies to SENSOR 2. Both transfer functions add up and form

G3( SENSOR 3) ( s ) =

0,485 = e 0 ,8 s u H 12,6s + 1

or

G3( SENSOR 2) ( s ) =

0,543 = e 0,3 s u H 3,3s + 1

for the operating points u M 0 = 5V (fan speed) and u H 0 = 3V (heater output). Due to the selected time scale, especially the value for the dead time is only an approximate value. As mentioned above, the missing effect of the air pressure on the air temperature at a constant heater output is indirectly measured through the effect of the fan speed. Figure 16 indicates the respective experimental set-up.

Figure 16. MCON work sheet to measure the step response (fan -> air temperature) When comparing this work sheet (simulation file LTRTEMPV.SIM) to the previous sheet, they only differ in the fact that the signal sources for the control of the channels 0 and 1 on the D/A converter are exchanged. Now, the fan is controlled by a square-wave generator (5V +/-1V, period: 100s) and the heater by a constant signal (3V). Figures 17 and 18 below show the respective test result in a plot diagram and an enlarged detail.

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MCON - Measuring
6.00 5.00 4.00 3.00 2.00 0.00 50.00 Time[s] 100.00 MCON V1.4 LTRTEMPV.SIM TEMPV01.PLT 02.04.02 16.23 Temperature (2) Temperature (3) Fan control Heating control

Figure 17. Plot diagram of the step response (fan -> air temperature)

MCON - Measuring
3.00

0,328V 2.75
2.50

Temperature (2) Temperature (3) Fan control Heating control

2.25 50.00 62.50 Time[s] 75.00 MCON V1.4 LTRTEMPV.SIM TEMPV01.PLT 02.04.02 16.23

T=8,75s Figure 18. Enlarged detail of the step response (fan -> air temperature) According to the known analysis, the transfer functions are

G1 ( s ) G2 ( s ) =

0,164 0,425 = e 0,94 s = e 0, 24 s G2 ( s) , 8,75s + 1 u M 0,4 s + 1

and after a first approximation

G2 ( s) =

0,386 , with u M 0 = 5V , u H 0 = 3V . = e 0 , 7 s p 8,35s + 1

The product of the transfer functions for the dead time and the time constant represents the sum of the values for the individual transfer functions. As already shown in figure 1, the negative sign has also been moved to the following summing point. A respective measurement via the throttle movement on the same terms leads to a similar result for G2 .

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LTR701 Controlled air and temperature system

1.3.2 Examination of the control loop properties 1.3.2.1 Simple air pressure control loop
Figure 3 indicates the block diagram for this type of control loop, in which the air temperature is not affected. It controls a first-order time-delay element with a very low time constant. If the controlled system can be described accurately with this model (no further parasitic time constants), any PI controller can be used without causing stability problems. However, as the measurement of the step response has shown, due to the turbulence it seems to be useful to filter the measured pressure value with an additional first-order time-delay element. In this case, stability problems may well occur. Since the controlled system does not contain an I component, it is necessary to use at least a PI controller to obtain steady-state exactness. An additional D component does not seem to be useful, because of the noisy measured pressure signal. Figure 19 below shows the work sheet for the air pressure control with a PI controller.

Figure 19. MCON work sheet for the air pressure control The left part of the work sheet (simulation file LTRCPR1.SIM) indicates the measurement and the recording of the throttle position in die plot diagram, the measurement and the display of the temperature of SENSOR 2 and the measurement, the display and the recording of the actual air pressure value (SENSOR 4) in the plot diagram from top to bottom. Before the reference point with the pressure setpoint, the actual value is filtered with a first-order time-delay element. The pressure setpoint is determined by a square-wave generator (1.5V +/-0.5V, period: 20s). It is displayed and transferred into the plot diagram. The pressure system deviation is supplied to a PI controller,

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whose output directly controls the fan. The actuating signal is also indicated and transferred into the plot diagram. Additionally, the heater is constantly controlled (here with 0V), i.e. the air temperature is not affected. The simulator parameters adjusted in the program represent a measuring time of 40s for a period of 10ms for the scanning rate as well as 100ms for the rate of storing measured values. Before conducting any experiments, it is necessary to determine the parameters for the controller with the structure

GR ( s) = K P +

KI . s

A very simple method is the selection of the controller parameters, so that the highest possible system time constant is reduced. Here, it means for the ratio

KP = 2,4s . KI
When it is necessary to keep the manipulated variable for preset setpoint step-changes within its limits, the controller parameters K P = 5,3; K I = 2,2 for a setpoint step-change of +/-0.5V are determined in experiments. The result is shown in figure 20.

MCON - Measuring
10.00 8.00 6.00 4.00 2.00 MCON V1.4 LTRCPR1.SIM CPRES01.PLT 03.04.02 14.10 Pressure Setpoint pressure flap Fan output

0.00

15.00 Time[s]

30.00

Figure 20. Response to setpoint changes of the pressure control To measure the disturb action, it is sufficient to set an amplitude of 0V on the pressure setpoint generator and to manually activate the throttle valve. The respective result is shown in figure 21.

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MCON - Measuring
8.75 7.00 5.25 3.50 1.75 0.00 0.00 15.00 Time[s] 30.00 MCON V1.4 LTRCPR1.SIM CPRESF01.PLT 03.04.02 14.30 Pressure Setpoint pressure flap Fan output

Figure 21. Disturbance action (throttle valve manually set OPEN -> CLOSED, CLOSED -> OPEN) of the pressure control system

1.3.2.2 Simple air temperature control loop

Figure 2 shows the block diagram for the control loop, in which the air flow is not taken into consideration. For the selection of the controller, the same assumptions apply as for the air pressure control loop, only that in this case an additional first-order time-delay element is not needed. Since the measuring signal for the temperature is not as noisy as the measuring signal for the pressure, it is possible to use a PID controller. The work sheet illustrated in figure 22 shows the air temperature control for a constant fan speed. It controls the air temperature of the temperature sensor connected to SENSOR 3 (sensor with a handle mounted to the end of the pipe). As demonstrated on the work sheet (simulation file LTRCTMP2), the actual temperature value is indicated and transferred into the plot diagram. The same applies to the setpoint value of the temperature, which is determined by a square-wave generator (4V +/-1V or approx. 50-70C, period: 100s). A PID controller uses the system deviation to calculate the actuating signal, that is directly used for the control of the heater and is displayed on an oscilloscope. The directly measured air pressure is only indicated. The constant actuating signal (5V) for the fan speed is also transferred into the plot diagram. The simulator parameters adjusted in the program represent a measuring time of 200s for a period of 10ms for the scanning rate as well as 100ms for the rate of storing measured values. Before conducting any experiments, it is necessary to determine the parameters for the ideal PID controller with the structure

GR ( s ) = K P + K D s +

KI . s

The PID controller in the MCON program also uses an additional time constant for the D component. It has the value of the scanning rate, but is not taken into consideration of further reflections. If the controller parameters are selected, so that the highest possible system time constant is reduced, initially

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Figure 22. MCON work sheet for the air temperature control SENSOR 3 an alternative controller display is assumed, which indicates the two counter time constants:

GR ( s ) = K R

(TR1 s + 1)(TR 2 s + 1) s

A simple comparison of the coefficients provides the following relations:

KI = KR K P = K R (TR1 + TR 2 ) K D = K RTR1TR 2
If TR1 = 12,6 , which is the highest possible system time constant, TR 2 = 0,1 and K P = 20,0 , the rest of the controller parameters are K I = 1,57 , K D = 1,98 . When the controller parameters are adjusted and the constant fan speed is determined, it is necessary to take into consideration the main side condition, that, with a maximum heater output, none of the temperature measuring points must reach a temperature of 140C, otherwise the heater would be switched off. This is particularly important for the measuring point at the beginning of the pipe (SENSOR 2). Figure 23 below shows the result of the above settings.

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LTR701 Controlled air and temperature system

MCON - Measuring
5.25 4.50 3.75 3.00 2.25 1.50 0.00 75.00 Time[s] 150.00 MCON V1.4 LTRCTMP2.SIM CTEMP02.PLT 04.04.02 11.57 Temperature Fan control Setpoint Temperature

Figure 23. Response to setpoint changes of the air temperature control for SENSOR 3 In comparison, now the air temperature control for SENSOR 2 (sensor without a handle mounted to the beginning of the pipe) is examined. The respective work sheet is illustrated in figure 24.

Figure 24. MCON work sheet of the air temperature control for SENSOR 2

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When this work sheet (simulation file LTRCTMP1.SIM) is compared to the previous sheet, the blocks for the temperature control and the pressure measurement are identical. The actual temperature value is only measured with a different channel on the A/D converter. A square-wave generator has been added for the control of the fan speed and for the measurement of the throttle position, whose measured value is multiplied with the constant factor of 0.2 for an improved display in the plot diagram. When the controller is set as described above, the controller parameters are with a maximum system time constant of 3.3s.

K P = 20, K I = 5,88, K D = 1,94

To measure the response to setpoint changes, the square-wave generator for the fan speed is set to a fixed value (5V +/-0V, period: irrelevant) and the square-wave generator for the temperature setpoint is set variably (4V +/-1V, period: 50s). Figure 25 shows the test result.

MCON - Measuring
5.25 4.50 3.75 3.00 2.25 MCON V1.4 LTRCTMP1.SIM CTEMP03.PLT 04.04.02 14.51 Temperature (2) Setpoint Temperature Fan control Flap

0.00

50.00 Time[s]

Figure 25. Response to setpoint changes of the air temperature control for SENSOR 2 Compared with SENSOR 3, the response is much faster, mainly because the time constant of the sensor is much lower. To measure the disturb action, the square-wave generator for the fan speed is set variably (5V +/-1.5V, period: 50s) and the square-wave generator for the temperature setpoint is set to a fixed value (4V +/-0V, period: irrelevant). The throttle valve is also moved from CLOSED -> OPEN and vice versa. The test result is illustrated in figure 26.

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LTR701 Controlled air and temperature system

MCON - Measuring
6.25 5.00 3.75 2.50 1.25 0.00 0.00 50.00 Time[s] MCON V1.4 LTRCTMP1.SIM CTEMP04.PLT 04.04.02 14.47 Temperature (2) Setpoint Temperature Fan control Flap

Figure 26. Disturb action (fan, throttle) of the air temperature control for SENSOR 2

1.3.2.3 Cascade control

As a first example for a cascade control system, we selected the control loop structure illustrated in figure 5. With a constant preset heater output, the air temperature forms the external controlled variable, whereas the air flow is cascade controlled by the activation of the fan. Figure 27 shows the respective work sheet.

Figure 27. MCON work sheet for the cascade temperature control (fan: controlled, heater: constant)

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LTR701 Controlled air and temperature system

Possible experiments

The work sheet (simulation file CASCTMP1.SIM) only contains the constant control (5V) for the heater and the cascade control. The air pressure (or air flow rate) is cascade controlled with a P controller ( K P = 1,75 ), with the measured pressure value also being filtered through a first-order time-delay element. The actuating signal of the P controller is conducted through a limiter (2-10V) to ensure a minimum air flow of 20%. The setpoint for the cascade control loop is the actuating signal of the master PI controller ( K P = 14,4, K I = 1,5 ) to control the temperature of SENSOR 3. Again the temperature setpoint is produced by a square-wave generator (4V +/-0.5V or approx. 55-65C, period: 100s). The plot diagram contains the actual value and the setpoint value for the temperature as well as the actuating signals for the heater and the fan speed. The simulator parameters adjusted in the program represent a measuring time of 200s for a period of 10ms for the scanning rate as well as 100ms for the rate of storing measured values. First, the controller settings must be adjusted for the internal control loop and then for the external control loop. The controller parameters have been determined in a few experiments and do not guarantee for an optimum controller response. The test result of the response to setpoint changes is illustrated in figure 28.

MCON - Measuring
8.75 7.00 5.25 3.50 1.75 0.00 75.00 Time[s] 150.00 MCON V1.4 CASCTMP1.SIM CCTEMP01.PLT 04.04.02 16.31 Temperature (3) Heater output Setpoint Temperature Fan output

Figure 28. Response to setpoint changes of the cascade control SENSOR 3 (fan: controlled, heater: constant) The control loop structure illustrated in figure 4 is another example for a cascade control. With a constant preset fan speed, the air temperature again forms the external controlled variable, whereas the heater output is cascade controlled. Figure 29 shows the respective work sheet. The work sheet (simulation file CASCTMP2.SIM) only contains the constant control (4V) of the fan speed and the cascade control. The air pressure (or air flow rate) is cascade controlled with a P controller ( K P = 1,75 ), i.e. its actual value remains constant. The actuating signal of the P controller directly controls the heater and is transferred to the plot diagram via a limiter (0-10V) to improve the display. The setpoint for the cascade control loop is the actuating signal of the master PI controller.

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Possible experiments

LTR701 Controlled air and temperature system

Figure 29. MCON work sheet for the cascade temperature control (fan: controlled, heater: constant) ( K P = 9,9, K I = 1,66 ) to control the temperature of SENSOR 3. The temperature setpoint is supplied by a square-wave generator (4V +/-1V or approx. 50-70C, period: 100s). The plot diagram contains the actual value and the setpoint value of the temperature as well as the actuating signal for the heater and the fan speed. The simulator parameters adjusted in the program represent a measuring time of 200s for a period of 10ms for the scanning rate as well as 100ms for the rate of storing measured values. As mentioned above, the controller parameters have been determined in experiments. Figure 30 illustrates the test result of the response to changed setpoints.

MCON - Measuring
8.75 7.00 5.25 3.50 1.75 0.00 0.00 75.00 Time[s] 150.00 MCON V1.4 CASCTMP2.SIM CCTEMP02.PLT 05.04.02 10.11 Temperature (3) Fan control Setpoint Temperature Heating control

Figure 30. Response to setpoint changes of the cascade control SENSOR 3 (heater: controlled, fan: constant)

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LTR701 Airstream and Temperature Control Plant

MCON Software-Documentation Version 1.4

Date: 12-April-2000

MCON Version 1.4

MCON Version 1.4 1 The Installation of MCON 2 Main Menu 2.1 File Menu 2.2 IO- Menu Interface 2.3 Simulator Menu 2.4 Window Menu 2.5 Help Menu 2.6 Worksheet Menu 2.7 Plot Data Menu 2.8 Symbol Bar 3 Windows and Dialogs 3.1 Worksheet 3.2 The Object Window 3.3 Measured Data Window 3.4 Windows During A Running Simulation 3.5 The Simulation Window 3.6 Simulation Parameters Dialog 3.7 Settings Dialog 4 Quick Start of MCON 4.1 General 4.2 Creating a Simulation 4.3 Definition of the Simulation Parameters 4.4 Using IO-adapter cards 4.5 Start of the Simulation 4.6 Simulation Results 4.7 Problems and Limitations 4.8 Description of Special Terms 5 Simulation of a Tank System in Example 5.1 Description of the Plant 5.2 A Simple Tank Simulation 5.3 Controlling the Plant 5.4 Extension of the Model 5.5 Controlling the Real Plant 6 File Formats 6.1 The Simulation File 6.2 The Block Library 6.3 Measured Data File 7 Support und Updates 7.1 Problems with MCON 7.2 Updates 7.3 Contact Addresses 1 2 2 3 4 4 5 5 6 6 7 7 8 11 13 15 16 16 17 17 17 17 17 18 18 18 18 19 19 20 22 23 24 26 26 26 26 27 27 27 27

MCON Version 1.4

1 The Installation of MCON

The installation of MCON is very simple. Start MS Windows on your computer and insert the MCON disk in the disk drive. Now start the program SETUP.EXE either by means of the Windows file manager or by using the start menu of your Windows program manager. After the setup program has started, you have to confirm the installation of MCON and enter the destination path. MCON will be installed on your hard disk and a group called MCON is generated with the Windows program manager. Please follow the instructions of the setup program. If you want to apply MCON to a technical process you will need a DA/AD converter card with a suitable MCON driver. MCON is manufactured with drivers for the DAC6214, the DIC24, the DAC98, the PCL812 and same special drivers for amira laboratory setups. To install a DA/AD converter card follow the instructions in your hardware documentation. Now start MCON and select a driver of your AD/DA converter card by means of the menu IOInterface/select. In the following select the menu IO-Interface/setup to tell the driver the address of the card. Now MCON is ready to work.

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MCON Version 1.4

2 Main Menu
After the program has started you will see the main window of MCON on your desktop. The essential part of this window is the menu bar. Nearly all commands are selected using this menu bar.

Figure 2.1: The main window of MCON The menus in this bar are descibed in the following section. Figure 2.1 shows small symbols below the menu bar. They are used as shortcuts for some commands in the menu bar (see chapter 2.8). The following menus are continuously available from the main menu bar of MCON:

2.1 File Menu

Figure 2.2: The file menu The file menu contains functions to open, close or print files as well as functions to configure the program. { New, creates a new, empty simulation file (*.SIM) in the computer memory. This file may be saved to the hard disk using the menu item Save as ... The file name is undefined at this time. { Open, opens and loads a simulation file (*.SIM), a measured data file (*.PLT) or a block library (*.OBD) from the disk depending on the selected file name extension. A previously loaded file will be overwritten. Page 2

MCON Version 1.4 { Save, saves a simulation file from the computer memory to the hard disk. The file name is as it was used during opening that file. { Save as ..., saves a simulation file (*.SIM) or a measured data file (*.PLT) from the computer memory to the hard disk by assigning a corresponding file name. The type of the file which is to be saved is defined by its file name extension. In case of multiple measured data windows only the active window is saved. { Settings, creates a dialog of multiple pages for adjusting different parameters of the program. { Printer ..., offers a standard dialog to select and configure a printer. The selected settings are valid during the run time of the program. { Print Worksheet, produces a hardcopy of the work area on the printer. The menu item File/Printer is to be considered hereby. { Print Data, produces a hardcopy of the measured data window on the printer. The menu item File/Printer is to be considered hereby. In case of multiple measured data windows only the active window is printed. { Licence Disk, takes the licence data from a licence disk and stores it in the Demo-version of MCON. The Demo-version is changed to a full version by this step. { End, terminates the program.

2.2 IO-Interface Menu

Figure 2.3: The IO-interface menu The IO-Interface menu is used to select and configure the driver of an AD/DA converter card. { Select, allows for selecting an IO-driver for the installed IO-adapter card of the PC. The driver 'DUMMY.DRV' is to be chosen when no adapter card is installed in the computer. This driver is selected automatically after the software installation. { Parameter, calls the options dialog of the IO-driver. The appearance of the dialog depends on the selected IO-driver. Normally the IO-address of the adapter card is to be assigned at least.

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MCON Version 1.4

2.3 Simulator Menu

Figure 2.4: The simulator menu The Simulator menu contains functions to start, stop or set the parameters of a simulation. { Parameter, displays a dialog to adjust the parameters for the simulation which are included in the simulation file. { Start, starts the calculation of the simulation file stored in the computer memory with respect to the adjusted simulation parameters and the selected IO-driver. { Stop, terminates a running simulation.

2.4 Window Menu

Figure 2.5: The window menu The window menu is used to control the important windows of MCON. { Worksheet, displays or hides the window containing the work area. A hook is added to the menu item, when this window is visible. { Objects, displays or hides the window containing the block objects. A hook is added to the menu item, when this window is visible.

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MCON Version 1.4

2.5 Help Menu

Figure 2.6: The help menu The Help menu contains functions to call the online help. { Content, displays the overview page of this help file. { Search, searches for a specific keyword in this help file. { using Help, displays the instructions to operate the Windows help system. { Sample, displays an application of MCON. { Info ..., displays a window with information about the Copyright, the version as well as the registration of the program. Additional menus are available depending on the active window.

2.6 Worksheet Menu

Figure 2.7: The worksheet menu The worksheet menu is visible when the worksheet window is active. The functions of this menu are used to connect, cut or move functional blocks on the worksheet. { Connect, allows for connecting two blocks. { Cut, removes the connection between blocks. { Move down, moves all objects from the work area 100 pixel to the right and downwards.

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MCON Version 1.4

2.7 Plot Data Menu

Figure 2.8: The plot data menu The plot data menu is visible when a plot data window is active. { Configuration, allows for adjusting parameters for the measured data window. Colour and style of a curve as well as different character sets are selectable.

2.8 Symbol Bar

The symbol bar of MCON is located below the main menu. It provides a faster activating of MCON functions. The bar contains the following symbols:

Create a new simulation. Selecting this symbol with the left mouse key is equivalent to the main menu item File/New.

Open a simulation file from the hard disk. Selecting this symbol with the left mouse key is equivalent to the main menu item File/Open.

Save the simulation file from memory to hard disk. Selecting this symbol with the left mouse key is equivalent to the main menu item File/Save.

Display or hide the work area. Selecting this symbol with the left mouse key is equivalent to the main menu item Windows/Worksheet.

Display or hide the object window. Selecting this symbol with the left mouse key is equivalent to the main menu item Windows/Objects.

Start the simulation. Selecting this symbol with the left mouse key is equivalent to the main menu item Simulator/Start.

Stop the simulation. Selecting this symbol with the left mouse key is equivalent to the main menu item Simulator/Stop. Page 6

MCON Version 1.4

3 Windows and Dialogs

The following chapter decribes the windows and dialogs required to operate MCON.

3.1 Worksheet
The worksheet or work area is a window for placing and connecting blocks which are to be simulated. Placing objects is described with the section Object Window. Figure 3.1 shows a typical worksheet.

Figure 3.1: The worksheet The connections between single blocks are directed meaning that they start at the output of a source object and end at the input of a destination object. This is emphasized on the work area by an arrow pointing to the destination object. A new connection is constructed by using either the item Worksheet/Connect from the main menu or the item Connect from the popup menu.

Figure 3.2: The block popup menu The popup menu (Figure 3.2) appears after clicking on the work area. The mouse cursor will be changed to a copper bit in this case. The connection will now start at the block on which one clicks at next. Or it will start from the block on which the mouse cursor was located when the popup menu appeared. A dark-red rubber line starting from the selected output of the source object and ending at the mouse cursor will be displayed either in horizontal or vertical direction. Any click on the work area produces a green base point which is the start point for Page 7

MCON Version 1.4 the next movement of the mouse cursor. The mouse movement has to end in the input of the selected destination object. In this case the connection lines are displayed in black, the base points turn to blue and a red arrow appears. The mouse cursor returns to its original shape. Another starting point for a connection to an object is obtained by inserting a node in an existing connection line. This is carried-out by clicking on the work area outside of any object and moving the 'Start' point near to an existing connection line. A dialog will ask the user if a node should be inserted. A positive answer will insert a node which can be a new starting point for a connection line to the input of a destination object. Any connection line which does not end in a free input of a destination object is removed when the left mouse key clicks on its source object. To remove an existing connection either the item Worksheet/Cut from the main menu or the item Cut from the popup menu is used. The mouse cursor will change to a knife which should be moved near to the connection line which is to be deleted. Any block located on the work area has its own parameter set where the type and number of the parameters depend on the type of the block. Only the parameter Description is available for all blocks. The parameters of a block are only adjustable by means of the item Parameter from the popup menu which was activated by clicking on the specific block. The popup menu contains three other items Flip, Delete and Move which are enabled only when the mouse cursor was previously located at a block and the left mouse key was pressed to activate the popup menu. Selecting the item Delete will delete the block together with all connections starting from this object and ending at this object. The item Move is used to move the selected block to a different position at the work area. All of its connections will be moved accordingly. Selecting the item Flip will mirror the block with respect to the Y-axis which changes the signal direction. Meaning that the signal flow in a typical feedback path is now from right to left.

3.2 The Object Window

The object window displays all blocks which are defined in the loaded block library from MCON. As for the blocks, the window is divided in five groups. Figure 3.3 shows the object window.

Figure 3.3: The object window Page 8

MCON Version 1.4 The group which is to be displayed is selectable by the tab from the lower part of the object window. If not all of the group selector tabs are visible the object window is to be sized up or the selector tabs are scrolled by a double arrow. Any visible block from the object window is moveable to the work area by using the 'drag and drop' method. To do this, the mouse cursor is to be placed above the selected object, the left mouse key is to be pressed and hold by moving the mouse cursor to the work area. Releasing the left mouse key above a free place on the work area displays the selected block at this position. Every function of MCON is realized by a block. The following lists the currently available blocks where blocks with similar functions are grouped together. Group Sources Symbol Name Decription Any calculation of a simulation starts with a source. A source block contains only outputs but no inputs. The following lists the standard source blocks. Constant Source The block constant source provides a constant signal. Square Wave The block square wave generator provides a Generator symmetric square wave signal. Sine Generator The block sine generator provides a signal with a sine shape. Triangular The block triangular generator provides a signal with Generator a triangular shape. Sawtooth The block sawtooth generator provides a signal with Generator a sawtooth shape. The output signal starts with a linear ramp from the negative amplitude to the positive amplitude and then jumps back to the negative amplitude. Potentiometer The Potentiometer is a visualizing block. It allows for a manually adjustable signal during the run time of the simulation. The chain of calculations of a simulation either ends in a loop or in a sink. Sinks are blocks providing only inputs and no outputs. Typically the sink blocks are visualizing objects which prepare or display data during or after the simulation. The following lists the standard sinks. Plotter The Plotter is a visualizing block. It samples its input signals and displays them in a measured data window at the end of the simulation. All of the signals sampled by different plotter blocks will be displayed together in one measured data window. Oscilloscope The oscilloscope is a visualizing block. It displays its input signal in its window. Amplification, time resolution as well as trigger conditions are adjustable manually by using the mouse. Indicating The indicating instrument is a visualizing block. It Instrument displays its input signal in a window during run time of the simulation. Zero Sink The zero sink has no special function. It is used only to terminate open outputs. Page 9

Sinks

MCON Version 1.4 Arithmeti Arithmetic blocks are used for calculations with one or multiple signals. This c Blocks kind of block provides at least one input and one output. The following lists the standard arithmetic blocks. Summing The summing element or summing junction adds its Element two input signals. Branch Node The branch node provides two output signals identical to one input signal. Difference The difference element calculates the difference of Element its two input signals. Multiplier The mutiplier element calculates the product of its Element two input signals. Square-Law The square-law element calculates the square Element (second power) of its input signal. Square Root This block calculates the square root of its input Element signal. Input signals less than or equal to zero result in an output signal of zero. Reciprocal This block calculates the reciprocal value of its input Element signal. To avoid program abortion for a zero input signal the output signal retains its value belonging to the last valid input signal. Divider Element This block returns the quotient of its two input signals. To avoid program abortion for a zero input signal the output signal retains its value belonging to the last valid input signal. Standard The standard control blocks provide the main functions of typical control Control simulations. The capability reaches from a simple proportional amplifier to a Blocks complete PID controller. Each block has one input and one output. Any dynamic function and its corresponding parameters are defined for the frequency domain. The internal calculations will use their transform to the discrete time domain based on the Tustin formulation. A correct calculation is therefore obtained only for a suitable short sampling period. Proportional This block amplifies its input signal in a proportional Element way. Integral Element This block integrates its input signal. The limitation of the integral element is switched off when the lower limit is equal to the upper limit. Derivative This block derivates approximately its input signal Element by calculation the difference quotient. PI Controller This block calculates a complete ProportionalIntegral-(PI) controller. Its input signal should be the control error signal (difference between setpoint and measured signal). The limitation of the integral element is switched off when the lower and upper integration limit are the same.

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MCON Version 1.4 PID Controller This block calculates a complete ProportionalIntegral-Derivative-(PID) controller. Its input signal should be the control error signal (difference between setpoint and measured signal). The limitation of the integral element is switched off when the lower and upper integration limit are the same. This block calculates a first-order lag element. This block calculates a second-order lag element. This block is a combination of a derivative and a first order lag (delay) element.

IOBlocks

This block amplifies its input signal with a given factor and limits the result Transportation- The transportation-lag element delays its input signal Lag Element with a multiple of the sampling period. The IO-blocks provide the transfer of signals between the simulation and the real world. An installed IO-adapter card in the PC and a suitable driver for MCON are required of course. Any IO-block either belongs to the group of sources (meaning a real signal input) or a sink (meaning a real signal output). The number of available IO-channels depends on the installed adapter card. Because the IO-driver configuration is not included in the SIM-file any error due to a missing IO-channel is detectable only at the beginning of a simulation. The following IO-blocks are available. Analog Input This block reads an analog input from an IO-adapter card. Analog Output Digital Input Digital Output Counter Output Stage Release This block converts a digital number to an analog output signal of an IO-adapter card. This block reads a binary signal from an IO-adapter card. This block transfers a binary signal to an IO-adapter card. This block reads a counter from an IO-adapter card. This block controls the output stage release required for laboratory experiments from the company amira.

First-Order Element Second-Order Element Delayed Derivative Element Limiter Element

3.3 Measured Data Window

The measured data window is displayed automatically at the end of a simulation when at least one plot object was included in the simulation structure. The menu bar is extended by the additional item Plot Data as long as this window is active.

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MCON Version 1.4 The legend at the right side of the measured data window indicates the description as well as the kind of representation of all curves (even if they are defined as inactive).

Figure 3.4: The measured data window The representation of the measured data is adjustable by using the menu Plot Data/Configuration. The same manipulations are reachable directly from the measured data window: { Zoom Section To do this, select the upper left corner of the section which is to be zoomed by the left mouse key, hold this key pressed by moving the mouse to the lower right corner of the section and then release the left mouse key. The mouse must not leave the data range limited by its axes during this operation. The selected section is now displayed in full size. { Display the Complete Data Range It is only required to click in the data range inside a zoomed section with the right mouse key to return to the original complete data range. A doubble click on the drawing section or using the menu Plot Data/Configuration shows the Plot Konfiguration dialog (Figure 3.5).

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MCON Version 1.4

Figure 3.5: The plot configuration dialog. This dialog provides adjustments of the measured data window. The dialog is divided in four groups wihch is indicated by lines. The upper part of the dialog is used to enter the title string for the plot and to select a character set for this text. The title string is entered in the edit-field and the corresponding character set is selected after pressing the key to the right of this field. The second part of the dialog determines if the measured points as well as if the connection lines between the measured points are to be taken for representing the curve. The curve will be invisible when neither the measured points nor the connection lines are selected. The next part of the dialog offers the definition of the axes description. Besides the character set the number of digits as well as the decimal positioning of a label are adjustable. The parameters of each curve are set by means of the lower dialog part. At first a specific curve is to be chosen by using the selector list located near to the text 'Curve'. Any of the following parameters is to be defined for each curve. The switch active determines if the curve is included in the plot or not. Conversely to an invisible curve (see above), an inactive curve will also not be considered for the scaling of the axes. Inactivating the first curve with the name 'axes' removes the representation of the axes and labels. The style of a curve is determined by choosing a linestyle (important for black/white hardcopy prints) from the style selector list and selecting a line colour by means of the switch 'Colour'. The switch 'OK' takes the settings as valid for the representation of the measured results and terminates the dialog. The switch 'Cancel' leaves the measured data window unchanged. The switch 'Help' displays the plot dialog help page.

3.4 Windows During A Running Simulation

The windows of visual blocks are another kind of windows in MCON which are visible only if a simulation is running. These blocks are Potentiometer, Oscilloscope and Indicating Instrument. Visual blocks allow for entering parameters or displaying current data values during a running simulation.

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MCON Version 1.4

Figure 3.6: The potentiometer The Potentiometer(Figure 3.6) is a signal source. It's output signal can be adjusted manually using the mousepointer. The signal range is defined with the parameters lower limit and upper limit.

Figure 3.7: The indicating instrument The Indicating Instrument(Figure 3.7) is a sink. The input signal is displayed in a window. If the input signal is in the range between the parameters lower limit and upper limit the pointer will stay in the yellow area and the LED in the lower left indicates green. If the signal is outside of this range, the pointer reaches the red area and the colour of the LED changes to red. If the input signal is not bigger than 10% of the nominal value range, it is diplayed in a decimal format in the lower part of the window.

Figure 3.8: The oscilloscope

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MCON Version 1.4 The Oscilloscope (Figure 3.8) is again a sink.The input signal is displayed in a window. The signal is buffered, so in case the amplitude and the time basis are set correctly each sample can be displayed. Amplitude and time basis can be changed using the buttons on the right side of the window. The measurement is taken continuously or triggered with respect to a positive or negative slope. The sliders in the right side and the bottom of the Oscilloscope are used to set the triggervalue and -delay. All settings are displayed at the bottom of the window.

3.5 The Simulation Window

The menu item Simulator/Start starts the simulation. A window will appear displaying the progress of data acquisition, current messages as well as offering a button to terminate the simulation. Additional Windows with information or measured data may be opened depending on the selected visualizing objects. A simulation file has to be translated to a function list before a simulation can be started. During this automatic operation the following warnings and errors may be displayed. Warnings: { Missing blocks, means that not all blocks displayed on the worksheet are used in the calculation. { IO-Blocks are ignored, means that the IO-Interface is not used. The IO-Interface input signals are always 0, the output signale are ignored. You will see this warning, if the realtime simulation is not used. Warnings does not prevent the simulation. Errors: { Open outputs, means that there are block with an unconnected output. MCON is not able to work with unconnected outputs. { No blocks, means that there are no blocks on the worksheet. { Computing power insufficient, means the realtime simulation can not be calculated with the selected sampletime (The calculating time must not be longer than 30% of the sampletime.). { Illegal IO-channel number, means that the used IO-channel does not exist on your IO-Interface. { Error in the real time engine is an internal error in MCON. The simulation cannot be carried-out in case of errors. The window is to be closed by means of the 'Terminate simulation'-button. The 'Terminate simulation'-button may be used to terminate the simulation at any time. This button is to be used also in case of errors during run time of the simulation to close the window. The menu item Simulator/Stop or the Symbol Stop may be used alternatively.

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MCON Version 1.4

3.6 Simulation Parameters Dialog

This dialog provides the adjustment of the general simulation parameters. These parameters include the measuring time, prestore time, measuring period, sampling period as well as switches for real time operation and automatic termination. { Measuring Time, is the time in seconds for the data acquisition of the plotter blocks. { Prestore Time, is the time in seconds between the start of the simulation and the start of the data acquisition. { Measuring Period, is the time in seconds between two successive data samplings (measured points). The quotient Measuring Time versus Measuring Period has always to be smaller than 16384 because the measuring will be terminated at once otherwise. A typical screen provides a representation of about 1000 measured points. A greater number of measured points is therefore a waste of memory as well as computing power. { Sampling Period, is the sampling period in seconds used to calculate the discrete simulation structure. The sampling period has to be adjusted significantly shorter than the smallest time constant of the discrete simulation structure. Otherwise a sufficient correspondance with the analog system is guaranteed no longer. Conversely a sampling period which is too small causes a long calculation time and may prevent from real time operation. { Simulation in Real Time, is a switch for setting the real time or the virtual time operation for the simulation. Real time operation is possible only for a sampling period greater than 10ms. A simulation in virtual time is typically faster but does not allow any IO-operation with adapter cards. { Automatic Termination, is a switch to determine if the simulation is terminated automatically at the end of the measuring time or if the simulation runs continuously.

3.7 Settings Dialog

The adjustment of different parameters of the program is provided by a dialog with multiple pages (windows). Each page of the dialog operates on parameters belonging to a specific task. { Worksheet, adjusts parameters for operations on the work area. To help placing the blocks the work area may be provided with a grid. Previously placed blocks will be left unchanged. There are three different grid steps available 1 pixel (no grid), 8 pixel (fine grid) and 16 pixel (rough grid). { Visualizing Blocks, adjusts parameters for the representation of visualizing blocks during the simulation. During real time operation any visualizing block is updated with an assignable cycle time. This cycle time has to be adjusted with respect to the hardware and the required computing power. Three buttons 'Ok', 'Cancel', 'Help' are located at the right side of the dialog. The button 'Help' provides opening the on-line help. The button 'Ok' is used to terminate the dialog by taking all parameter adjustments as valid. The dialog is aborted by means of the button 'Cancel'. Any new parameter settings will be ingored in this case.

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MCON Version 1.4

4 Quick Start of MCON

This chapter gives an overview on operating with MCON. All the required steps are described shortly. More details will be described with an example in chapter 5.

4.1 General
MCON operates block oriented, meaning that every block positioned on the work area is calculated separately. The calculation result is then transferred to the following block. The linkage between the blocks is defined by directed connections. Every block is calculated once per sampling period. Any chain of calculations starts with a source (a block with outputs only) and ends with a sink (a block with inputs only) or a recursion. The following describes the main steps working with MCON:

4.2 Creating a Simulation

The menu item File/New creates a new, empty simulation file in the memory. Alternatively a previously saved file may be loaded by means of the menu item File/Open. A window with the work area is displayed afterwards. The menu item Window/Worksheet or the corresponding icon toggles the mode of the window from visible to invisible and vice versa. Using the menu item Window/Object Window displays the object window. By the method 'drag and drop' the left mouse key is useable to transfer blocks from the object window to the work area.Clicking on an object at the work area opens a popup menu to move or to delete this object. Clicking on the work area opens a popup menu used to define connections between blocks or to disconnect blocks. To construct a connection click on the work area and select the menu item Connect. The mouse cursor will change to a copper bit. Because a connection has to be directed you will have to click at first on the source object and then on the destination object. The default direction is always from left to right because the default input of an object is located at the left side of any object. In case an object provides more than one input or output the connection with the shortest distance to the mouse pointer is selected automatically.

4.3 Definition of the Simulation Parameters

Two different sets of parameters are important for a simulation. At first the general simulation parameters are to be adjusted using the menu item Simulator/Parameter. Secondly the default settings of the parameters of each block on the work area may be changed. To do this click with the left mouse key on the corresponding object on the work area and select the item Parameter from the appearing popup menu. A window will be displayed allowing for adjustments of the parameters of this block. Depending on the type of the selected block a specific number of parameters may be set individually for this block.

4.4 Using IO-adapter cards

IO-adapter cards are used to connect the simulation with a real process. Corresponding blocks provide input and output of analog or digital signals including counting events. By means of the menu item IO-Interface/Select an IO-driver suitable for the installed adapter card is to be selected followed by a driver configuration which matches the card settings. The option Real time belonging to the general simulation parameters has to be active. Otherwise the IO-blocks will be ignored. Page 17

MCON Version 1.4

4.5 Start of the Simulation

The menu item Simulator/Start starts the simulation. A window will appear displaying the progress of the data acquisition, relevant messages as well as a button to terminate the simulation. Further windows with information or measured data may be opened automatically depending on the type of visualizing objects (sinks).

4.6 Simulation Results

When at least one plotter object was selected the measured data window will appear automatically after terminating or cancelling the simulation. Any other window of visualizing objects will be closed at the same time.

4.7 Problems and Limitations

A list of known problems and limitations follows: { The selected sampling period has to be significantly shorter than the smallest time constant of any of the selected blocks to avoid improper results. This is a general problem of any digital simulation and has to be considered. { Closed control loops containing only blocks with a proportional behaviour will not be simulated correctly. A time delay of one sampling period is introduced implicitly in the feedback path before the summing point. This may cause an unstable behaviour under extreme conditions.

4.8 Description of Special Terms

{ Simulation The term Simulation in connection with MCON allways means a simulation file independent of the special task like a simple measurement acquisition, a control application or a complex simulation of a real process. { Real time The software has to operate in real time in case of controlling a real plant or when the behaviour of this plant is to be simulated in real time. Meaning that the virtual computing time for each sampling period has to be equal to the real time. Because the required computing time has allways to be less then the adjusted sampling period, any simulation in real time will take a longer timer than without real time simulation. To operate MCON in real time the sampling period must not fall below a minimum valueof 10ms. Otherwise the real time operation mode is switched off automatically. Furthermore the required computing time for one step must be smaller than 50% of the sampling period. This is checked automatically after starting the simulation. The real time operation is controlled by interrupts. Any hardware accesses with a higher interrupt priority (like swapping memory contents to the hard disk or multimedio outputs) will result in addtional time delays. To obtain an exact real time behaviour it is recommended to either use a longer sampling period or a PC with more compution power.

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5 Simulation of a Tank System in Example

This example demonstrates the single steps to design the model as well as to control a tank system. The first step describes the technical data of the system and the mathematical relations. The resulting mathematical model is translated to a simulation file for MCON in the second step. Measuring operations for this simple plant are demonstrated. The model is extended by a controller in the third step. The behaviour of the closed control loop may be evaluated by measurements. Flexible setpoint adjustments as well as different measuring devices extend the model in the fourth step. The last step allows for comparison of the simulated model and the real plant. MCON will operate as a controller for the real plant.

5.1 Description of the Plant

A tank system as a simple nonlinear plant is taken as an example for a closed control loop. The tank system consists of a cylindric tube with a bottom and a pump supplying the tank with water from a reservoir. The water flows back into the reservoir through an opening (nominal outflow valve) at the bottom of the tank. Specific parameters for this tank system are arbitrary in principle. But we will use the laboratory experiment TS201 of the company amira GmbH as an example and will take the parameters accordingly. Cross section of the tank : A = 78.53 cm Cross section of the nominal outflow : Sn = 0.2827 cm Outflow coefficient : Az = 0.7 Tank height : H = 60 cm Maximum pump flowrate : P = 100 ml/s The mentioned laboratory experiment may also be taken for a comparison of a real plant and the corresponding simulation with MCON. Furthermore this system is directly controllable when the controller itself is realized with MCON. The following points have to be considered during creation of the mathematical model of the plant mentioned above: {The tank behaves like an integrator with an integrator constant equal to the reciprocal of the tank cross section. {The outflowing volume stream at the tank bottom is to be calculated with respect to the liquid level h of the tank according to Torricelli's law: Qab = Sn * SQRT( 2 * g * h ) {The flow configuration at the nominal outflow is considered by the outflow coefficient Az.

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5.2 A Simple Tank Simulation

Let us consider for the first step a simple tank with an inflow but without an outflow. The tank behaves like a real integrator with an integrator constant equal to the reciprocal of the tank cross section. From the window objects we now select (drag) an integrator block from the group standard and move (drop) it to the empty work area. For our tank model the tank cross section is 78.53 cm resulting in an integrator constant of 0.0127. Because the minimum tank liquid level is 0 the lower integration limit is to be adjusted to 0. The upper integration limit is set to 60 meaning 60 cm (block parameters do not include units !). To adjust the mentioned values click with the left mouse key on the integrator block on the work area and select the item Parameter from the popup menu. Besides the numbers for the block its description is determined with the title "Tank". Further blocks are required like a constant source block simulating an inflow of 10ml/s as well as a block to measure the tank liquid level. Both blocks are to be placed in the work area in the same way as for the first block. The constant source block receives a description "Pump" as well as a number of 10. Now all the neccessary parameters of the blocks are adjusted. The next step is to create meaningful connections between the blocks. This is carried-out by clicking with the left mouse key on an empty position on the work area and selecting the item Connect from the popup menu. The shape of the mouse cursor will change to a copper pin and the text "Start" will appear. Now click on the constant source block to create a connection to the integrator block. The text near to the mouse cursor is changed now to "Stop". Now complete the connection by clicking on the integrator block which is the destination of the connection. The same procedure is to be used to create the second connection between the integrator block and the measuring block. The work area will then look like the following:

Figure 5.1: A simple tank model The corresponding simulation file is T_TUT_1.SIM which is contained in the directory DATA. To adjust the general simulation parameters select the item Parameter from the main menu item Simulator. Now a measuring time of 500s, a measuring period of 0.1s as well as a sampling period of 0.05s are adjusted in example. To obtain a fast simulation the real time operation is switched off and the automatic termination is switched on. The simulation is started by means of the menu item Simulator/Start. The resulting measurement is as follows:

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Figure 5.2: Height measurements for the simple tank model If the tank model is extended by an outflow located at the bottom side of the tank the outflowing volume stream is to be calculated according to the Torricelli's law with respect to the liquid level. To simulate this relation two blocks of type 'proportional' element from the group 'standard' and the block 'square root' from the group 'arithmetic' are required. The liquid level is multiplied with the factor 2g meaning 1962 (with respect to cm), the square root is calculated for the resulting product and this result is multiplied with Sn and Az meaning 0.19789. The splitting of a signal is obtained by means of the block 'node'. The difference between the flowrate supplied by the pump and the outflowing volume stream is calculated with the block 'difference'. The work area may then look as follows:

Figure 5.3: A tank model with outflow The corresponding simulation file is T_TUT_2.SIM which is contained in the directory DATA. Adjusting a pump flowrate of 20 ml/s as well as a measuring time of 300 s results in the following:

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Figure 5.4: Height measurements for the tank model with outflow An equilibrium between the inflow and outflow is obtained for a liquid level of approx. 5 cm. The next step is

5.3 Controlling the Plant

This section describes the extension of the tank simulation by a controller. The following blocks are added: { a 'difference' block from the group 'arithmetic' { a 'node' from the group 'arithmetic' { a 'PI controller' from the group 'standard' { a 'limiter' from the group 'standard' The application of the 'node' and the 'difference' block is indicated in the figure below. The 'PI controller' has a limited integral portion in the range from 0 to 100. The reason for this limitation is to avoid arbitrary great output signals of the integral portion when the setpoint is not reachable in short time with respect to the given pump flowrate. The 'limiter' simulates the limited pump flowrate in the range from 0 to 100 (ml/s). The 'constant source' block operates now as a setpoint instead of replacing the pump. We select a setpoint of 30 (cm). The work area may now look as follows:

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Figure 5.5: The controlled tank system The shown simulation file is stored in the file with the name T_TUT_3.SIM which is contained in the directory DATA. With the controller parameters determined by experiments: Kp = 5 Ki = 0.5 the following result is obtained:

Figure 5.6: Step response of the controlled tank system The next step is described in section

5.4 Extension of the Model

The model is now extended by a flexible setpoint adjustment. Additional measuring blocks are inserted. The 'constant source' block is replaced by a 'potentiometer'. Its parameters are to be adjusted such that setpoints are selectable in the range from 0 to 60. The 'plotter' to measure the liquid Page 23

MCON Version 1.4 level is replaced by an 'oscilloscope'. An 'indicating instrument' is introduced to measure the pump flowrate. Its parameters are to be set such that the scale is only in the range from 0 to 100 (ml/s). An additional 'node' is required to connect to the 'indicating instrument' . These are only some of the possibilities to obtain a deeper inside in the control behaviour. The work area with the extensions as mentioned above may look like:

Figure 5.7: The extended model The corresponding simulation file is T_TUT_4.SIM which is contained in the directory DATA. To observe the effects of the extensions the switch automatic termination from the main menu item Simulator/Parameter has to be disabled. After starting the simulation it will run continuously until it is stopped manually. Three other windows will be visible during run time of the simulation. The windows may overlap each other but they can be moved apart easily. These windows disappear automatically when the simulation is stopped. The liquid level setpoint is adjusted by means of the window titled 'Poti' (similar to figure 3.6). The effects are observable directly from the other windows. The current pump flowrate is displayed in the window titled 'indicating Instrum...' (similar to figure 3.7). The liquid level of the tank is displayed with respect to time in the window titled 'Scope' (similar to figure 3.8). The parameters of the time axis as well as the gain factor may have to be adjusted. Carrying-out experiments with a real plant is demonstrated in the chapter Controlling the Real Plant.

5.5 Controlling the Real Plant

To control the real plant an analog IO-adapter card as well as the full version of MCON are required. The control of the real plant has to operate in real time. Only for the reason of a simple understanding the controller will no longer operate with signals in cm instead it will read the sensor voltage of the laboratory experiment. A suitable setpoint adjustment in cm may be added easily later on. Page 24

MCON Version 1.4 As can be seen from the following figure some changes in the simulation file are required:

Figure 5.8: The real plant control The information about the liquid level is transduced by the level sensor connected to the IOadapter card. The card reads a sensor voltage in the range from -10V to +10V (channel 1). This signal is the output signal of the block 'A-In'. Because the sensor signal decreases for an increasing liquid level the gain factor of this block is set to -1. The liquid level setpoint is adjustable by the block 'Poti' as before but in a range from -10 to +10. The control error signal (difference between setpoint and measured liquid level) is connected to the controller. The controller parameters have to be adapted due to the changed signal ranges. The 'limiter' has to limit the controller output signal in a range which is valid for the given IO-adapter card (typically -10 to +10 for a DAC6214). The block titled 'A-Out' transfers the control signal to the selected channel (channel 1) of the IO-adapter card. Any of the blocks measuring signals are to be adapted to the new signal ranges. The simulation file contains an additional block titled 'output stage release' which allows for controlling the security circuits mounted in any laboratory experiment of the company amira GmbH. Otherwise MCON would not be able to control such an experiment. The shown simulation file is stored in the file with the name T_TUT_5.SIM which is contained in the directory DATA.

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6 File Formats
MCON knows three different file formats.

6.1 The Simulation File

The name extension of a simulation file is SIM. The simulation file contains all information about the simulation structure together with the general simulation parameters as well as the parameters of all blocks belonging to the simulation. The configuration parameters of the IO-adapter card are stored in MCON.INI instead. To display a simulation file a suitable block library has to be loaded (see below).

6.2 The Block Library

The name extension of a block library is ODB. In general it is not neccessary to load a block library by hand. The file DEFAULT.ODB is loaded automatically after the start of MCON. The block library contains the default block parameters, information about the connections, function numbers and graphic representations of the single blocks. The applied block library has to fit to the version of MCON.

6.3 Measured Data File

The name extension of a measured data file is PLT. Besides the measured data this file contains information about the graphic representation like title, colours, character sets and linestyles.

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7 Support und Updates

7.1 Problems with MCON
In case of problems or questions during working with MCON please consider the following remarks: { Warning: The simulation file was created with a different version of MCON. This warning appears when the version number stored in the simulation file is different from the version of the program. This message may be ignored normally. Furthermore this message will disappear after storing the simulation file with the current MCON version. { You obtain an unexpected result: Please check for a suitable sampling period. { The program aborts a running simulation with number overflow: MCON operates with numbers in the range from 1.5 * 10-45 to 3.4 * 1038 . Any number overflow may be obtained in case of unstable control loops or when unsuitable feedbacks or damping factors have been selected. { Your AD/DA adapter card is not supported by MCON. Please contact your distributor and ask for newest card drivers. { Error messages from WINDOWS or other program aborts. Please contact the manufacturer of MCON. Note down the error conditions, the used hardware and software as well as the exact error message. { The installed software does not operate. Please contact your disbributor.

7.2 Updates
After inserting the original disk containing an older registered version of MCON, any installed newer DEMO version of MCON is convertable to a registered version by means of the menu item File/License from the DEMO version. The newest MCON DEMO version is obtainable { from your distributor { from the internet: www.amira.de

7.3 Contact Addresses

{ Internet:[email protected] { Tel.:+49 203 3780950 { Fax.:+49 203 3780956 { Post:amira GmbH Bismarckstr. 67 47057 Duisburg

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