EE-223 Instrumentation and Introduction Process Control Trainer

Measurement (4 in 1)

Introduction to Process Control Trainer (4 in 1)

Process Control Trainer (4 in 1) IT-5200
Process Control Trainer contains an educational board with a pressurized vessel and a set of
sensors and actuators for level, pressure, temperature and flow. A control module containing
the interface circuits for the sensors and the actuators and ON/OFF control, proportional
integral and derivative (PID controller) is also included. Moreover, a separate Programmable
Logic Controller (PLC) can be used to perform control experiments.

Figure 1 Process Control Trainer 4 in 1 (IT-5200)

Figure 2 Programmable Logic Controller

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
Let’s go briefly through various components of Process Control Trainer

Figure 3 Process Control Trainer

Figure 4 Process Control Trainer Diagram

To understand the function and placement of each component, we will refer to diagram given in Fig 4.
EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
The Water Storage tank (Fig 5) has 32 liters capacity and it will serve as our main storage tank.

Figure 5 Water Tank 32 liters

The Delivery valve (Fig 8) will always remain open. It is used when disconnecting the main water
storage tank for servicing.

Figure 6 Delivery Valve

Next to delivery valve, there is a strainer to filter out water, electronic flow sensor and pump. The
readings of flow sensor are available on flow sensor interface of the control module. See Fig 26.

Figure 7 Strainer, Flow Sensor, Pump

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
The non return valve ensures that working fluid flows in only one direction. In case of high reverse
pressure, the pressure switch cuts off the motor.

Figure 8 Pump, Non Return Valve, Pressure Switch

Flow meter gives the readings in US gallons per minute (GPM) or liters per minute (LPM). Note that
1 US Gallon is approximately equal to 3.785 liters.

Figure 9 Flow Meter (US Gallons per minute)

Manual valve will be used for manual control of flow.

Figure 10 Manual Valve

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)

The motorized valve will be actuated from motorized valve driver (see Fig 34). Note that if the red
line is horizontal, it means the valve is open. If its vertical, it means the valve is closed.

Figure 11 Motorized Valve

The heater indicator light will turn on when the heater is actuated.

Figure 12 Heater Indicator

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
Now let’s see various sensors, valves and gauges connected with the process control tank.

Figure 13 Process Control Tank

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
The drain valve is used to manually drain the process control tank.

Figure 14 Drain Valve

The needle valve is used to drain the process control tank manually. Needle valve has more fine drain
as compared to drain valve.

Figure 15 Needle Valve (for fine drain)

The solenoid valve is used to drain the process control tank. It is actuated by Solenoid Valve Driver
(see Fig 36)

Figure 16 Solenoid Valve

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
The thermocouple is used to measure temperature to actuate the over heat protection system.
Whenever the internal temperature of the process control tank exceeds 45 centigrade, the heater is cut
off.

Figure 17 Thermocouple and Heater connection

Figure 18 Over Temperature Protection System

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
The heating element is actuated by heater driver (see Fig 35)

Figure 19 Heating Element

The level sensor with Linear Variable Differential Transformer (LVDT) is used to measure
level.

Figure 20 Level Sensor with LVDT

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
The temperature gauge gives temperature readings in centigrade. Another sensor PT-100 is a
Resistance Temperature Detector (RTD) is located very close to this gauge in the process control
tank. Its readings are taken from temperature sensor interface (see Fig 27)

Figure 21 Temperature Gauge

Pressure gauge gives readings of pressure in psi or bar. Another electronic pressure gauge is located
right next to this analog pressure gauge. Its readings are taken from pressure sensor interface (see Fig
28)

Figure 22 Pressure gauge

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)

Figure 23 Electronic Pressure Gauge

The overflow valve is used to handle overflow, as well air input when draining the process control
tank.

Figure 24 Overflow Valve

The float switch indicates whether a certain level is reached or not. Its reading is taken from float
switch output in level sensor interface (see Fig 26)

Figure 25 Float Switch

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
Now, lets look at the sensor interfaces, controllers and actuators.

Figure 26 Sensor Interfaces, Control Modules (ON OFF and PID) and Actuators

The level sensor interface takes readings from level sensor LVDT (see Fig 19) and converts the phase
shift to DC output. The controller scheme in this training system is designed around DC voltages. The
output of the level sensor connected as input to signal conditioner which is a voltage to voltage
converter. Gain and offset can also be set in this level sensor interface. The output of float switch (fig
24) is also read from this level sensor interface.

Figure 27 Level Sensor Interface

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
The flow sensor interface is used to take readings from electronic flow sensor (see fig 7). The flow
sensor outputs the flow readings in frequency. The output of this flow sensor is then given as input to
frequency to voltage converter with gain and offset adjustment. The output of this F to V converter is
in DC volts.

Figure 28 Flow Sensor Interface

Temperature sensor interface takes the readings from PT-100 RTD and gives output at pin 11 in DC
volts.

Figure 29 Temperature Sensor Interface

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
The pressure sensor interface takes readings from electronic pressure sensor and gives output at pin 11
in DC volts.

Figure 30 Pressure Sensor Interface

The digital PID controller can be connected to computer via USB and can be programmed to have
variable gains for KP, KI and KD. It can control one parameter through its analog output. It can also
operate two relays.

Figure 31 Digital PID Controller

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
The analog PID controller can be programmed in analog fashion by adjusting its gains for
Proportional, Integral and Derivative control. It can control just one parameter.

Figure 32 Analog PID Controller

The ON-OFF controller with Hysteresis is used to control one output through ON-OFF control
scheme.

Figure 33 ON-OFF Controller

The set point 1 is a variable DC supply (0 to 10V), and set point 2 goes from -10 to +10 volts. Vcc
and Vee provide fixed voltages.

Figure 34 DC Supplies (SETPOINT 1 and 2)

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
The water pump driver takes input as DC volts, converts it Pulse Width Modulated (PWM) Output,
this PWM output is then power amplified and then fed to the motor to drive the pump. The motor and
pump move in only 1 direction.

Figure 35 Water Pump Driver

The motorized valve driver is used to take input as DC volts and is used to drive the motorized valve
driver (see Fig 11)

Figure 36 Motorized Valve Driver

EE-223 Instrumentation and Introduction Process Control Trainer
Measurement (4 in 1)
The heater driver works similar to water pump driver except that its output goes to heating element
(see Fig 18)

Figure 37 Heater Driver

The solenoid valve driver is used to operate the solenoid valve to drain the process control tank. Its
input is in DC volts which is power amplified and fed to solenoid (see Fig 16)

Figure 38 Solenoid Valve Driver