Process Control

Process Control

General Accessories
Programmable Logic Controller 38-350

Features for 38-350

This equipment is a fully functioning industrial PLC unit housed in a rugged metal case.
All connections are via 4mm sockets. The unit is capable of operating with 24V or 5V
logic signals and can also accept 4-20mA current loop inputs via the current to voltage
converters and the voltage comparator. A variable 4-20mA current source with adjustable
span and zero is also provided. The voltage comparator has variable hysteresis allowing
the PLC to control analogue events. It connects to the Process Trainer via the 38-200
Process Interface and regulates the system using on/off control elements.
The user may create sequences using conventional ladder logic and demonstrate
the programming on the controller itself, without a process actually being connected.

! Stand-alone PLC fully

compatible with PROCON

Along with the Process Trainer, Interface and Controller the following may be studied:
Production of Ladder Logic Diagrams for sequence control and evaluation using
manual switches and LEDs.
Sensing and Sequencing Control of the following system elements is possible:
Level and Flow Process Trainer: Control of the water pump; Control of the solenoid.
Level and Flow Process Trainer with Level Sensor pack: Sensing the level in the
Process Tank; Control of the water pump; Control of solenoid valves.
Temperature Process Trainer: Sensing Temperature; Control of the Heater;
Control of the Circulating pump.

! Uses Industrial Standard

PLC unit
! Power supply included

Gives users the ability to extend investigations to include developing their own control
algorithms, as well as enabling more extensive data capture and instrumentation.
Advanced process control techniques, such as Fuzzy logic and Neural networks can
be used to control PROCON systems.
Special functions include: " Outputting analogue values " Interrogating analogue
inputs " Inputting and outputting digital signals in a variety of formats " A PID
function to form 2 standard PID loops " Timer functions " PWM output production
" Integration of analogue outputs " A pulse function " Setting the maximum rate
of change of a variable.

! PLC can be programmed

in instruction list or ladder
logic formats

System Features
! Trainers for Level and Flow,

! Introductory guide to PLCs

Temperature, Pressure & pH.

! Hand-held programmer
option

! Uses industry standard

Process Controller, 4-20mA

signals and RS232/RS485
serial communication bus.
easily reconfigurable using
modern push fittings.

Features for 38-370

!
!
!
!
!
!

Microprocessor based
Intelligent signal conditioning
3 analogue & 2 digital inputs
2 analogue & 2 digital outputs
RS232/485 serial outputs
Advanced control methods
can be studied

Ordering Information

! Discovery software.
! Fully protected by earth

leakage circuit breaker.

A range of Industrial Process Control Trainers that operate using browser-based

Discovery software in real-time control applications including simulations.

Complete Systems
PROCON Level/Flow Process Control Training System
(38-100, 200, 300, 400, 420, 490, 901-M).
PROCON Temperature Process Control Training System
(38-600, 200, 300, 480, 490, 901-M).
PROCON Level/Flow & Temperature Process Control Training System
(38-100, 38-600, 200 x2, 300 x2, 400, 420, 490 x2, 901-M).
PROCON Pressure Process Control Training System (38-714, 200, 300, 490, 930-M)
PROCON pH Process Control Training System (38-716, 200, 300, 490, 940-M)
Complete PROCON System (five processes, 38-003, 004 and 005)
Industrial Process Fault Finding Training System

38-001
38-002
38-003
38-004
38-005
38-010
34-250

Optional PROCON Accessories

RS485 lead
38-801
Air Compressor
38-820
Chart Recorder
38-830
Mobile Trolley
38-840
Water Pressure Regulator
(for use with 38-480)
38-481

Software
Discovery software pack for Level/Flow and Temperature
Discovery software pack for Pressure
Discovery software pack for pH

38-901-M
38-930-M
38-940-M

Optional Equipment
38-350
38-370
38-610

Programmable Logic Controller

Data Acquisition Unit
Forced Air Cooler

Separate Items
Process Interface
Process Controller
Level Sensor Pack
Flow Sensor Pack
Temperature Auxiliary Control Pack
Digital Display Module

NB. All training systems are also available for 120 volt supplies.
Please specify which voltage value you require when ordering.
Feedback reserves the right to change these specifications without notice.
Registered in England number 990620.
A subsidiary of Feedback plc.
Process Control Training Systems - PCTS 0205-4

Process Control Training Systems

! High degree of modularity -

Data Acquisition Unit 38-370

Industrial Process Trainer

34-250
PLC Interface for 34-250 34-252-1
Basic Process Trainer
38-100
Temperature Trainer
38-600
Pressure Trainer
38-714
pH Trainer
38-716

PROCON

Printed in England.

38-200
38-300
38-400
38-420
38-480
38-490

Contact:
Feedback Instruments Ltd
Park Road, Crowborough,
E. Sussex, TN6 2QR, England.
Tel: +44 (0) 1892 653322
Fax: +44 (0) 1892 663719
E mail: feedback@fdbk.co.uk
Website: www.fbk.com

Feedback Incorporated
P.O Box 400,
437 Dimmocks Mill Road,
Hillsborough, NC 27278, USA
Tel: (919) 644 6466
Fax: (919) 644 6470
E-mail: info@fbk.com
Website: www.fbk.com

Process Trainers are available for:

Level & Flow, Temperature, Pressure and pH control

Study areas covered using PROCON Process Control Training systems include:
Setting and calibrating 4-20mA loops
Sensors and calibration
Operating manual, solenoid and motorised control valves
Determining the characteristics of control valves
Understanding transducers and transmitters
Setting zero and span of transmitters
Use and understanding of process control terms
Understanding the operational features of an industrial process controller
Controller calibration
Recognition and understanding of different types of control function
Use and understanding of proportional control, PI and PID control
Tuning PID controllers
Autotuning controllers
The systems are configured using a series of units including a Process Rig,
Process Interface, Process Controller and various Sensors that measure
process variables.
The systems are ready-to-run and contain all the software and PC based
instrumentation required to perform a wide range of process control assignments.

System Benefits
! Complete with on-screen

courseware, instruction and

questions
! Provides all required virtual

instrumentation with unique

Discovery software
! Ideally suited for Technician

and Vocational courses

! Extendable to cover more

complex process control

problems
! Covers a wide range of

competencies
! Industrially relevant

processes and components

! Compact bench-top systems
! Clean process fluids of

water or air used by

appropriate trainers

Industrial Process Fault Finding

Training System 34-250

Discovery software

Familiarisation of Pressure Trainer

Learning material is provided in the form of browser-based Discovery software.

The unique Discovery software environment provides real-time, on-screen process
monitoring with animated mimic screens together with theory, background information and
questions. The free movement between screens allows a user-friendly graphical interface.

Features

!
!
!
!
!
!
!
!
!
!
!
!
!

! Self contained process

Interactive hardware/software configuration

Browser based curriculum
Self-paced learning
Practical demonstration of theoretical background
Simulations - temperature modelling
Interactive patching diagrams
Shows real-time process changes
Hands off for tutors - Hands on for students
Embedded Virtual Instrumentation
Automatic controller configuration
Data export to spreadsheet for analysis
Changeable timescales for playback of results
Dual playback for comparison of process variables

! Wide range of easy to apply

faults
! Mechanical, electrical,
electronic & process faults
! May be driven from external
PLC or process controller
! Fully protected for safety
! Comprehensive Instructors
and Students Manuals

pH

pH

Real-time data capture & measurement

Detailed explanatory layout

Familiarisation of pH Trainer

Integrated interactive simulations

Discovery software is a Windows based application compatible with Windows 98, ME,
2000 and XP operating systems.
Discovery Software is available for all four Process Trainers:
Discovery software pack for Level/Flow and Temperature
Discovery software pack for Pressure
Discovery software pack for pH

Detailed background material

! Teaches fault diagnosis and

fault finding methodologies

38-901-M
38-930-M
38-940-M

This Trainer is designed to provide a platform that enables students to trace

faults down to a detailed level, in a systematic way, through a relatively easyto-understand process.
Faults can be introduced by the instructor via switches concealed behind a locked
compartment, to which the student does not have access. These switches provide
short circuits and open circuits and can also switch in or out circuit elements to
simulate a variety of fault conditions. Additional faults can be inserted into the
process through the replacement of working components with faulty ones,
e.g. faulty float switches; faulty relays; faulty sensors and faulty solenoid coils.
The system has been designed to teach a methodical approach to fault diagnosis
in industrial processes. The methodologies taught within the system are equally
relevant to any student or trainee studying fault diagnosis.
Designed to be used by people studying industrial process maintenance, it can
also be used as a process trainer in its own right, using either Electronic
Controllers (PID) or Programmable Logic Controllers (PLCs).
The process involves initially filling a header tank with water and then cycling the
level between a set upper and lower limit, whilst simultaneously creating a demand
from the header tank via two on/off solenoid drain valves into a sump tank. Flow is
produced by a pump and controlled by relay operated on/off solenoid valves which
control:
the inflow of water to the header tank
the outflow of water from the header tank
The level of water in the header tank is monitored by float switches which open
and close at the following points:
Header tank low (nearly empty)
Header tank normal operation lower limit
Header tank normal operation upper limit
Header tank overflow
Alternative flow and level control strategies can be introduced by the connection
of an industrial process controller or a PLC unit with analogue I/O using 4-20mA
current loop I/O via a motorised control valve with a pulse flow meter and proportional level control sensor. The 38-300 Process Controller is ideal for this task.
Optional Accessory 34-252-1 PLC Interface allows easy connection of a PLC to
the 34-250.

Curriculum Coverage
! Introduction to the system
! Fault finding methodologies
! Fault analysis flow charts
! Fault finding from circuit
diagrams
! Fault identification to Line
Replaceable Unit level
! Simple electronic fault
finding
! Diagnostic tools
! Maintenance procedures
! Process control techniques
! Fault finding processes
controlled from electronic
controllers
! Interfacing to Programmable
Logic Controllers (PLCs)
! Fault finding in PLC based
systems

pH Training System 38-005

Level & Flow Training System 38-001

Features

Features

! All components resistant to

agressive fluids

! Contains a selection of level

& flow sensors & indicators
! Flow controlled by linear
motorised control valve
! On/Off and proportional
control
! P, PI and full PID control
with autotune facility
! Couples with Temperature
Trainer for dual loop control

! Motorised agitator
! Removable pH probe
! Industry standard 4-20mA
control signals
! A precision motorised
control valve
! Four tanks

! Modern push fittings

! Modern push fittings

! Water used as the process

fluid
! Comprehensive lab notes
and Discovery software

! Comprehensive lab notes

and Discovery software

Curriculum Coverage
! Introduction, familiarisation
and calibration of the pH rig
! Interface familiarisation
and calibration
! Controller familiarisation
and calibration
! Valve characteristics
! Manual control of pH
! Open loop response
! On/off control of pH
! Simple proportional control
! Effect of proportional band
! Study of proportional and
integral control
! Study of proportional and
derivative control
! Study of proportional,
integral and derivative
control

The pH Training System is based around the pH Rig and is a self-contained

educational platform for teaching pH level control and effluent treatment
methods.
The System comprises two independently pumped fluid circuits mounted on a
robust bench-top panel which allows the study of the principles of process control
using the pH of the mixed effluent and reagent fluids as the process variable.
The system is suitable for individual student work or for group demonstrations.
Effluent and reagent are contained in separate holding tanks prior to being
pumped into the reaction tank where mixing is carried out.
The reaction tank contains an accurate pH probe and agitator. The agitator is
designed to constantly mix the contents of the reaction tank. The pH probe is
designed to monitor the pH level of the effluent/reagent mixture and is supplied
with a transmitter which produces a standard 4-20mA output signal.
The signal is passed to the Process Controller as the process variable.
A precision, motorised control valve is present in the reagent feed to allow
accurate delivery control. The valve is designed to be controlled by standard
4-20mA control signals. Total effluent and reagent fluid shut-off capability is
provided by two normally-closed solenoid valves.
A treated fluid tank is provided to facilitate easy disposal of the process fluid.
All components have been carefully selected to be resistant to aggressive fluids.
Recommended chemical solutions (customer supplied)
Reagent tank: Hydrochloric Acid at 0.05 Mole.
Effluent tank: Sodium Hydroxide at 0.05 Mole.

The Basic Process Trainer is a single loop system allowing the study of the
principles of process control, using liquid level and flow rates as the measured
process variables. The system is a completely self-contained, low pressure
flowing water circuit supported on a bench-mounted panel, making it suitable for
individual student work or for group demonstrations.
It comprises a dual compartment process tank, linked to a sump tank by manual
and solenoid operated valves. Water is pumped through the system, via a
variable area flow meter and motorised control valve. Level is measured in the
process tank. Flow is measured through an optical pulse flowmeter.

Curriculum Coverage
Curriculum coverage

Ancillary Equipment - used with all Training Systems

!
! Float level transmitter

Process Interface 38-200

Process Controller 38-300

! competencies.
Pulse flow transmitter

The Process Interface is connected to the

system and provides all necessary power
outlets for the Process Trainer, sensors and
Process Controller. It accepts up to four
4-20mA transmitter signal inputs and allows
signal patching so that different control
schemes can be quickly configured. It also
provides a 4-20mA current source, two
current to voltage converters and a voltage
comparator with adjustable hysteresis which
can be used to provide a simple 2-state
control loop in addition to the main controller
loop. Protection is provided by a residual
current circuit breaker.

The ABB Industrial Process Controller is

microprocessor based and is easily
configured by the user to provide a range
of control functions from 2-state control
to 3-term PID control. It also features local
or remote set-point, re-transmission of
set-point or process variable, 4 logic
inputs, 4 relay outputs, ramp/soak (profile
sequencing) and an autotune facility
which can analyse the requirements of
a process and configure the control
parameters for optimum performance.
Together with the Process Interface, it
provides a simple and convenient means
of controlling the system.

!
On-Off control
! Complete
with on-screen
instruction
! courseware,
Study of P, PI
and PID and
control of Level and Flow
questions.

Extra Ancillary Equipment - Programmable Logic Controller 38-350

A Programmable Logic Controller is available. It is fully compatible with the Procon
range and can be used with the 38-200. It provides an alternative control method
with on/off elements to the standard 38-300 (see description on back page).

! Flow & Level familiarisation

and calibration
! Ideally
suited for Technician
Vocational
courses. and
! and
Interface
familiarisation
calibration
! Extendable to cover more

! complex
Controller
familiarisation
process
control
and calibration
problems.

Covers a wide range of

!
Tuning PID
controllers
! Provides
all required
with unique
! instrumentation
Advanced process
control

Discovery software.
! Industrially relevant processes
and components.
! Compact bench-top systems.
! Water and air used as the
process fluids.

Temperature Training System 38-002

Pressure Training System 38-004

Features

Features

! Temperature monitored in
primary and secondary
circuits, flow also monitored

! Safe low pressure operation

! P, PI and PID control with

autotune facility

! Differential and Gauge

pressure sensors

! Primary circuit flow controlled

by motorised control valve

! Current controlled (4-20mA)

pneumatically operated
control valve

! Fully gauged for pressure

and flow rate

! Primary circuit heater and

pump

! Standard industrial
components

! Secondary circuit fanassisted cooling radiator

! Self-sealing outlets for

manometer

! Modern push fittings

! Safety valves fitted as

standard

! Water used as the process

fluid. Operates from mains
water supply using 38-480

Curriculum Coverage
! Temperature familiarisation
and calibration
! Interface familiarisation and
calibration
! Controller familiarisation and
calibration
! Pulse flow transmitter
! On-Off control
! Study of P, PI and PID control
of Temperature and Flow
! Manual flow control
! Temperature process control
! Complex control loops

Dual loop (process) control using Level/flow and

Temperature Trainers:
! Remote Set Point Control
! Set Point Ratio Control
! Cascade Control
! Feedforward Control

! Air used as the process fluid

The Temperature Training System is a two loop system, using water as the process
fluid which allows the study of the principles of process control using primary and
secondary circuit temperatures as the process variables to be controlled.
Both circuits pass through the heat exchanger and the secondary circuit contains
a fan-assisted cooling radiator. Thermocouple temperature sensors are located
in the inlet and outlet streams of both primary and secondary sides of the heat
exchanger and the outlet of the radiator. The primary flow is also monitored.
The Trainer can be used with the cold mains water supply through the Auxiliary
Temperature Control Pack 38-480 which is supplied as part of the kit. This
comprises a motorised control valve, a flow meter and a signal conditioning unit.
Alternatively the Temperature Trainer can be connected to the Level & Flow
Process Trainer, which then supplies the cold water circuit. This combination
allows more complex control systems to be investigated.
A Forced Air Cooler 38-610 is also available. It accelerates the process dynamics
using a constant input temperature, allowing a high temperature differential to
be monitored for longer periods (see below).

Optional Equipment for Temperature Training System

Forced Air Cooler 38-610
This equipment is designed to be used with
the Temperature Trainer between the
Temperature and Level & Flow Trainers to
maintain a constant fluid input temperature.

Specification
Cooling in kW for 10C differential: 1.8kW.
Pressure drop across cooling coils: 14kPa.
Air flow across cooling unit: 370m3 per min.
Water flow rate (nominal): 10 litres per min.

The Pressure Training System is a single loop pneumatic control system.

It enables the study of the principles of both pressure regulation of a process
and the control of flow in a pressurised system.
The System comprises a low pressure air circuit supported on a bench-mounted
panel, making it suitable for individual student work or for group demonstration.
The Pressure Trainer requires a compressed air supply at a recommended
input pressure of 40psi. An input filter/drier is used to clean the supplied air.
Separately regulated branches provide air for the process and for valve control.
The process branch comprises a regulator, a variable area flow meter, a
pneumatically operated control valve, an orifice block with changeable orifice
plates and both differential and point of measure pressure sensors. The process
air flow can be discharged to atmosphere via adjustable diffused outlets.
An air receiver tank can be switched in and out of the circuit. The valve control
branch comprises a regulator and an electrically operated current to pressure
input converter. This is used to regulate the pneumatic control valve in the
process line.
The input converter operates from a 4-20mA signal.
Signal conditioning for the sensors is provided by pressure transmitters.
The Differential Pressure Transmitter gives a linear differential pressure sensor
output.
The system is fully equipped with pressure gauges to indicate the pressures
around the system.

Curriculum Coverage
! Pressure safety, familiarisation and calibration
! I/P converter and Pneumatic
control valve operation
! Controller familiarisation
and calibration
! Automatic control systems
! Serial communication
! Pressure sensor, transmitter
and I/P converter- Linearity
and Hysteresis
! Pneumatic control valve characteristics at different
pressure ranges
! System response and Air
receiver
! Principles of Proportioning
valve and proportional
process control
! Study of P, PI and PID
control of Pressure
! Calibration of the differential
pressure sensor & transmitter
! Flow control in the Process
rig

Temperature Training System 38-002

Pressure Training System 38-004

Features

Features

! Temperature monitored in
primary and secondary
circuits, flow also monitored

! Safe low pressure operation

! P, PI and PID control with

autotune facility

! Differential and Gauge

pressure sensors

! Primary circuit flow controlled

by motorised control valve

! Current controlled (4-20mA)

pneumatically operated
control valve

! Fully gauged for pressure

and flow rate

! Primary circuit heater and

pump

! Standard industrial
components

! Secondary circuit fanassisted cooling radiator

! Self-sealing outlets for

manometer

! Modern push fittings

! Safety valves fitted as

standard

! Water used as the process

fluid. Operates from mains
water supply using 38-480

Curriculum Coverage
! Temperature familiarisation
and calibration
! Interface familiarisation and
calibration
! Controller familiarisation and
calibration
! Pulse flow transmitter
! On-Off control
! Study of P, PI and PID control
of Temperature and Flow
! Manual flow control
! Temperature process control
! Complex control loops

Dual loop (process) control using Level/flow and

Temperature Trainers:
! Remote Set Point Control
! Set Point Ratio Control
! Cascade Control
! Feedforward Control

! Air used as the process fluid

The Temperature Training System is a two loop system, using water as the process
fluid which allows the study of the principles of process control using primary and
secondary circuit temperatures as the process variables to be controlled.
Both circuits pass through the heat exchanger and the secondary circuit contains
a fan-assisted cooling radiator. Thermocouple temperature sensors are located
in the inlet and outlet streams of both primary and secondary sides of the heat
exchanger and the outlet of the radiator. The primary flow is also monitored.
The Trainer can be used with the cold mains water supply through the Auxiliary
Temperature Control Pack 38-480 which is supplied as part of the kit. This
comprises a motorised control valve, a flow meter and a signal conditioning unit.
Alternatively the Temperature Trainer can be connected to the Level & Flow
Process Trainer, which then supplies the cold water circuit. This combination
allows more complex control systems to be investigated.
A Forced Air Cooler 38-610 is also available. It accelerates the process dynamics
using a constant input temperature, allowing a high temperature differential to
be monitored for longer periods (see below).

Optional Equipment for Temperature Training System

Forced Air Cooler 38-610
This equipment is designed to be used with
the Temperature Trainer between the
Temperature and Level & Flow Trainers to
maintain a constant fluid input temperature.

Specification
Cooling in kW for 10C differential: 1.8kW.
Pressure drop across cooling coils: 14kPa.
Air flow across cooling unit: 370m3 per min.
Water flow rate (nominal): 10 litres per min.

The Pressure Training System is a single loop pneumatic control system.

It enables the study of the principles of both pressure regulation of a process
and the control of flow in a pressurised system.
The System comprises a low pressure air circuit supported on a bench-mounted
panel, making it suitable for individual student work or for group demonstration.
The Pressure Trainer requires a compressed air supply at a recommended
input pressure of 40psi. An input filter/drier is used to clean the supplied air.
Separately regulated branches provide air for the process and for valve control.
The process branch comprises a regulator, a variable area flow meter, a
pneumatically operated control valve, an orifice block with changeable orifice
plates and both differential and point of measure pressure sensors. The process
air flow can be discharged to atmosphere via adjustable diffused outlets.
An air receiver tank can be switched in and out of the circuit. The valve control
branch comprises a regulator and an electrically operated current to pressure
input converter. This is used to regulate the pneumatic control valve in the
process line.
The input converter operates from a 4-20mA signal.
Signal conditioning for the sensors is provided by pressure transmitters.
The Differential Pressure Transmitter gives a linear differential pressure sensor
output.
The system is fully equipped with pressure gauges to indicate the pressures
around the system.

Curriculum Coverage
! Pressure safety, familiarisation and calibration
! I/P converter and Pneumatic
control valve operation
! Controller familiarisation
and calibration
! Automatic control systems
! Serial communication
! Pressure sensor, transmitter
and I/P converter- Linearity
and Hysteresis
! Pneumatic control valve characteristics at different
pressure ranges
! System response and Air
receiver
! Principles of Proportioning
valve and proportional
process control
! Study of P, PI and PID
control of Pressure
! Calibration of the differential
pressure sensor & transmitter
! Flow control in the Process
rig

pH Training System 38-005

Level & Flow Training System 38-001

Features

Features

! All components resistant to

agressive fluids

! Contains a selection of level

& flow sensors & indicators
! Flow controlled by linear
motorised control valve
! On/Off and proportional
control
! P, PI and full PID control
with autotune facility
! Couples with Temperature
Trainer for dual loop control

! Motorised agitator
! Removable pH probe
! Industry standard 4-20mA
control signals
! A precision motorised
control valve
! Four tanks

! Modern push fittings

! Modern push fittings

! Water used as the process

fluid
! Comprehensive lab notes
and Discovery software

! Comprehensive lab notes

and Discovery software

Curriculum Coverage
! Introduction, familiarisation
and calibration of the pH rig
! Interface familiarisation
and calibration
! Controller familiarisation
and calibration
! Valve characteristics
! Manual control of pH
! Open loop response
! On/off control of pH
! Simple proportional control
! Effect of proportional band
! Study of proportional and
integral control
! Study of proportional and
derivative control
! Study of proportional,
integral and derivative
control

The pH Training System is based around the pH Rig and is a self-contained

educational platform for teaching pH level control and effluent treatment
methods.
The System comprises two independently pumped fluid circuits mounted on a
robust bench-top panel which allows the study of the principles of process control
using the pH of the mixed effluent and reagent fluids as the process variable.
The system is suitable for individual student work or for group demonstrations.
Effluent and reagent are contained in separate holding tanks prior to being
pumped into the reaction tank where mixing is carried out.
The reaction tank contains an accurate pH probe and agitator. The agitator is
designed to constantly mix the contents of the reaction tank. The pH probe is
designed to monitor the pH level of the effluent/reagent mixture and is supplied
with a transmitter which produces a standard 4-20mA output signal.
The signal is passed to the Process Controller as the process variable.
A precision, motorised control valve is present in the reagent feed to allow
accurate delivery control. The valve is designed to be controlled by standard
4-20mA control signals. Total effluent and reagent fluid shut-off capability is
provided by two normally-closed solenoid valves.
A treated fluid tank is provided to facilitate easy disposal of the process fluid.
All components have been carefully selected to be resistant to aggressive fluids.
Recommended chemical solutions (customer supplied)
Reagent tank: Hydrochloric Acid at 0.05 Mole.
Effluent tank: Sodium Hydroxide at 0.05 Mole.

The Basic Process Trainer is a single loop system allowing the study of the
principles of process control, using liquid level and flow rates as the measured
process variables. The system is a completely self-contained, low pressure
flowing water circuit supported on a bench-mounted panel, making it suitable for
individual student work or for group demonstrations.
It comprises a dual compartment process tank, linked to a sump tank by manual
and solenoid operated valves. Water is pumped through the system, via a
variable area flow meter and motorised control valve. Level is measured in the
process tank. Flow is measured through an optical pulse flowmeter.

Curriculum Coverage
Curriculum coverage

Ancillary Equipment - used with all Training Systems

!
! Float level transmitter

Process Interface 38-200

Process Controller 38-300

! competencies.
Pulse flow transmitter

The Process Interface is connected to the

system and provides all necessary power
outlets for the Process Trainer, sensors and
Process Controller. It accepts up to four
4-20mA transmitter signal inputs and allows
signal patching so that different control
schemes can be quickly configured. It also
provides a 4-20mA current source, two
current to voltage converters and a voltage
comparator with adjustable hysteresis which
can be used to provide a simple 2-state
control loop in addition to the main controller
loop. Protection is provided by a residual
current circuit breaker.

The ABB Industrial Process Controller is

microprocessor based and is easily
configured by the user to provide a range
of control functions from 2-state control
to 3-term PID control. It also features local
or remote set-point, re-transmission of
set-point or process variable, 4 logic
inputs, 4 relay outputs, ramp/soak (profile
sequencing) and an autotune facility
which can analyse the requirements of
a process and configure the control
parameters for optimum performance.
Together with the Process Interface, it
provides a simple and convenient means
of controlling the system.

!
On-Off control
! Complete
with on-screen
instruction
! courseware,
Study of P, PI
and PID and
control of Level and Flow
questions.

Extra Ancillary Equipment - Programmable Logic Controller 38-350

A Programmable Logic Controller is available. It is fully compatible with the Procon
range and can be used with the 38-200. It provides an alternative control method
with on/off elements to the standard 38-300 (see description on back page).

! Flow & Level familiarisation

and calibration
! Ideally
suited for Technician
Vocational
courses. and
! and
Interface
familiarisation
calibration
! Extendable to cover more

! complex
Controller
familiarisation
process
control
and calibration
problems.

Covers a wide range of

!
Tuning PID
controllers
! Provides
all required
with unique
! instrumentation
Advanced process
control

Discovery software.
! Industrially relevant processes
and components.
! Compact bench-top systems.
! Water and air used as the
process fluids.

Industrial Process Fault Finding

Training System 34-250

Discovery software

Familiarisation of Pressure Trainer

Learning material is provided in the form of browser-based Discovery software.

The unique Discovery software environment provides real-time, on-screen process
monitoring with animated mimic screens together with theory, background information and
questions. The free movement between screens allows a user-friendly graphical interface.

Features

!
!
!
!
!
!
!
!
!
!
!
!
!

! Self contained process

Interactive hardware/software configuration

Browser based curriculum
Self-paced learning
Practical demonstration of theoretical background
Simulations - temperature modelling
Interactive patching diagrams
Shows real-time process changes
Hands off for tutors - Hands on for students
Embedded Virtual Instrumentation
Automatic controller configuration
Data export to spreadsheet for analysis
Changeable timescales for playback of results
Dual playback for comparison of process variables

! Wide range of easy to apply

faults
! Mechanical, electrical,
electronic & process faults
! May be driven from external
PLC or process controller
! Fully protected for safety
! Comprehensive Instructors
and Students Manuals

pH

pH

Real-time data capture & measurement

Detailed explanatory layout

Familiarisation of pH Trainer

Integrated interactive simulations

Discovery software is a Windows based application compatible with Windows 98, ME,
2000 and XP operating systems.
Discovery Software is available for all four Process Trainers:
Discovery software pack for Level/Flow and Temperature
Discovery software pack for Pressure
Discovery software pack for pH

Detailed background material

! Teaches fault diagnosis and

fault finding methodologies

38-901-M
38-930-M
38-940-M

This Trainer is designed to provide a platform that enables students to trace

faults down to a detailed level, in a systematic way, through a relatively easyto-understand process.
Faults can be introduced by the instructor via switches concealed behind a locked
compartment, to which the student does not have access. These switches provide
short circuits and open circuits and can also switch in or out circuit elements to
simulate a variety of fault conditions. Additional faults can be inserted into the
process through the replacement of working components with faulty ones,
e.g. faulty float switches; faulty relays; faulty sensors and faulty solenoid coils.
The system has been designed to teach a methodical approach to fault diagnosis
in industrial processes. The methodologies taught within the system are equally
relevant to any student or trainee studying fault diagnosis.
Designed to be used by people studying industrial process maintenance, it can
also be used as a process trainer in its own right, using either Electronic
Controllers (PID) or Programmable Logic Controllers (PLCs).
The process involves initially filling a header tank with water and then cycling the
level between a set upper and lower limit, whilst simultaneously creating a demand
from the header tank via two on/off solenoid drain valves into a sump tank. Flow is
produced by a pump and controlled by relay operated on/off solenoid valves which
control:
the inflow of water to the header tank
the outflow of water from the header tank
The level of water in the header tank is monitored by float switches which open
and close at the following points:
Header tank low (nearly empty)
Header tank normal operation lower limit
Header tank normal operation upper limit
Header tank overflow
Alternative flow and level control strategies can be introduced by the connection
of an industrial process controller or a PLC unit with analogue I/O using 4-20mA
current loop I/O via a motorised control valve with a pulse flow meter and proportional level control sensor. The 38-300 Process Controller is ideal for this task.
Optional Accessory 34-252-1 PLC Interface allows easy connection of a PLC to
the 34-250.

Curriculum Coverage
! Introduction to the system
! Fault finding methodologies
! Fault analysis flow charts
! Fault finding from circuit
diagrams
! Fault identification to Line
Replaceable Unit level
! Simple electronic fault
finding
! Diagnostic tools
! Maintenance procedures
! Process control techniques
! Fault finding processes
controlled from electronic
controllers
! Interfacing to Programmable
Logic Controllers (PLCs)
! Fault finding in PLC based
systems

Process Control

Process Control

General Accessories
Programmable Logic Controller 38-350

Features for 38-350

This equipment is a fully functioning industrial PLC unit housed in a rugged metal case.
All connections are via 4mm sockets. The unit is capable of operating with 24V or 5V
logic signals and can also accept 4-20mA current loop inputs via the current to voltage
converters and the voltage comparator. A variable 4-20mA current source with adjustable
span and zero is also provided. The voltage comparator has variable hysteresis allowing
the PLC to control analogue events. It connects to the Process Trainer via the 38-200
Process Interface and regulates the system using on/off control elements.
The user may create sequences using conventional ladder logic and demonstrate
the programming on the controller itself, without a process actually being connected.

! Stand-alone PLC fully

compatible with PROCON

Along with the Process Trainer, Interface and Controller the following may be studied:
Production of Ladder Logic Diagrams for sequence control and evaluation using
manual switches and LEDs.
Sensing and Sequencing Control of the following system elements is possible:
Level and Flow Process Trainer: Control of the water pump; Control of the solenoid.
Level and Flow Process Trainer with Level Sensor pack: Sensing the level in the
Process Tank; Control of the water pump; Control of solenoid valves.
Temperature Process Trainer: Sensing Temperature; Control of the Heater;
Control of the Circulating pump.

Data Acquisition Unit 38-370

Gives users the ability to extend investigations to include developing their own control
algorithms, as well as enabling more extensive data capture and instrumentation.
Advanced process control techniques, such as Fuzzy logic and Neural networks can
be used to control PROCON systems.
Special functions include: " Outputting analogue values " Interrogating analogue
inputs " Inputting and outputting digital signals in a variety of formats " A PID
function to form 2 standard PID loops " Timer functions " PWM output production
" Integration of analogue outputs " A pulse function " Setting the maximum rate
of change of a variable.

! Uses Industrial Standard

PLC unit
! Power supply included
! PLC can be programmed
in instruction list or ladder
logic formats

PROCON Level/Flow Process Control Training System

(38-100, 200, 300, 400, 420, 490, 901-M).
PROCON Temperature Process Control Training System
(38-600, 200, 300, 480, 490, 901-M).
PROCON Level/Flow & Temperature Process Control Training System
(38-100, 38-600, 200 x2, 300 x2, 400, 420, 490 x2, 901-M).
PROCON Pressure Process Control Training System (38-714, 200, 300, 490, 930-M)
PROCON pH Process Control Training System (38-716, 200, 300, 490, 940-M)
Complete PROCON System (five processes, 38-003, 004 and 005)
Industrial Process Fault Finding Training System

38-001
38-002
38-003
38-004
38-005
38-010
34-250

Software
38-901-M
38-930-M
38-940-M

Optional Equipment
38-350
38-610

Programmable Logic Controller

Forced Air Cooler

Separate Items
Industrial Process Trainer
34-250
PLC Interface for 34-250 34-252-1
Basic Process Trainer
38-100
Temperature Trainer
38-600
Pressure Trainer
38-714
pH Trainer
38-716

Process Interface
Process Controller
Level Sensor Pack
Flow Sensor Pack
Temperature Auxiliary Control Pack
Digital Display Module

NB. All training systems are also available for 120 volt supplies.
Please specify which voltage value you require when ordering.
Feedback reserves the right to change these specifications without notice.
Registered in England number 990620.
A subsidiary of Feedback plc.
Process Control Training Systems - PCTS 0205-4

Printed in England.

38-200
38-300
38-400
38-420
38-480
38-490

System Features
! Trainers for Level and Flow,

! Hand-held programmer
option

Temperature, Pressure & pH.

! Uses industry standard

Process Controller, 4-20mA

signals and RS232/RS485
serial communication bus.
! High degree of modularity -

Features for 38-370

!
!
!
!
!
!

easily reconfigurable using

modern push fittings.

Microprocessor based
Intelligent signal conditioning
3 analogue & 2 digital inputs
2 analogue & 2 digital outputs
RS232/485 serial outputs
Advanced control methods
can be studied

Optional PROCON Accessories

RS485 lead
38-801
Air Compressor
38-820
Chart Recorder
38-830
Mobile Trolley
38-840
Water Pressure Regulator
(for use with 38-480)
38-481

Contact:

Discovery software pack for Level/Flow and Temperature

Discovery software pack for Pressure
Discovery software pack for pH

Process Control Training Systems

! Introductory guide to PLCs

Ordering Information
Complete Systems

PROCON

Feedback Instruments Ltd

Park Road, Crowborough,
E. Sussex, TN6 2QR, England.
Tel: +44 (0) 1892 653322
Fax: +44 (0) 1892 663719
E mail: feedback@fdbk.co.uk
Website: www.fbk.com

Feedback Incorporated
P.O Box 400,
437 Dimmocks Mill Road,
Hillsborough, NC 27278, USA
Tel: (919) 644 6466
Fax: (919) 644 6470
E-mail: info@fbk.com
Website: www.fbk.com

! Discovery software.
! Fully protected by earth

leakage circuit breaker.

A range of Industrial Process Control Trainers that operate using browser-based

Discovery software in real-time control applications including simulations.
Process Trainers are available for:

Level & Flow, Temperature, Pressure and pH control

Study areas covered using PROCON Process Control Training systems include:
Setting and calibrating 4-20mA loops
Sensors and calibration
Operating manual, solenoid and motorised control valves
Determining the characteristics of control valves
Understanding transducers and transmitters
Setting zero and span of transmitters
Use and understanding of process control terms
Understanding the operational features of an industrial process controller
Controller calibration
Recognition and understanding of different types of control function
Use and understanding of proportional control, PI and PID control
Tuning PID controllers
Autotuning controllers
The systems are configured using a series of units including a Process Rig,
Process Interface, Process Controller and various Sensors that measure
process variables.
The systems are ready-to-run and contain all the software and PC based
instrumentation required to perform a wide range of process control assignments.

System Benefits
! Complete with on-screen

courseware, instruction and

questions
! Provides all required virtual

instrumentation with unique

Discovery software
! Ideally suited for Technician

and Vocational courses

! Extendable to cover more

complex process control

problems
! Covers a wide range of

competencies
! Industrially relevant

processes and components

! Compact bench-top systems
! Clean process fluids of

water or air used by

appropriate trainers