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3500

Mobile Instrumentation and Process Control Training


Systems

LabVolt Series

Datasheet

Festo Didactic
en 120 V - 60 Hz
09/2015
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Table of Contents
General Description _______________________________________________________________________2
Features & Benefits _______________________________________________________________________2
List of Available Training Systems ___________________________________________________________2
Optional Equipment_______________________________________________________________________3
Additional Equipment Required to Perform the Exercises ________________________________________3
Optional Manual(s) _______________________________________________________________________3
Equipment Description ____________________________________________________________________3
Optional Equipment Description __________________________________________________________ 2 2

General Description
The Mobile Instrumentation and Process Control Training Systems form a program that consists of self-
contained workstations designed for hands-on training in the measurement, control, and troubleshooting of
pressure, flow, level, temperature, heat exchange, and analytic processes.
The different workstations can operate independently, or be interconnected into several configurations to
simulate complex processes. All processes are sized to be "real world" in time lag and process response.
Process dynamics can be altered by various means to provide several degrees of stability and damping.
The Flow, Level, Heat Exchanger, Multi-Process, and Analytic Process Stations utilize water as the process
media, while the Pressure and Temperature Process Stations utilize air. All process stations include a
microprocessor-based controller, an advanced graphic data manager for recording and visualizing process
sequences, and alarm lamps, with all connections terminated by banana jacks on the station main control
panel.

Features & Benefits


• Each station is constructed on a sturdy and durable steel frame with casters for mobility
• Patch-connected signal conditioners, controllers, and transmitters to permit alternate control schemes and for
flexibility in incorporating new technology as it is developed
• Realistic process response times
• Multi-element and ratio control capability
• Microprocessor-based controllers
• A communication port permits supervisory control and data acquisition in the training system
• Coupling of two or more stations’ control loops allows implementation of complex alternate control schemes
• A locking door gives access to a fault-insertion panel, in addition to providing storage space for the tubing, the
electrical leads, and the manuals.
• Plant-specific training requirements can readily be addressed by removing mutually compatible instruments from the
stations and mounting them on mobile racks, then connecting them to the processes
• Comprehensive curriculum included

List of Available Training Systems


Model
Qty Description
number
1 Pressure Process Station ________________________________________________________________ 3501-M0
1 Flow Process Station ____________________________________________________________________ 3502-M0
1 Level Process Station ___________________________________________________________________ 3503-M0
1 Temperature Process Station _____________________________________________________________ 3504-M0
1 Multi-Process Station ___________________________________________________________________ 3505-M0

2 © Festo Didactic
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Optional Equipment
Model
Qty Description
number
1 Calibration Bench ______________________________________________________________________ 3550-M0
1 Mobile Instrumentation and Process Control Training System (Manuals on CD-ROM) ______________ 32868-A0
1 Calibration Bench for Mobile Workstations (Student Manual) ________________________________ 76015-20 1
1 Calibration Bench for Mobile Workstations (Instructor Guide) ________________________________ 76015-30 2

Additional Equipment Required to Perform the Exercises


Model
Qty Description
number
1 Personal Computer _____________________________________________________________________ 8990-00 3

Optional Manual(s)
Model
Qty Description
number
1 Mobile Instrumentation and Process Control Training System (Manuals on CD-ROM) ______________ 32868-A0
1 Calibration Bench for Mobile Workstations (Student Manual) ________________________________ 76015-20 4
1 Calibration Bench for Mobile Workstations (Instructor Guide) ________________________________ 76015-30 5

1 This manual is included with the Calibration Bench, Model 3550-M.


2 This manual is included with the Calibration Bench, Model 3550-M.
3 Refer to the Computer Requirements in the System Specifications section of this datasheet if the computer is to be provided by the end-user.
4 This manual is included with the Calibration Bench, Model 3550-M.
5 This manual is included with the Calibration Bench, Model 3550-M.

© Festo Didactic 3
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Equipment Description
Pressure Process Station
3501-M0
The Pressure Process Station consists
of two 7.5 L (2 gal US) air tanks, an air
pressure regulator, an exhaust
assembly connected to a silencer, a
pneumatically operated flow control
valve, and needle valves at the tanks
and exhaust assembly connections. All
devices have their air connections
terminated by quick-connect fittings
on the main control panel of the
station. Each device is independently
terminated to permit students to
connect the pressure process into
several configurations. The process
instrumentation includes a kPa/psi-
graduated pressure gauge, an
electronic pressure transmitter, and a
current-to-pressure (I/P) converter
mounted on the side of the station with air supply and signal connections terminated by quick-connect fittings
on the main control panel of the station. A flowmeter and an orifice assembly are also provided.

4 © Festo Didactic
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Example of pressure process performed using the Pressure Process Station, Model 3501.

List of Manuals
Manual
Description
number
3500 Series Process Control Stations (User Guide) ______________________________________________ 32868-E0
Pressure Process Station (Student Manual) ____________________________________________________ 75941-20
Pressure Process Station (Job Sheets - Instructor) _______________________________________________ 75941-30

Table of Contents of the Manual(s)


Pressure Process Station (Student Manual) (75941-20)
• 1 Pressure Transmitter Time Response Characteristic
• 2 Pressure Process Characteristics
• 3 Pressure Process Proportional Control

© Festo Didactic 5
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

• 4 Pressure Process Proportional Plus Integral Control


• 5 Pressure Process Proportional Plus Integral Plus Derivative Control
• 6 Notch Tuning of a Pressure Process
• 7 Ultimate Period Tuning of a Pressure Process
• 8 Open Loop Tuning of a Pressure Process
• 9 Operation of a Pressure Measurement Channel
• 10 Troubleshooting a Pressure Measurement Channel
• 11 Operation of a Pressure Control Channel
• 12 Troubleshooting a Pressure Control Channel
• 13 Calibration of an Air Flow Transmitter
• 14 Air Flow VRS Differential Pressure for an Orifice
• 15 Operation of an Air Flow Measurement Process
• 16 Troubleshooting an Air Flow Measurement Process
• 17 Operation of an Air Flow Control Process
• 18 Troubleshooting an Air Flow Control Process

Optional Equipment
Model
Qty Description
number
1 Calibration Bench ______________________________________________________________________ 3550-M0

Specifications
Parameter Value
Power Requirements
Current 15 A
Service Installation Standard single-phase ac outlet
Air Supply Requirement 690 kPa (100 psig) instrument dry air at 142 dm³/min (5 ft³/min)
Microprocessor-Based Controller
Type Single station micro-controller
Performs the standard proportional, integral, and derivative (PID) control
actions. Can be configured to function as a single controller or as two
independent controllers with individual built-in options. For each controller, P, I,
Functions
PD, PI, and PID control can be implemented, as well as cascade control and self
tuning control. Linear/non-linear inputs and outputs include specific arithmetic
functions and characterization.
Four, input range of either 1-5 V dc or 4-20 mA selectable by toggle switch on
Analog Inputs the main control panel of the Process Station. Input bias, gain, conditioning
(square, square root), and filtering are available for every input.
Two, 5 V dc nominal open circuit voltage, 1 mA max. Used for remote status
Digital (Dry Contact) Inputs
changes and tracking functions.
Two; Output 1: 4-20 mA into a 500 Ω max. resistor; Output 2: configurable for
Analog Outputs transmission of the measurement, setpoint, conditioned input, or Output-1
signal as a 1-5 V dc output signal into a 2 kΩ min. resistor.
Two, isolated, dry-contact outputs, 24 V dc, 1 A max. Used for remote indication
Digital (Auxiliary) Outputs
of controller or alarm status as required.
Consists of an alphanumeric display, a graphics display, status indicators, an
Front Panel
alarm indicator, and a keypad
6 © Festo Didactic
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Parameter Value
Can provide a 25 V dc nominal voltage for powering up to two 4-20 mA
Transmitter Powering Capability
transmitters.
Graphic Data Manager
Type Endress + Hauser Memograph M RSG40
Display Characteristics Thin-film-transistor (TFT), color, 17.8 cm (7 in)
Signal analysis, interface/modem, OPC-server, ReadWin 2000, mathematic
Functions
formula editor, energy package (water+steam)
20 analog inputs (U, I, TC, RTD, frequency, pulse), 14 digital inputs (control,
Inputs
event, and counting inputs)
Outputs 12 relay outputs, 2 analog outputs (I, pulse)
Interface RS 232, RS 485, Ethernet, Modbus RTU, Modbus TCP, PROFIBUS DP, USB
Storage/Recording Internal memory, SD card, USB stick
Current-to-Pressure (I/P)
Converter
Function Converts 4-20 mA signals into 21-103 kPa (3-15 psig) pneumatic signals.
Dry oil-free compressed air filtered to contain no particles larger than 25
Air Supply microns; air pressure must be at least 34 kPa (5 psig) greater than converter
outlet pressure without exceeding 700 kPa (100 psig).
An integrated volume booster provides flow rates up to 283 dm³/min (10 ft³/
Output Flow Rate
min).
Linearity ±0.5% of full scale
Air Consumption 0.9 dm³/min (0.03 ft³/min)
Response Time Typically less than 1 second at mid-range (dead-ended)
Electronic Pressure Transmitter
Function Produces a 4-20 mA signal proportional to sensed gauge pressure.
Pressure Sensing Element Silicon strain gauge sensor
LCD digital indicator with configuration push-buttons displaying measurements
Display
with a choice of units. Push-buttons allow zero and span adjustment.
Span Limits 70 and 2100 kPa (10 and 300 psig)
Range Limits 0 and 2100 kPa (0 and 300 psig)
Maximum overrange 3100 kPa (450 psig)
Orifice Assembly
ß Ratio 0.5
Pressure Regulator
Type Relieving; outlet pressure can be reduced even when the system is dead-ended.
Outlet Pressure Adjustment Range 35-700 kPa (5-100 psig)
Pressure Adjustment Low-torque, non-rising pressure adjustment knob with integral locking device
Pressure Gauge 0-1000 kPa (0-150 psig) range, 6.4 cm (2.5 in) dial, ANSI-grade 3-2-3% accuracy
Pressure Gauge
Range 0-700 kPa (0-100 psig)
Dial Diameter 8.9 cm (2.5 in)
Accuracy 1%
Flowmeter
Type Variable area with metering float

© Festo Didactic 7
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Parameter Value
Range 23-142 dm³/min (0.8-5 ft³/min)
Pneumatically Operated Flow
Control Valve
Operating Signal 21-103 kPa (3-15 psig), pneumatic signal
Actuating Mechanism Air-to-open spring diaphragm
Body Material 316 stainless steel
Physical Characteristics
Intended Location On the floor (stands on casters)
Dimensions (H x W x D) 1854 x 1156 x 724 mm (73.0 x 45.5 x 28.5 in)
Net Weight 141.8 kg (312 lb)

Flow Process Station


3502-M0
The Flow Process Station consists of a
centrifugal pump, a 75 L (20 gal US)
water reservoir, a programmable ac
variable frequency pump drive,
manual valves, and process piping
made of clear thermoplastic (PVC). The
process instrumentation includes a
flowmeter, two headers, and a
differential pressure (D/P) transmitter
with LCD display, configuration
pushbuttons, and digital
communication platform providing
4-20 mA and/or digital output signals.
The D/P transmitter is mounted on the
side of the station and has air
connections terminated by quick-
connect fittings on the main control
panel. Pressure taps are provided at
various points along the process piping to permit measurement of the pressure drops and evaluation of the
system overall performance.

8 © Festo Didactic
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Piping diagram of the Flow Process Station, Model 3502.

List of Manuals
Manual
Description
number
3500 Series Process Control Stations (User Guide) ______________________________________________ 32868-E0
Flow Process Station (Student Manual) ________________________________________________________ 75942-20
Flow Process Station (Instructor Guide) _______________________________________________________ 75942-30

Table of Contents of the Manual(s)


Flow Process Station (Student Manual) (75942-20)
• 1 Flow Transmitter Time Response Characteristic
• 2 Flow Process Characteristic
• 3 Flow Vrs Differential Pressure for a Venturi
• 4 Calibration of a Flow Transmitter
• 5 Flow Process Proportional Control
• 6 Flow Process Proportional Plus Integral Control
• 7 Flow Process Proportional Plus Integral Plus Derivative Control
• 8 Ultimate Period Tuning of a Flow Process
• 9 Notch Tuning of a Flow Process
• 10 Open Loop Tuning of a Flow Process
• 11 Operation of a Flow Measurement Channel
• 12 Troubleshooting a Flow Measurement Channel
• 13 Operation of a Flow Control Process
• 14 Troubleshooting a Flow Control Process
• 15 Bottom Drain Level Control
• 16 Emergency Feedwater Injection System

Optional Equipment

© Festo Didactic 9
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Model
Qty Description
number
1 Calibration Bench ______________________________________________________________________ 3550-M0

Specifications
Parameter Value
Power Requirements
Current 15 A
Service Installation Standard single-phase ac outlet
Air Supply Requirement 690 kPa (100 psig) instrument dry air at 57 dm³/min (2 ft³/min)
Microprocessor-Based Controller
Type Single station micro-controller
Performs the standard proportional, integral, and derivative (PID) control
actions. Can be configured to function as a single controller or as two
independent controllers with individual built-in options. For each controller, P, I,
Functions
PD, PI, and PID control can be implemented, as well as cascade control and self
tuning control. Linear/non-linear inputs and outputs include specific arithmetic
functions and characterization.
Four, input range of either 1-5 V dc or 4-20 mA selectable by toggle switch on
Analog Inputs the main control panel of the Process Station. Input bias, gain, conditioning
(square, square root), and filtering are available for every input.
Two, 5 V dc nominal open circuit voltage, 1 mA max. Used for remote status
Digital (Dry Contact) Inputs
changes and tracking functions.
Frequency Inputs Two, 1 to 9999 Hz, 250 Ω input impedance
Two; Output 1: 4-20 mA into a 500 Ω max. resistor; Output 2: configurable for
Analog Outputs transmission of the measurement, setpoint, conditioned input, or Output-1
signal as a 1-5 V dc output signal into a 2 kΩ min. resistor.
Two, isolated, dry-contact outputs, 24 V dc, 1 A max. Used for remote indication
Digital (Auxiliary) Outputs
of controller or alarm status as required.
Consists of an alphanumeric display, a graphics display, status indicators, an
Front Pane
alarm indicator, and a keypad.
Can provide a 25-V dc nominal voltage for powering up to two 4-20 mA
Transmitter Powering Capability
transmitters.
Graphic Data Manager
Type Endress + Hauser Memograph M RSG40
Display Characteristics Thin-film-transistor (TFT), color, 17.8 cm (7 in)
Signal analysis, interface/modem, OPC-server, ReadWin 2000, mathematic
Functions
formula editor, energy package (water+steam)
20 analog inputs (U, I, TC, RTD, frequency, pulse), 14 digital inputs (control,
Inputs
event, and counting inputs)
Outputs 12 relay outputs, 2 analog outputs (I, pulse)
Interface RS 232, RS 485, Ethernet, Modbus RTU, Modbus TCP, PROFIBUS DP, USB
Storage/Recording Internal memory, SD card, USB stick
Electronic Differential Pressure
(D/P) Transmitter

10 © Festo Didactic
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Parameter Value
Transmits a 4-20 mA signal and/or digital signal proportional to sensed
Function
differential pressure. The type of transmitted signal is software selectable.
Pressure Sensing Element Silicon strain gauge sensor
A built-in digital platform provides digital communications, for transmission of
Digital Communications pressure measurements to a PC-based workstation, and for remote
configuration and monitoring.
LCD digital indicator with configuration push-buttons displaying measurements
Display
with a choice of units. Push-buttons allow zero and span adjustment.
Span Limits 0.87 and 50 kPa (3.5 and 200 inH2O)
Range Limits -50 and 50 kPa (-200 and 200 inH2O)
Accuracy 0.1% of span
Zero Suppression To the upper range limit minus the span
Zero Elevation To the lower range limit
AC Variable Frequency Pump Drive
Industrial-type programmable drive providing speed control of the motor that
drives the Process Station pump. Uses the latest solid-state PWM technology.
Description
Drive programming and operation is controlled manually using the drive keypad
or remotely via the drive external input.
Output Power 0.75 kW (1 hp)
Output Frequency Range 0.5-400 Hz, programmable in 0.1 Hz increments
Maximum/Minimum Frequency Separately programmable to 400 Hz in 0.1 Hz increments
Programmable 0.1 to 600 seconds to maximum frequency in 0.1 second
Acceleration/Deceleration Time
increments
Torque Boost Automatic or fixed
Keypad Forward, reverse, stop, up/down arrow, program, shift, and enter keys
Alphanumeric LCD display indicating motor speed in Hz, r/min, motor current,
Display
and percent load
Flowmeter
Type Variable area with metering float
Range 4-38 L/min (1-10 gal US/min)
Physical Characteristics
Intended Location On the floor (stands on casters)
Dimensions (H x W x D) 1854 x 1155 x 724 mm (73.0 x 45.5 x 28.5 in)
Net Weight 173.6 kg (381.9 lb)

© Festo Didactic 11
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Level Process Station


3503-M0
The Level Process Station consists of a
centrifugal pump, a water reservoir, a
20 cm (8 in) diameter, 92 cm (36 in)
high level column with bubbler pipe, a
pneumatically operated flow control
valve, needle valves, and process
piping made of clear thermoplastic
(PVC). The pump is operated at fixed
speed. It can be activated through a
push-button on the front panel, or
remotely using a dry contact.

Piping diagram of the Level Process Station, Model 3503.

12 © Festo Didactic
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

List of Manuals
Manual
Description
number
3500 Series Process Control Stations (User Guide) ______________________________________________ 32868-E0
Level Process Station (Student Manual) _______________________________________________________ 75943-20
Level Process Station (Instructor Guide) _______________________________________________________ 75943-30

Table of Contents of the Manual(s)


Level Process Station (Student Manual) (75943-20)
• 1 Level Transmitter Time Response Characteristic
• 2 Level Process Characteristics
• 3 Calibration of a Level Transmitter
• 4 Level Measurement using a Bubbler
• 5 Level Measurement of an Open Tank
• 6 Level Measurement with Zero Suppression
• 7 Level Measurement with a Wet Reference Leg
• 8 Level Process Proportional Control
• 9 Level Process Proportional Plus Integral Control
• 10 Level Process Proportional Plus Integral Plus Derivative Control
• 11 Notch Tuning of a Level Process
• 12 Ultimate Period Tuning of a Level Process
• 13 Open Loop Tuning of a Level Process
• 14 Operation of a Level Measurement Channel
• 15 Troubleshooting a Level Measurement Channel
• 16 Operation of a Level Control Process
• 17 Troubleshooting a Level Control Process
• 18 Operation of a Flow Measurement Channel
• 19 Operation of a Flow Control Process
• 20 Operation of a Two Element Control Process
• 21 Operation of a Three Element Control Process

Optional Equipment
Model
Qty Description
number
1 Calibration Bench ______________________________________________________________________ 3550-M0

Specifications
Parameter Value
Power Requirements
Current 15 A
Service Installation Standard single-phase ac outlet
Air Supply Requirement 690 kPa (100 psig) instrument dry air at 57 dm³/min (2 ft³/min)
Microprocessor-Based Controller
Type Single station micro-controller
Performs the standard proportional, integral, and derivative (PID) control
Functions actions. Can be configured to function as a single controller or as two
independent controllers with individual built-in options. For each controller, P, I,

© Festo Didactic 13
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Parameter Value
PD, PI, and PID control can be implemented, as well as cascade control and self
tuning control. Linear/non-linear inputs and outputs include specific arithmetic
functions and characterization.
Four, input range of either 1-5 V dc or 4-20 mA selectable by toggle switch on
Analog Inputs the main control panel of the Process Station. Input bias, gain, conditioning
(square, square root), and filtering are available for every input.
Two, 5 V dc nominal open circuit voltage, 1 mA max. Used for remote status
Digital (Dry Contact) Inputs
changes and tracking functions.
Two; Output 1: 4-20 mA into a 500 Ω max. resistor; Output 2: configurable for
Analog Outputs transmission of the measurement, setpoint, conditioned input, or Output-1
signal as a 1-5 V dc output signal into a 2 kΩ min. resistor.
Two, isolated, dry-contact outputs, 24 V dc, 1 A max. Used for remote indication
Digital (Auxiliary) Outputs
of controller or alarm status as required.
Consists of an alphanumeric display, a graphics display, status indicators, an
Front Panel
alarm indicator, and a keypad.
Can provide a 25-V dc nominal voltage for powering up to two 4-20 mA
Transmitter Powering Capability
transmitters.
Graphic Data Manager
Type Endress + Hauser Memograph M RSG40
Display Characteristics Thin-film-transistor (TFT), color, 17.8 cm (7 in)
Signal analysis, interface/modem, OPC-server, ReadWin 2000, mathematic
Functions
formula editor, energy package (water+steam)
20 analog inputs (U, I, TC, RTD, frequency, pulse), 14 digital inputs (control,
Inputs
event, and counting inputs)
Outputs 12 relay outputs, 2 analog outputs (I, pulse)
Interface RS 232, RS 485, Ethernet, Modbus RTU, Modbus TCP, PROFIBUS DP, USB
Storage/Recording Internal memory, SD card, USB stick
Current-to-Pressure (I/P)
Converter
Function Converts 4-20 mA signals into 21-103 kPa (3-15 psig) pneumatic signals.
Dry oil-free compressed air filtered to contain no particles larger than 25
Air Supply microns; air pressure must be at least 34 kPa (5 psig) greater than converter
outlet pressure without exceeding 700 kPa (100 psig).
An integrated volume booster provides flow rates up to 283 dm³/min (10 ft³/
Output Flow Rate
min).
Linearity ±0.5% of full scale
Air Consumption 0.9 dm³/min (0.03 ft³/min)
Response Time Typically less than 1 second at mid-range (dead-ended)
Electronic Differential Pressure
(D/P) Transmitter
Transmits a 4-20 mA signal and/or digital signal proportional to sensed
Function
differential pressure. The type of transmitted signal is software selectable.
Pressure Sensing Element Silicon strain gauge sensor

14 © Festo Didactic
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Parameter Value
A built-in digital platform provides digital communications, for transmission of
Digital Communications pressure measurements to a PC-based workstation, and for remote
configuration and monitoring.
LCD digital indicator with configuration push-buttons displaying measurements
Display
with a choice of units. Push-buttons allow zero and span adjustment.
Span Limits 0.87 and 50 kPa (3.5 and 200 inH2O)
Range Limits -50 and 50 kPa (-200 and 200 inH2O)
Accuracy 0.1% of span
Zero Suppression To the upper range limit minus the span
Zero Elevation To the lower range limit
Flowmeter
Type Variable area with metering float
Range 4-38 L/min (1-10 gal US/min)
Pneumatically Operated Flow
Control Valve
Operating Signal 21-103 kPa (3-15 psig), trim with equal percentage flow characteristic
Actuating Mechanism Air-to-open
Body Material Bronze
Physical Characteristics
Intended Location On the floor (stands on casters)
Dimensions (H x W x D) 1981 x 1156 x 724 mm (78 x 45.5 x 28.5 in)
Net Weight 201.8 kg (444 lb)

Temperature Process Station


3504-M0
The Temperature Process Station
mainly consists of a 20-200°C
(70-400°F) oven with built-in capillary-
bulb temperature switch (on/off
controller), thermostat, air cooling
injector, adjustable damper, and
overheating protection. The process
instrumentation includes a capillary-
bulb thermometer mounted on the
side of the oven, as well as an RTD
temperature transmitter and a J-type
thermocouple temperature transmitter
with electrical connections terminated
by banana jacks on the main control
panel.

© Festo Didactic 15
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

The temperature process of the Temperature Process Station, Model 3504.

List of Manuals
Manual
Description
number
3500 Series Process Control Stations (User Guide) ______________________________________________ 32868-E0
Temperature Process Station (Student Manual) _________________________________________________ 75944-20
Temperature Process Station (Instructor Guide) ________________________________________________ 75944-30
HART Device Configuration (Student Manual) __________________________________________________ 86050-00
HART Device Configuration (Instructor Guide) __________________________________________________ 86050-10

Table of Contents of the Manual(s)


Temperature Process Station (Student Manual) (75944-20)
• 1 Temperature Transmitter Time Response Characteristic
• 2 Temperature Process Characteristic
• 3 Calibration of a Temperature Transmitter
• 4 Temperature Measurement using a Thermocouple
• 5 Temperature Measurement using an RTD
• 6 On-Off Temperature Control
• 7 Temperature Process Proportional Control
• 8 Temperature Process Proportional Plus Integral Control
• 9 Temperature Process Proportional Plus Integral Plus Derivative Control
• 10 Notch Tuning of a Temperature Process
• 11 Ultimate Period Tuning of a Temperature Process

16 © Festo Didactic
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

• 12 Open Loop Tuning of a Temperature Process


• 13 Operation of a Temperature Measurement Channel
• 14 Troubleshooting a Temperature Measurement Channel
• 15 Operation of a Temperature Control Process
• 16 Troubleshooting a Temperature Control Process
• 17 Hardwired Alarms using Capillary Bulb Switch
• 18 Microprocessor Based Controller Software Alarms

HART Device Configuration (Student Manual) (86050-00)


• 1-0 HART Protocol Overview
• 2-0 HART Point-to-Point
• 2-1 Two-Wire Transmitter
• 2-2 Four-Wire Transmitter (Optional)
• 2-3 Output Device (Optional)
• 3-0 HART Multidrop
• 3-1 HART Multidrop with Multiple Transmitters

Optional Equipment
Model
Qty Description
number
1 Calibration Bench ______________________________________________________________________ 3550-M0

Specifications
Parameter Value
Power Requirements
Current 15 A
Service Installation Standard single-phase ca outlet
Air Supply Requirement 690 kPa (100 psig) instrument dry air at 57 dm³/min (2 ft³/min)
Microprocessor-Based Controller
Type Single station micro-controller
Performs the standard proportional, integral, and derivative (PID) control
actions. Can be configured to function as a single controller or as two
independent controllers with individual built-in options. For each controller, P, I,
Functions
PD, PI, and PID control can be implemented, as well as cascade control and self
tuning control. Linear/non-linear inputs and outputs include specific arithmetic
functions and characterization.
Four, input range of either 1-5 V dc or 4-20 mA selectable by toggle switch on
Analog Inputs the main control panel of the Process Station. Input bias, gain, conditioning
(square, square root), and filtering are available for every input.
Two, 5 V dc nominal open circuit voltage, 1 mA max. Used for remote status
Digital (Dry Contact) Inputs
changes and tracking functions.
Two; Output 1: 4-20 mA into a 500 Ω max. resistor; Output 2: configurable for
Analog Outputs transmission of the measurement, setpoint, conditioned input, or Output-1
signal as a 1-5 V dc output signal into a 2 kΩ min. resistor.
Two, isolated, dry-contact outputs, 24 V dc, 1 A max. Used for remote indication
Digital (Auxiliary) Outputs
of controller or alarm status as required.

© Festo Didactic 17
Mobile Instrumentation and Process Control Training Systems, LabVolt Series,
3500

Parameter Value
Consists of an alphanumeric display, a graphics display, status indicators, an
Front Panel
alarm indicator, and a keypad.
Can provide a 25-V dc nominal voltage for powering up to two 4-20 mA
Transmitter Powering Capability
transmitters.
Graphic Data Manager
Type Endress + Hauser Memograph M RSG40
Display Characteristics Thin-film-transistor (TFT), color, 17.8 cm (7 in)
Signal analysis, interface/modem, OPC-server, ReadWin 2000, mathematic
Functions
formula editor, energy package (water+steam)
20 analog inputs (U, I, TC, RTD, frequency, pulse), 14 digital inputs (control,
Inputs
event, and counting inputs)
Outputs 12 relay outputs, 2 analog outputs (I, pulse)
Interface RS 232, RS 485, Ethernet, Modbus RTU, Modbus TCP, PROFIBUS DP, USB
Storage/Recording Internal memory, SD card, USB stick
Oven
Type Gravity convection airflow
Heating Up to 200°C (392°F)
Cycles the oven heating element on and off to maintain the oven temperature at
Capillary-Bulb Temperature Switch the thermostat temperature setting. The switch has an adjustable differential. A
built-in overheating protection circuit takes over if the temperature switch fails.
Thermometer
Sensing Element Capillary bulb
Dial 8.9 cm (3.5 in) diameter, 40-175°C (100-350°F) graduated
Thermocouple Temperature
Transmitter
Produces a 4-20 mA signal proportional to the temperature sensed in the oven
Function
of the Process Station.
Temperature Sensing Element J-type iron-constantan thermocouple probe
Temperature Measurement Range 0-200°C (32-392°F)
Zero and Span Adjustability 80% of selected range
Accuracy 0.5% of span including linearity, hysteresis, and stability
Response Time 400 ms maximum
RTD Temperature Transmitter
Produces a 4-20 mA signal proportional to the temperature sensed in the oven
Function
of the Process Station.
Temperature Sensing Element Platinum RTD, 100 Ω at 0°C (32°F)
Temperature Measurement Range 0-200°C (32-392°F)
Zero and Span Adjustability 100% of selected range
Accuracy 0.1%; RTD signal linearization is performed.
Solid-State Triac Driver
Permits control of the electrical power applied to the heating element of the
Function
Process Station oven, using a 4-20 mA input signal.
Physical Characteristics
Intended Location On the floor (stands on casters)

18 © Festo Didactic
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Parameter Value
Dimensions (H x W x D) 1854 x 1156 x 724 mm (73.0 x 45.5 x 28.5 in)
Net Weight 137.3 kg (302.1 lb)

Multi-Process Station
3505-M0
The Multi-Process Station consists of a
pump, a water reservoir, a
programmable ac variable frequency
pump drive, a 20 cm (8 in) diameter,
92 cm (36 in) high level column, a
pneumatically operated flow control
valve, needle valves, and process
piping made of clear thermoplastic
(PVC). The pump can be operated
either at fixed speed or variable speed.

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Piping diagram of the Multi-Process Station, Model 3505.

List of Manuals
Manual
Description
number
3500 Series Process Control Stations (User Guide) ______________________________________________ 32868-E0
Multi-Process Station (Student Manual) _______________________________________________________ 85629-00

Table of Contents of the Manual(s)


Multi-Process Station (Student Manual) (85629-00)
• 1 Level Measurement I – Dry Method using a Bubble Pipe
• 2 Level Measurement II – Calibration of a Level Transmitter
• 3 Pressure Measurement
• 4 Flow Measurement: Differential Pressure vs Flow Using a Venturi or Orifice Plate
• 5 Level Process Characteristics with Control Valve
• 6 Level Process Characteristics with Variable Speed Pump
• 7 Flow Process Characteristic with Control Valve
• 8 Pressure Process Characteristic
• 9 Proportional Control – Level Process with Control Valve
• 10 Proportional Control – Flow Process with Variable Speed Pump
• 11 Proportional Plus Integral Control – Level Process with Control Valve
• 12 Proportional Plus Integral Control – Pressure Process

20 © Festo Didactic
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• 13 Proportional Plus Integral Plus Derivative Control – Level Process with Control Valve
• 14 Proportional Plus Integral Plus Derivative Control – Flow Process with Variable Speed Pump
• 15 Ultimate Period Tuning of a Level Process
• 16 Ultimate Period Tuning of a Flow Process – Approximation Method
• 17 Open Loop Tuning of a Level Process using the Reaction Rate Method
• 18 Open Loop Tuning of a Pressure Process
• 19 Troubleshooting a Level Control Process
• 20 Operation of a Two Element Control Process
• 21 Three-Element Control Process
• 22 Auto-Tune Controller

Optional Equipment
Model
Qty Description
number
1 Calibration Bench ______________________________________________________________________ 3550-M0

Specifications
Parameter Value
Power Requirements
Current 15 A
Service Installation Standard single-phase ac outlet
Air Supply Requirement 690 kPa (100 psig) instrument dry air at 57 dm³/min (2 ft³/min)
Microprocessor-Based Controller
Type Single station micro-controller
Performs the standard proportional, integral, and derivative (PID) control
actions. Can be configured to function as a single controller or as two
independent controllers with individual built-in options. For each controller, P, I,
Functions
PD, PI, and PID control can be implemented, as well as cascade control and self
tuning control. Linear/non-linear inputs and outputs include specific arithmetic
functions and characterization.
Four, input range of either 1-5 V dc or 4-20 mA selectable by toggle switch on
Analog Inputs the main control panel of the Process Station. Input bias, gain, conditioning
(square, square root), and filtering are available for every input.
Two, 5 V dc nominal open circuit voltage, 1 mA max. Used for remote status
Digital (Dry Contact) Inputs
changes and tracking functions.
Frequency Inputs Two, 1-9999 Hz, 250 Ω input impedance
Two; Output 1: 4-20 mA into a 500 Ω max. resistor; Output 2: configurable for
Analog Outputs transmission of the measurement, setpoint, conditioned input, or Output-1
signal as a 1-5 V dc output signal into a 2 kΩ min. resistor.
Two, isolated, dry-contact outputs, 24 V dc, 1 A max. Used for remote indication
Digital (Auxiliary) Outputs
of controller or alarm status as required.
Consists of an alphanumeric display, a graphics display, status indicators, an
Front Panel
alarm indicator, and a keypad.
Can provide a 25 V dc nominal voltage for powering up to two 4-20 mA
Transmitter Powering Capability
transmitters.
Graphic Data Manager

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Parameter Value
Type Endress + Hauser Memograph M RSG40
Display Characteristics Thin-film-transistor (TFT), color, 17.8 cm (7 in)
Signal analysis, interface/modem, OPC-server, ReadWin 2000, mathematic
Functions
formula editor, energy package (water+steam)
20 analog inputs (U, I, TC, RTD, frequency, pulse), 14 digital inputs (control,
Inputs
event, and counting inputs)
Outputs 12 relay outputs, 2 analog outputs (I, pulse)
Interface RS 232, RS 485, Ethernet, Modbus RTU, Modbus TCP, PROFIBUS DP, USB
Storage/Recording Internal memory, SD card, USB stick
Current-to-Pressure (I/P)
Converter
Function Converts 4-20 mA signals into 21-103 kPa (3-15 psig) pneumatic signals.
Dry oil-free compressed air filtered to contain no particles larger than 25
Air Supply microns; air pressure must be at least 34 kPa (5 psig) greater than converter
outlet pressure without exceeding 700 kPa (100 psig).
An integrated volume booster provides flow rates up to 283 dm³/min (10 ft³/
Output Flow Rate
min).
Linearity ±0.5% of full scale
Air Consumption 0.9 dm³/min (0.03 ft³/min)
Response Time Typically less than 1 second at mid-range (dead-ended)
Pneumatically Operated Flow
Control Valve
Operating Signa 21-103 kPa (3-15 psig), trim with equal percentage flow characteristic
Actuating Mechanism Air-to-open
Body Material Bronze
AC Variable Frequency Pump Drive
Industrial-type programmable drive providing speed control of the motor that
drives the Process Station pump. Uses the latest solid-state PWM technology.
Description
Drive programming and operation is controlled manually using the drive keypad
or remotely via the drive external input.
Output Power 0.75 kW (1 hp)
Output Frequency Range 0.5-400 Hz, programmable in 0.1 Hz increments
Maximum/Minimum Frequency Separately programmable to 400 Hz in 0.1 Hz increments
Programmable 0.1 to 600 seconds to maximum frequency in 0.1 second
Acceleration/Deceleration Time
increments
Torque Boost Automatic or fixed
Keypad Forward, reverse, stop, up/down arrow, program, shift, and enter keys
Alphanumeric LCD display indicating motor speed in Hz, r/min, motor current,
Display
and percent load
Electronic Differential Pressure
(D/P) Transmitters (Two)
Transmit a 4-20 mA signal and/or digital signal proportional to sensed
Function
differential pressure. The type of transmitted signal is software selectable.
Pressure Sensing Element Silicon strain gauge sensor

22 © Festo Didactic
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Parameter Value
A built-in digital platform provides digital communications, for transmission of
DigitalCommunications differential pressure measurements to a PC-based workstation, as well as
remote configuration and monitoring.
LCD digital indicator with configuration push-buttons displaying measurements
Display
with a choice of units. Push-buttons allow zero and span adjustment.
0.87 and 50 kPa (3.5 and 200 inH2O) for transmitter 1;7 and 210 kPa (28 and
Span Limits
840 inH2O) for transmitter 2
-50 and 50 kPa (-200 and 200 inH2O) for transmitter 1;-210 and 210 kPa (-840
Range Limits
and 840 inH2O) for transmitter 2
Accuracy 0.1% of span
Zero Suppression To the upper range limit minus the span
Zero Elevation To the lower range limit
Low-Pressure Gauge
Range 0-1000 mm H2O (0-40 in H2O)
Accuracy ±2%
Minor Graduations 10 mmH2O (0.5 inH2O)
Compound-Pressure Gauge
Range 100/0/300 kPa (30 in Hg/0/30 psi)
Accuracy ±1%
Minor Graduations 5 kPa (1 inHg/1 psi)
Flowmeter
Type Variable area with metering float
Range 4-38 L/min (1-10 gal US/min)
Physical Characteristics
Intended Location On the floor (stands on casters)
Dimensions (H x W x D) 1981 x 1156 x 724 mm (78.0 x 45.5 x 28.5 in)
Net Weight 213 kg (470 lb)

Optional Equipment Description


Calibration Bench (Optional)
3550-M0
The Calibration Bench is designed for
basic study of the operation and
calibration of process instrumentation.
It can be used to calibrate the
pressure gauges, pressure
transmitters, D/P transmitters,
temperature transmitters, and I/P
converters found on the Process
Stations of the Mobile Instrumentation
and Process Control Training System.
The Calibration Bench consists of a
strong waist-high table with riser shelf and panel-mounted equipment including a 24 V dc outlet, a 0-250 kPa

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(0-30 psig) pressure gauge, a 0-750 kPa (0-100 psig) air pressure regulator with pressure gauge, and a 0-250
kPa
(0-30 psig) air pressure regulator with pressure gauge.
The Calibration Bench also includes a 5 cm (2 in) pipe stand for instrument mounting, a pressure calibrator, a
digital multimeter with analog bar graph display, and a NIST-certified digital process calibrator with bipolar
current (±25 mA) and voltage (±1.5 V and ±15 V) outputs, frequency (square wave) source, and true RMS
multimeter.

List of Manuals
Manual
Description
number
Calibration Bench for Mobile Workstations (Student Manual) _____________________________________ 76015-20
Calibration Bench for Mobile Workstations (Instructor Guide) _____________________________________ 76015-30

Table of Contents of the Manual(s)


Calibration Bench for Mobile Workstations (Student Manual) (76015-20)
• 1 Calibration of a Pressure Gauge
• 2 Calibration of a Pressure Transmitter
• 3 Calibration of a Differential Pressure Transmitter
• 4 Calibration of a Temperature Transmitter
• 5 Calibration of a Current to Pressure Converter
• 6 Calibration of a Strip Chart Recorder
• 7 Alignment of a Control Valve

Specifications
Parameter Value
Power Requirements
Current 18 A
Service Installation Standard single-phase ac outlet
Air Supply Requirement 690 kPa (100 psig) instrument dry air at 57 dm³/min (2 ft³/min)
Pressure Calibrator
Sphygmomanometer, with precision gauge and squeeze bulb for applying
Type
pressure manually
Pressure Range 0-40 kPa (0-160 inH2O)
Digital Multimeter
Function Measures ac/dc voltages, current, resistance, continuity, and diode
Display 3½ digit, 3200 count, 31 segment analog bar graph
Range Selection Autoranging or manual
Protection Inputs are overload protected and 10 A fused
Digital Process Calibrator
Permits calibration of process signals into dc voltage or current signals of
Function standardized range. Includes a frequency calibration function, as well as digital
multimeter functions.
Calibration Source Precision 0.03% accurate voltage and current source
Calibration Output Range Bipolar current (±25 mA) and voltage (±1.5 V, ±15 V)

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Parameter Value
Frequency Source Wide frequency range, with adjustable amplitude, pulse width, and duty cycle
Measures ac/dc voltages, current, temperature, frequency, duty cycle, pulse
Digital Multimeter width, resistance, continuity, and diode. Provides true RMS measurement for
non-linear voltage and current loads.
Power Auto power off with disable function
Certification Comes with NIST Certificate
Physical Characteristics
(Workbench and Riser)
Dimensions (H x W x D) 1118 x 2134 x 914 mm (44.0 x 84.0 x 36.0 in)
Net Weight 164.9 kg (362.8 lb)

Personal Computer (Optional)


8990-00
The Personal Computer consists of a
desktop computer running under
Windows® 7. A monitor, keyboard,
and mouse are included.

Specifications
Parameter Value
Power Requirements
Current 2A
Service Installation Standard single-phase ac outlet

© Festo Didactic 25
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Reflecting the commitment of Festo Didactic to high quality standards in product, design, development, production,
installation, and service, our manufacturing and distribution facility has received the ISO 9001 certification.

Festo Didactic reserves the right to make product improvements at any time and without notice and is not responsible
for typographical errors. Festo Didactic recognizes all product names used herein as trademarks or registered
trademarks of their respective holders. © Festo Didactic Inc. 2015. All rights reserved.

Festo Didactic SE
Rechbergstrasse 3
73770 Denkendorf
Germany
P. +49(0)711/3467-0
F. +49(0)711/347-54-88500

Festo Didactic Inc.


607 Industrial Way West
Eatontown, NJ 07724
United States
P. +1-732-938-2000
F. +1-732-774-8573

Festo Didactic Ltée/Ltd


675 rue du Carbone
Québec QC G2N 2K7
Canada
P. +1-418-849-1000
F. +1-418-849-1666

www.labvolt.com
www.festo-didactic.com

26 © Festo Didactic