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TRAINER
Product Code 315A
Instruction manual
Contents
1 Description 5 Troubleshooting 9 Theory
2 Specifications 6 Components used 10 Software
3 Installation requirements 7 Packing slip 11 Experiments
4 Installation Commissioning 8 Warranty 12 Components’ manuals
06-08-2008 Im315A
Apex Innovations
Description
Specifications
Shipping details
Gross volume 0.30m3, Gross weight 70kg, Net weight 31 kg
Installation requirements
Installation Commissioning
INSTALLATION
• Unpack the box(es) received and ensure that all material is received as per
packing slip (provided in instruction manual). In case of short supply or breakage
contact Apex Innovations / your supplier for further actions.
• Fit the mounting pads to the set up and place the set up on support table.
• Connect SS pipe (supplied loose) from rotameter outlet to process tank inlet.
• Remove packing wire inserted in the rotameter by removing plug on the top of the
rotameter. (Use small nose pliers)
• Pierce a hole in to the rubber cap fitted on pressure gauge(s) with pin or needle.
• Air supply: Ensure that clean and oil free air is received from compressed air
source (compressor / mini compressor) by venting out the air for few minutes.
Then connect air supply to the set up.
• Clean the SS Tray. Remove pump from its box.
• Connect the set up to "USB" port of the computer.
• Electric supply: Before connecting electric supply ensure that supply voltage is 230
V AC and earth neutral voltage is less than 5 V Ac.
COMMISSIONING
• Ensure that flow transmitter is connected to orifice meter placed in flow line. The
connection should have proper polarity. (Note: Orifice meters and flow
transmitters are marked as H and L).
• Fill supply tank with distilled water and keep the pump inside the water.
• Keep the setup over the tray. Take the pump cable and pump outlet tube to the
top side through the hole on the base plate. Connect the cable to the pump switch
and connect the tube to the inlet of control valve.
• Return the bypass line back to SS tray through the hole provided on the base
plate. The assembly looks as shown below.
NOTE: FOR LONGER SHUT DOWN, REMOVE WATER FROM THE SUPPLY TANK AND CLEAN IT.
Troubleshooting
Note: For component specific problems refer components’ manual
Problems Possible causes / remedies
Incorrect flow • Air trap in pressure signal line to flow
reading transmitter
• Reversed High-Low pressure signal connections from
orifice to the flow transmitter
• Differential pressure value is displayed on the
interfacing unit which is proportional to square of the
flow rate.
Control valve does • Valve diaphragm breakage
not operate • Faulty I/P converter
• No output from Interfacing unit
I/P converter does • Insufficient supply air pressure
not work • Faulty electrical input signal
• Clogged orifice
No communication • Improper USB port connection
with computer • Computer USB port not configured
Components used
Components Details
Control unit ADAM-4022T Serial based dual loop PID controller;
Analog input 4, Analog output 2, Digital input 2,
Digital output 2. with RS485 communication.
RS485-USB converter Make Advantech, Model ADAM 4561
Differential pressure Make Yokogawa, Model EJA 110-DMS-5A-92NN,
transmitter Calibration range 0-200 mm H2O, Output square
root
Level transmitter Make WIKA, Model SL-1, Measuring range 250mm,
Output 4-20mA supply 10-30 Vdc, conn.
1/2"BSP(M)
I/P converter Make Control air inc, Type T500-AC, Input 4-20 mA
DC, output 3-15 psig, end connection 1/4 NPT
Power supply Make Meanwell, model S-15-24, O/P 24 V, 0.7 A
Control valve Make Apex, Model MX-102, Size ½”x1/4”, Body
SS316, Trim SS316, Travel 10mm, Spring range 3-
15 psig, Characteristics linear, Action air to close,
Valve coefficient 0.47
Rotameter Make Eureka, Model MG 11, Range 10-100 lph,
Connection ¼” BSP back, screwed, Packing PTFE +
Silicon
Pump Submersible pump, Model HQB 4500, Head max.
4.5m, Output 4500 lph, Watts 100, Volts 220-240
AC, 50Hz
Air filter regulator Make Airmatic, Model MB10-02-1-PAP-PD, Range 0-
2 Kg/cm^2, Type Relieving
Pressure gauge Make Waaree, Code: PW2.5GNNNS9 0-2.5 1/4"B,
Dia.2.5", Gly. filled, Brass internals, S.S. casing,
Range 0-2.5 Kg/cm2, 1/4"BSP (M) back connection
Pressure gauge Make Waaree, Code: PW2.5GNNNS9 0-7 1/4"B,
Dia.2.5", Gly. filled, Brass internals, S.S. casing,
Range 0-7 Kg/cm2, 1/4"BSP (M) back connection
Packing slip
This product is warranted for a period of 12 months from the date of supply against
manufacturing defects. You shall inform us in writing any defect in the system
noticed during the warranty period. On receipt of your written notice, Apex at its
option either repairs or replaces the product if proved to be defective as stated
above. You shall not return any part of the system to us before receiving our
confirmation to this effect.
The foregoing warranty shall not apply to defects resulting from:
Buyer/ User shall not have subjected the system to unauthorized alterations/
additions/ modifications.
Unauthorized use of external software/ interfacing.
Unauthorized maintenance by third party not authorized by Apex.
Improper site utilities and/or maintenance.
We do not take any responsibility for accidental injuries caused while working with
the set up.
Measured Variable
Computer
LOCAL
SLAVE
Controller
RS232/USB
MASTER
MASTER
LOCAL
LOCAL
LOCAL
SLAVE
SLAVE
SLAVE
Controller-1
Controller-2
Controller-3
RS232/USB RS485 RS485
MASTER
MASTER
MASTER
LOCAL
LOCAL
LOCAL
SLAVE
SLAVE
SLAVE
CLIENT SERVER
Controller-1
Controller-2
Controller-3
LAN RS232/USB RS485 RS485
PROCESS CONTROLLER
In automatic controlled process the parameter to be controlled is measured and
compared with the set point by process controller. The difference between the
measured signal and the set point is error. The controller performs on-line
calculations based on error and other setting parameters and generates an output
signal. The output signal drives the final control elements like control valve or a
damper to control the process to the set point.
Reference
Signal Error Controller Output
Controller Process Parametert
Feedback Signal
On/Off controllers
Set Value
Time
On-Off Controller
Offset
Parameter Value
Time
Propertional Controller
Time
Propertional - Integral Controller
The offset in proportional controller can be overcome by adding integral action. The
control algorithm that applies changes in output as long as deviation exits, so as to
bring the deviation to zero, is called integral action. Output of proportional-Integral
controllers is given by:
100 1
OP = b + × e + ∫ e ⋅ dt
PB Ti
Where OP is the output, b is the bias, PB is the proportional band in %, e is the error
signal, Ti is integral time; this is the time required to repeat proportional action.
Y
20
10
L X
0 10 20 30 40
Time
Where
Slope R: Slope of line drawn tangent to the point of inflection.
%ChangeinVariable Y
R= =
time(min) X
Dead time L: Time between the step change and the point where tangent line
crosses the initial value of the controlled variable (in min.)
∆P = Step change applied in %
Tu
Time
Continuous Cycling
Response curve for ultimate gain and period
The process is placed in the closed loop with a proportional controller. The
Proportional band is decreased until the process goes to continuous oscillations. The
corresponding value of proportional band is called as ultimate proportional band PBu
and the period of oscillation is called the ultimate period Tu. The PID controller
parameters are selected from the following table.
Output
X
A2
Input
A1
Time
Frequency Response
BODE diagram
In Bode diagram the magnitude ratio verses frequency is plotted on log-log co
ordinates and the phase angle verses frequency on semi-log coordinates.
10
Magnitude Ratio M
1
0.1
Log Scale
0.01 0.1 1 10
Frequency
0
Phase Angle Deg
-90
-180
0.01 0.1 1 10
Frequency
Bode Diagram
Stability criteria
• A system is stable if the phase lag is less than 180 Deg. at the frequency for
which the gain is unity (one).
• A system is stable if the gain is less than one (unity) at the frequency for which
the phase lag is 180 Deg.
Because the secondary loop exists as an element in the primary loop, the secondary
controller should be properly tuned before the primary controller, with the primary
controller in manual.
Whether the secondary should be tuned for optimum set point or load response
depends on whether severe load changes are expected in the secondary loop. If so,
observing response to load changes simulated by stepping the secondary controller
output while in manual should do tuning, followed by transfer to automatic. If not,
set point steps should be introduced.
In a cascade system that is cycling, it is often difficult to determine which controller
needs detuning. If the period of cycles is too short to belong to the primary loop, the
safest action is to widen the proportional band of secondary controller- a few percent
changes is enough. In this case, both periods may appear in either or both of the
controlled variables. But only one period is evident, widening the proportional band
of either controller could dampen the cycle, although it is probably more effective to
de-tune the primary controller.
Installing wwGenericSQLGrid
Insert PDCSoft CD in CD drive
Open CD using explorer. Double click on “SQLGRID” folder, double click on
wwGenericSQLGrid setup file.
Click on “System DSN”, “Add” select “Microsoft Access Driver (*.mdb)”, “Finish”.
Click “Finish”.
Check the Com port no. where USB is installed
1. Go to System properties (Click on Start – Control Panel – Performance and
Maintenance – System)
Click on Ports.
You will find that “ADAM-4561/4562 USB TO serial Comm. Port (Com4)”
Here Com port no. is Com4.
Click on “NEW”
For product no. 315A :In InTouch Application Manager window, Click on
Tools – Find Applications - Select D drive – “Cascade Control Trainer ADAM
4022T” folder and click OK.
Repeat for “Flow Loop Cascade ADAM 4022T” and for “Level Loop Cascade
ADAM 4022T”.
For product no. 326A :In InTouch Application Manager window, Click on
Tools – Find Applications - Select D drive – “Multi Process Trainer ADAM
4022T” folder and click OK.
Repeat for “Flow Loop Multiprocess ADAM 4022T” and for “Level Loop
Multiprocess ADAM 4022T”.
6. In “Windows to Open” Click “Select All” and click Ok. Now the application is
opened in development mode for respective control trainer.
InTouch:
1. Click on Start, All programs, Wonderware, InTouch to open InTouch-
Application Manager.
2. In InTouch-Application Manager click on File, New to open “Create New
Application” wizard, Click on Browse, select D drive, Select “set as default
directory” and click “next”. In window write “Apex Demo Application” as the
directory where you want the application to be created. Click “Next”. Enter
name as “Apexdemo” and description of Intouch application as “Apex Demo
application” Click Finish.
3. In Intouch application manager window double click on “Apexdemo”.
4. In InTouch windowmaker Click on File - New Window, In “Window Properties”
window. Type name as Yokogawa Temperature. Keep all other parameters as
default. Click OK.
InTouch:
1. Click on Start, All programs, Wonderware, InTouch to open InTouch-
Application Manager.
2. In InTouch-Application Manager click on File, New to open Create New
Application wizard. Follow the wizard instructions and after clicking Finish new
application is displayed in Application Manager.
3. Select the new application created and click on File, WindowMaker to open
application in development mode.
4. Click on File, New Window to open Windows Properties window. Set
parameters and click OK.
5. Inserting Symbol (Graphics from library): Click on Wizards tool. In
Wizards Selection select Symbol Factory, double click on Symbol and click on
New Window to open Symbol Factory by Reichard Software. In this window
select desired Category, Symbol and click OK.
6. Add Access Name: Click on Special, Access Names. In Access names
window click ADD. Type Access: MODBUS, Node name: Name of server
computer, Application name: VIEW, Topic name: Tagname click OK, Close.
(Note: The experiment nos 1 thru 6 are to get feel of the processes and PID
settings.)
Calculations
• From the above data, note the output required for maintaining the process at
desired set points.
• Set the output of the controller to the noted value and at steady state apply the
load change to the process. Load change can be given by slightly varying the
drain valve. Observe new steady state process value.
Note: The scale on the process tank is provided only for general use. However rely
on the screen data. It is not necessary to calibrate level transmitter with the scale on
process tank.
Similarly for flow loop the Rotameter float is only for general indication. However the
on screen process data (flow readings) is to be relied upon.
Procedure
(This experiment can be performed for both Level and Flow loops)
For level loop:
• Switch on Pump and adjust the Rotameter to 100LPH.
• Provide air supply to the regulator and adjusting it to 2 kg/cm^2
• Switch on the computer and ensure MODBUS communication is initialized by
executing Wonderware FactorySuite | IO Servers | Modicon Modbus)
• Execute Programs | Wonderware | InTouch for “Level loop ADAM 4022T”. Select
both HistData and Process in Windows to open and Click “Runtime”.
• Select On-Off mode Experiment (click on “Change Expt.” Button, click on
“Change”, Click on “On-Off mode” button.)
• Open the control valve by decreasing the controller output to 0%.
• Adjust the tank drain valve such that the tank level shall remain between 90 and
100%
• Change Hystresis value to 1%.(Range 0.1-10%)
• Change the values of the set point and observe the On-Off control operation.
(Note: In case of level loop if the process value is not reaching set point, close the
tank drain valve partially.)
Observations
Observe that if process value exceeds the set point and increases than the value of
(0.5x Hysteresis), controller closes the control valve and if process value decreases
Procedure
(This experiment can be performed for both Level and Flow loops)
For level loop:
• Switch on Pump and adjust the Rotameter to 100LPH.
• Provide air supply to the regulator and adjusting it to 2 kg/cm^2
• Switch on the computer and ensure MODBUS communication is initialized by
executing Wonderware FactorySuite | IO Servers | Modicon Modbus)
• Execute Programs | Wonderware | InTouch for “Level loop ADAM 4022T”. Select
both HistData and Process in Windows to open and Click “Runtime”.
• Select P Mode Experiment (click on “Change Expt.” Button, click on “Change”,
Click on “P Mode” button.)
• Open the control valve fully by decreasing the controller output to 0%. (Click on
Auto, Change it to Man then change OP to 0%)
• Adjust the tank drain valve such that the tank level shall remain between 90 and
100%. Change the controller to Auto mode
• From the default values of SP=50, PB=100, Bias=50, AM=Auto and Act =Direct;
observe the process value PV. Check if there is any offset.
• Increase the SP to 60% and check the offset. Repeat the observation for SP=70.
It will be observed that the process becomes steady with some offset.
• The offset can be eliminated by any of the following ways:
a) By Increasing/decreasing the bias value gradually by 1% (in steps).
b) By decreasing the PB. (Decrease the PB in steps of @10%. As the PB is
decreased offset is reduced. Below certain PB the process will show oscillatory
response.)
Procedure
(This experiment can be performed for both Level and Flow loops)
For level loop:
• Switch on Pump and adjust the Rotameter to 100LPH.
• Provide air supply to the regulator and adjusting it to 2 kg/cm^2
• Switch on the computer and ensure MODBUS communication is initialized by
executing Wonderware FactorySuite | IO Servers | Modicon Modbus)
• Execute Programs | Wonderware | InTouch for “Level loop ADAM 4022T”. Select
both HistData and Process in Windows to open and Click “Runtime”.
• Select PI Mode Experiment (click on “Change Expt.” Button, click on “Change”,
Click on “PI Mode” button.)
• Open the control valve fully by decreasing the controller output to 0%. (Click on
Auto, Change it to Man then change OP to 0%)
• Adjust the tank drain valve such that the tank level shall remain between 90 and
100%. Change the controller to Auto mode
• From the default values of SP=50, PB=50, IT=60, AM=Auto and Act =Direct;
observe the process value PV. Observe that the output continuously changes till
the process value matches with set point. Also note that the change in output
due to integral action is more when error is more.
• Increase the SP to 60% and observe that process value matches with set point
without any offset.
• Reduce the integral time to 30 seconds, change set point to 50%. Observe that
the output change is faster and process value reaches set point in lesser time as
compared with previous setting. Repeat and confirm this observation for still
lower values of integral time. Remember to apply step change of +/- 10% every
time.
• Observe the oscillatory response of the process value at lower values of integral
time.
• Repeat similar observations by keeping the integral time constant (default value)
and reducing proportional band. (After every change in Proportional Band the
integral value changes automatically which needs to be corrected to keep is
constant.) At lower values of Proportional band the output value shows oscillatory
response which in-turn oscillates process value.
• From above observations we can identify the need for controller tuning (i.e.
finding optimum setting of Proportional band and integral time).
Observations
• Adding integral action in control helps in eliminating offset.
• At lower values of Integral time process shows oscillatory response.
Procedure
(This experiment can be performed for both Level and Flow loops)
For level loop:
• Switch on Pump and adjust the Rotameter to 100LPH.
• Provide air supply to the regulator and adjusting it to 2 kg/cm^2
• Switch on the computer and ensure MODBUS communication is initialized by
executing Wonderware FactorySuite | IO Servers | Modicon Modbus)
• Execute Programs | Wonderware | InTouch for “Level loop ADAM 4022T”. Select
both HistData and Process in Windows to open and Click “Runtime”.
• Select PD Mode Experiment (click on “Change Expt.” Button, click on “Change”,
Click on “PD Mode” button.)
• Open the control valve fully by decreasing the controller output to 0%.
• Adjust the tank drain valve such that the tank level shall remain between 90 and
100%
• From the default values of SP=50, PB=100, DT=1, AM=Auto, bias=50 and Act
=Direct; observe the process value PV. Check if there is any offset.
• Set PB=50, DT=5 and change the SP to 60. Observe that the output changes in
steps as observed in proportional control. Whenever the process value is
changing the output value shows contribution of derivative effect also. As seen in
proportional control the process value may not match with set point and offset is
observed.
Observations
• Because of derivative action the output changes are more based on the rate of
change of process vale. The offset can not be eliminated by derivative action.
• As the flow measurement is noisy the derivative action responds to the noise
also.
Procedure
(This experiment can be performed for both Level and Flow loops)
For level loop:
• Switch on Pump and adjust the Rotameter to 100LPH.
• Provide air supply to the regulator and adjusting it to 2 kg/cm^2
• Switch on the computer and ensure MODBUS communication is initialized by
executing Wonderware FactorySuite | IO Servers | Modicon Modbus)
• Execute Programs | Wonderware | InTouch for “Level loop ADAM 4022T”. Select
both HistData and Process in Windows to open and Click “Runtime”.
• Select PID Mode Experiment (click on “Change Expt.” Button, click on “Change”,
Click on “PID Mode” button.)
• Open the control valve fully by decreasing the controller output to 0%. (Click on
Auto, Change it to Man then change OP to 0%)
• Adjust the tank drain valve such that the tank level shall remain between 90 and
100%. Change the controller to Auto mode
• From the default values of SP=50, PB=20, IT=30, DT= 2, AM=Auto and Act
=Direct; observe the process value PV. Change the set point by 10% and observe
the response by varying values of PB, IT and DT.
Observations
Compare the steady state response of the PID controller with P. PI and PD controller
obtained in the above experiment.
Observations
Compare the steady state response of the PID controller with P. PI and PD controller
obtained in the above experiment.
Procedure
(This experiment can be performed for both Level and Flow loops)
For level loop:
• Switch on Pump and adjust the Rotameter to 100LPH.
• Provide air supply to the regulator and adjusting it to 2 kg/cm^2
• Switch on the computer and ensure MODBUS communication is initialized by
executing Wonderware FactorySuite | IO Servers | Modicon Modbus)
• Execute Programs | Wonderware | InTouch for “Level loop ADAM 4022T”. Select
both HistData and Process in Windows to open and Click “Runtime”.
• Select Process Reaction Experiment (click on “Change Expt.” Button, click on
“Change”, Click on “Process Reaction Mode” button.)
• Open the control valve fully by decreasing the controller output to 0%. (Click on
Auto, Change it to Man then change OP to 0%)
• Adjust the tank drain valve such that the tank level shall remain between 90 and
100%. Change the controller to Auto mode
• From the default values change OP=70; observe the process value PV. Wait till it
comes to steady state.
• Start data logging.
• Apply a 20 - 30 % change to controller output. (Change control valve output to
30%) Record the step response. Wait for the steady state.
• Stop data logging when the process value is fairly steady.
• Click the “HistData” to see the data. Plot the step response (Process reaction
curve) from stored data. Find out the value of slope at the point of inflection and
time lag.
• Calculate P I D settings for different modes.
• Select PID Mode. Set the PID values obtained from the calculations. Apply the
step change & observe the response of the system. Allow the system to reach
steady state.
Observations
(Refer theory for formulae.)
• Step change to the system ∆P = Initial output - Final output of the controller.
• Plot the graph of process value Vs Time on a graph paper.
From process reaction curve:
• Slope of the process reaction curve R =
• Time lag L=
Calculate P, PI, PID setting from above values.
Observe response of the system for different PID settings.
Procedure
(This experiment can be performed for both Level and Flow loops)
For level loop:
• Switch on Pump and adjust the Rotameter to 100LPH.
• Provide air supply to the regulator and adjusting it to 2 kg/cm^2
• Switch on the computer and ensure MODBUS communication is initialized by
executing Wonderware FactorySuite | IO Servers | Modicon Modbus)
• Execute Programs | Wonderware | InTouch for “Level loop ADAM 4022T”. Select
both HistData and Process in Windows to open and Click “Runtime”.
• Select P mode Experiment (click on “Change Expt.” Button, click on “Change”,
Click on “P Mode” button.)
• Open the control valve fully by decreasing the controller output to 0%.
• Adjust the tank drain valve such that the tank level shall remain between 90 and
100%
• From the default values of SP=50, PB=100, Bias=50, AM=Auto and Act= Direct;
adjust bias value so that process value approximately matches with set point.
• Disturb the step change by providing step change of +2% to set point and
observe the system response.
• If the PV is steady, reduce the PB by @ 10% and disturb the system by applying
step change of -2%
• Repeat above steps and find out the PB for which the system shows continuous
oscillatory response.
• Record this PB as ultimate proportional band and period of oscillation as ultimate
period.
Calculate the PID values from the table. Select the PID controller and apply the
parameter values obtained from the above steps. Observe the response of the
process to a step change with these settings.
Observations
• Record the ultimate proportional band (Pbu) and ultimate period (Tu) from
above experiment. (Typical value Pbu=35%, Tu = 7 sec.)
• Calculate PID values by referring theory part for different control actions.
• Observe the process response for these settings.
• Compare the values obtained with open loop response.
Procedure
(This experiment can be performed for both Level and Flow loops)
For level loop:
• Switch on Pump and adjust the Rotameter to 100LPH.
• Provide air supply to the regulator and adjusting it to 2 kg/cm^2
• Switch on the computer and ensure MODBUS communication is initialized by
executing Wonderware FactorySuite | IO Servers | Modicon Modbus)
• Execute Programs | Wonderware | InTouch for “Level loop ADAM 4022T”. Select
both HistData and Process in Windows to open and Click “Runtime”.
• Select Stability Analysis Experiment (click on “Change Expt.” Button, click on
“Change”, Click on “Stability Analysis” button.)
• Open the control valve fully by decreasing the controller output to 0%.
• Adjust the tank drain valve such that the tank level shall remain between 90 and
100%
• From the default values of Ref point = 50%, Amplitude = 50% and period =10
sec. observe the output and process value variations.
• Change Reference point, Amplitude and Period so that continuous sinusoidal
waveform is observed for process value.
• Log the data for records.
• Change the period and repeat the observation for 3-4 different values of the
period.
(Note: Tf the process value is reaching zero, close the tank drain valve slightly.)
Calculations
• Calculate for each observation
Magnitude ratio as M = A2/A1
Phase angle = (X/T) x 360
Frequency = 1/T cycles / sec.
• Draw the graphs of:
Magnitude Vs frequency on log - log scale
Phase angle Vs frequency on semi-log coordinates.
• Study the graph for stable conditions mentioned in theory.
Calculations
• Calculate for each observation
Magnitude ratio as M = A2/A1
Phase angle = (X/T) x 360
Frequency = 1/T cycles / sec.
• Draw the graphs of:
Magnitude Vs frequency on log - log scale
Phase angle Vs frequency on semi-log coordinates.
STUDY THE GRAPH FOR STABLE CONDITIONS MENTIONED IN THEORY.
Procedure
For cascade loop:
• Switch on Pump and adjust the Rotameter to 100LPH.
• Provide air supply to the regulator and adjusting it to 2 kg/cm^2
• Switch on the computer and ensure MODBUS communication is initialized by
executing Wonderware FactorySuite | IO Servers | Modicon Modbus)
• Execute Programs | Wonderware | InTouch for “Cascade Control Trainer ADAM-
4022T” Select all in Windows to open and Click “Runtime”.
• For selecting Cascade experiment: Click “Experiment On”; Click “Experiment off”.
Then Click “Cascade”
• Open the control valve by changing secondary loop to “Manual” mode and
decreasing the controller output to 0%.
• Adjust the tank drain valve such that the tank level shall remain between 90 and
100%. Take Secondary loop to “Auto” mode.
• Default values of Primary loop are SP=50, PB=20, IT=30, DT=2, Act=Revese,
and that of secondary loop are PB= 100, IT=25, DT=2, Act=Direct. Note that
primary loop is “Level control” loop and secondary loop is “Flow Control” loop.
The output of primary loop is connected to secondary loop as a set point.
• Wait till the Process is at steady state. Change the set point of primary loop and
observe the response.
• For tuning cascade controller first tune Secondary Controller. Tune the
controller independently by keeping the Primary controller in manual mode. The
set point of secondary loop can be changed by changing output of primary loop.
• Tune the Primary Controller using trial and error approach, select the
proportional band and integral time, which gives a satisfactory response to step
change in set point.
Observations
• It is observed that the speed of response of the level control system is improved.
As the flow loop is fast responsive than the level control loop, for a small change
in primary controller output, the secondary controller tries to achieve the set
point.
• Time required to achieve the primary controller set point is less than that of
single loop control.
Technical specifications
Model 500X-AC
Make ControlAir
Input 4-20 mA
Output 3-15 psi
Min./Max supply pressure Min. 18 psig, Max 100 psig
Linearity +/-0.75 % of span
Repeatability <0.5% of span
Hysteresis <1% of span
Air consumption 0.05 scfm midrange typical
Port size ¼ NPT
Principle of operation
The unit is a force balance device in which a coil is suspended in the field of a
magnet by a flexure. The flexure moves towards the nozzle and creates back
pressure which acts as a pilot pressure to an integral booster relay. Input signal
increase causes increase in proportional output pressure.
Zero and span are calibrated by turning adjust screws on the front face of the unit.
Adjustment of the zero screw repositions the nozzle relative to the flexure. The span
adjustment is a potentiometer that controls the amount of current through the coil.
Calibration
1 Open protective covers to expose zero and span adjustment screws.
2 Connect the recommended air supply to the inlet of the transducer and an accurate
pressure gauge at the outlet.
3 Connect the electrical input and set it to 4 mA.
4 Observe the output pressure. If necessary adjust zero screw until reaching
minimum output pressure setting (3 psi). Turn zero screw counter clockwise to
increase pressure, clockwise to decrease pressure. If unable to achieve output
during calibration process, turn zero adjustment screw counter clockwise
for up to 30 revolutions, until output pressure rises.
5 Increase electrical input to 20 mA
Technical specifications
Model MG-1Z to 13
Make Eureka
Flow Rate Max. 10-100 Lph
Packing/Gaskets Neoprene
Measuring tube Borosilicate glass
Float 316SS
End fitting Aisi316
Cover Transparent Acrylic
Accuracy +/-3% full flow
Range ability 10:1
Scale length 75mm.
Max. Temp. 1000C
Max. Pressure 100 psig.
Connection ¼”BSP(M), Back to Back, Threaded Hose
Principle of operation
The loflometer valves must be opened slowly and carefully to adjust the desired flow
rate. A sudden jumping of the float, which may cause damage to the measuring
tube, must be avoided.
Fig.1 Edge
The upper edge of the float as shown in fig. 1 indicates the rate of flow. For
alignment a line marked R.P. is provided on the scale which should coincide with the
red line provided on measuring tube at the bottom.
Maintenance
The measuring tube and float become dirty, then remain in the pipeline when the
measuring tube is cleaned or changed. It is only necessary to remove the tube and
clean it with a soft brush, trichloroethylene or compressed air.
Troubleshooting
Problem Check
Leakage on glands Replace gland packing
Showing high/low flow rate than Consult manufacturers
expected
Showing correct reading initially Replace float
but starts showing high reading Incase of gases, check also leakage
after few days
Showing correct reading initially Clean the loflometer suitable solvent or soft
but starts showing high reading brush
after some months.
Fluctuation of float Maintain op. pressure as mentioned in our
test report.
Frequent breakage of glass tube Use loflometer to accommodate correct flow
rate.
Maintain operating pressure below pressure
rating of the tube.
Check piping layout.
Manufacturer’s address
If you need any additional details, spares or service support for this unit you may
directly communicate to the manufacturer / Dealer / Indian Supplier.
Introduction
Technical specifications
Model EJA110A-DMS5A-92NN
Make Yokogawa
Output signal 4 – 20mA DC with digital
communication (Linear)
Measurement span 1 to 100kPa (100 to 10000mmH2O)
Calibration range 0 – 200, 0 – 500 mmH2O
Wetted parts material Body – SCS14A, Capsule – SUS316L
Process connections without process connector (1/4BSP body connection)
Bolts and nuts material SCM 435
Installation Horizontal impulse piping left side high pressure
Electrical connection 1/2NPT female
Cover ‘O’ rings Buna-N
Supply 10 to 24VDC
Process temperature limit -40 to 120 0C
Housing Weather proof
Weight 3.9Kg
Manufacturer’s address
If you need any additional details, spares or service support for this unit you may
directly communicate to the manufacturer / Dealer / Indian Supplier.