603 - Process Trainer, Advanced

Product Dimensions
(L x W x H)
33 1/2" x 98" x 78 7/8" (860 x 2480 x 1982 mm)
750 lbs (340 kg)

Shipping Dimensions
(L x W x H)
(2) - 58" x 42.5" x 88" (147 x 108 x 223 mm)
1500 lbs (680kg)

A working, large scale, fluid process system allowing for hands-on training relating to the measurement and control of four process variables; level, pressure, temperature and flow. The device allows for the creation of simple and advanced process loops using common, industrial-quality instruments and controllers. An “open architecture” allows for integration of alternate instrumentation, as needed, to address local training needs, and new technologies.

The device includes the capability of establishing cascade, feed-forward, feedback, feedback split range, ratio, and three-element control schemes. Clear PVC piping allows the student to see process changes based on control parameters or intentional disturbances.

The trainer can be configured to create one complex process loop or two independent process systems, allowing for use by up to six students. Standard, user-specified, or user-supplied instrument packages can be easily installed on two mounting stanchions or on two, integral, 19" instrument racks.
Two-piece, welded, 1/8" wall, tubular steel frame (allows for disassembly into two sections).
Four, 4" diameter casters (two with locks) provided on each section.
Two, integral, 19" x 70" high, instrument mounting racks, with silk-screened modular instrument and controller panels.
Rack-mounted, locking storage box for accessories.
Front panel faces with high-durability laminate.
Clear, 3/4" diameter, PVC piping components throughout (high-temperature piping in area of heat exchanger, opaque).
Two, clear acrylic tanks (9 gallon and 14 gallon capacities).
Primary reservoir, polyethylene, 44 gallons.
Two, 1/2 HP centrifugal pumps.
24 VDC Power supply.
GFI circuit protection.
Four solenoid valves allowing for the creation of manual or externally-controlled flow supply and demand disturbances at the tank discharges and in bypasses surrounding control valves.
Power distribution panel, mounted in instrument rack, including power switch, GFI devices, and fuses for pumps, solenoid valves and heater.
Utility distribution panel, mounted with in instrument rack, and including a regulated 0 to 30 psi air supply with gauge and connectors, a regulated 0-60 psi air supply with gauge and connectors, and a 0-30 psi instrument air supply with gauge, 25 electric and 9 pneumatic “free line” connections allowing connection to the front panel face and second rack, and 24 VDC power connections.
Additional instrument air supply regulator.
Front panel-mounted, operator control panel, including switches and pilot lights for two pumps, four solenoid valves, and the system heater, as well as control relay connections for all equipment, 24 VDC power supply terminals and electric and pneumatic free line connections.
Industrial-quality, multi-pass, shell and tube heat exchanger.
One, 5.5 KW in-line water heater.
Six brass thermowells accommodating thermometers, thermocouples and RTDs.
Four, bi-metal thermometers.
Quick-disconnect fittings located throughout, allowing for attachment of instruments.
Two rotameters.
Two orifice assemblies.
One pitot tube assembly.
Three, industrial-quality Fisher pneumatically-operated control valves (two supplied normally closed and one supplied normally open).
Two pipe stanchions, allowing for attachment of differential pressure transmitters, pressure transmitters, and pressure switch at varying heights.
Multi-loop piping system allowing loops to be used independently or in combination (accommodates two work groups).
Provision for attachment to a calibration bench, or calibration workstation, via electrical and pneumatic tether.
Packaging for shipment via motor freight.
#080-467-1 - Video on temperature measurement (ISA).
#080-467-2 - Video on pressure measurement (ISA).
#080-467-3 - Video on level measurement (ISA).
#080-467-4 - Video on flow measurement (ISA).
#460-110 - Supplemental Touchscreen HMI Panel, 10" (A-B, PanelView)
#460-1101 - Articulated Support Arm, Chassis-Mount, 10"
#460-115 - Supplemental Touchscreen HMI Panel, 15" (A-B, PanelView)
#460-1151 - Articulated Support Arm, Chassis-Mount, 15"
#464-005 - Extended DC/AC/Analog Allen-Bradley SLC-500 package.- Allen-Bradley, Model SLC-5/03 PLC with features as follows: - 5/03 CPU with 8K memory. - 7-Slot rack. - DC Input card (16 inputs). - DC Relay output card (16 outputs). - AC Combination card (4 inputs and 4 outputs). - Two Analog Combination Card (2 inputs, 2 outputs, each). - Power supply, 5A.
#464-009 - On-line/Off-line Programming Software w/Comp. Interface
#464-028 - A-B,MicroLogix Analog PLC Package, Process Control
#464-029 - On-Line/off-Line Programming Software with Cable (RSLogix 500 Starter Ed.)
#464-048 - A-B,ControlLogix Analog PLC Package, Process Control
#464-049 - On-Line/off-Line Programming Software with Cable (A-B, Studio 500)
#464-088 - A-B, Compactlogix PLC Package, Process Control
#464-089 - On-Line/off-Line Programming Software with Cable (A-B, RSLogix 5000 Mini)
#581-012 - Textbook, "Industrial Control Electronics" (3rd edition) (Bartelt).
#582-002 - Textbook, "Measurement and Control Basics" (Hughes).
#583-002 - Textbook, "Fundamentals of Process Control" (Murrill).
#584-002 - Textbook, "Process Control Instrumentation" (Johnson).
#600-005 - Supplementary, Free-Standing Instrument Rack.
#600-010 - Optional AC variable speed drive module (for varying pump speed for control).
#600-0112 - Optional, 2-Unit Chiller Distribution Network
#600-0113 - Optional, 3-Unit Chiller Distribution Network
#600-021 - Ultrasonic Level Detector Assembly, Advanced, Hart
#600-021EH - Ultrasonic Level Detector Assembly, Hart, Endress & Hauser Preference
#600-022 - Ultrasonic level detector assembly, economy.
#600-023 - Capacitance-type level detector/transmitter.
#600-024 - Orifice plate set, 3-piece (Supplemental)
#600-025 - Vortex-type flow meter.
#600-025EH - Vortex-Type Flow Meter Assembly, Hart, Endress & Hauser Preference
#600-025R - Vortex-Type Flow Meter Assembly, Rosemont Preference
#600-026 - Displacement-Type Level Transmitter w/Flange Adaptor (Magnetrol)
#600-032 - Venturi tube flow assembly.
#600-033EH - Coriolis Effect Flow Meter, Hart, Endress & Hauser Preference
#600-033F - Coriolis effect flow assembly/transmitter (Fieldbus-capable).
#600-034 - Paddle-type flow measurement assembly/transmitter (Omega).
#600-035 - Turbine-type flow measurement assembly/transmitter (Omega).
#600-035E - Turbine-Type Flow Assembly/Transmitter, Economy
#600-036 - Magnetic flow measurement assembly/transmitter (Rosemount).
#600-036A - Magnetic Flow Meter Assembly, Economy (4-20 mA Output)
#600-036EH - Magnetic Flow Meter Assembly, Endress & Hauser Preference
#600-036R - Magnetic Flow Meter Assembly, Rosemount Preference
#600-040 - Valve Positioner, Pneumatic
#600-041 - Control valve positioner, electro-pneumatic.
#600-041F - Valve Positioner, Digital, FIELDVIEW
#600-041FF - Control Valve Positioner, FIELVIEW, Fieldbus
#600-042 - Handwheel for direct acting actuator only.
#600-045 - Motorized control valve (additional valve).
#600-050 - Optional device interface panel. (for adding optional instruments/motorized valves).
#600-051 - Strip chart recorder, 2-pen (Yokogawa, SR 1000) (additional).
#600-052 - Paperless Strip Chart Recorder, 2-Inputs
#600-055 - Gauge pressure transmitter (Honeywell ST-3000) (additional).
#600-056 - Differential pressure transmitter, supplemental.
#600-058 - I/P converter (Control Air) (additional).
#600-059 - 3-Valve manifold (supplemental).
#600-059R - 3-Valve Manifold (Supplemental) (Rosemount)
#600-060 - Industrial PID controller w/panel (Honeywell UDC-3500,1/4 DIN).
#600-099 - Descrete/Analog Allen-Bradley ControlLogix Package
#600-102 - Function generator, (optional test instrument).
#600-102E - Function Generator, Economy
#600-105 - Differential pressure gauge, low range (0-400in. H20)
#600-121 - Supply pressure regulator, upgrade, w/filter, oiler.
#600-132 - Supplementary Gauge and Meter Panel
#600-201 - Smart field communicator (for Honeywell ST 3000 Transmitters).
#600-205 - Digital multimeter/process calibrator (alternate calibration instrument).
#600-206 - Digital temperature calibrator
#600-207 - Digital volt/mA calibrator (Fluke, Model 715).
#600-310 - Chart recorder supply pack, 12/pens/20 rolls, supplemental.
#600-501 - Textbook series, 4-part, on process measurement and control (General Physics).
#600-902E - Electrical Free-Line Expansion Teather, Expanded
#603-001 - Standard Instrument & Control Package (Flow, Level, Press., Temp) (Honeywell Preference)
#603-001EH - Standard Instrument Package (Endress & Hauser Preference)
#603-001F - Standard Instrument & Control Package (Flow, Level, Press., Temp) (Foxboro Preference)
#603-001R - Standard Instrument & Control Package (Flow, Level, Press., Temp) (Rosemount Preference)
#603-009 - SCADA Distributed Control and Supervisory System
#603-009D - Distributed control system, Delta-V (Emerson).
#603-009F - Fieldbus card/software upgrade.
#603-033 - Coriolis Effect Flow Meter, Hart (Emerson, MicroMotion)
#603-080 - Pipe spool assortment (for flow of fluids experiments) (additional).
#603-400 - Extended spares kit.
#603-500 - Use/Exercise Guide, two-part (additional).
#603-PAC - Process Control, Advanced, Quick-Start Package (includes: #603, #603-001EH, #600-006A, #600-010, #600-022, #581-002, #581-007)
*Twenty one, 24in. test leads (10 red, 10 black, 1 green)
*Twenty two, 60in. test leads (10 red, 10 black, 2 green)
*1/4in. Diameter instrument connection tubing, of two colors (200')
*Fifteen, quick-disconnect nipples
*Ten, tubing tees
*Ten, tubing couplers
*Test Lead Holder (14 Slot)
*Use/Exercise Guide
208-230 Vac, 3 Phase, 5 Wire, 50/60 Hz, water source, instrument air source
Other voltages available, contact factory
The courseware, useful in both a instructor-led and or a self-directed format, includes one of several optional textbooks, a course guide and hands-on exercises.

Exercises include:
• Introduction to the Process Trainer, Advanced  • Review of process instrumentation terms, abbreviations and designations. •  Investigating thermocouple operating characteristics. •  Temperature measurements using a thermocouple in a process. •  Investigating RTD operating characteristics. •  Temperature measurement using an RTD in a process. •  Calibration of a pressure gauge. •  Setting and adjusting pressure switches. •  Calibration of a pressure transmitter. •  Level measurement using a bubbler. •  Installation and calibration of a level measurement channel. •  Level measurement with zero suppression. •  Level measurement with a wet reference leg. •  Flow vs. Differential pressure for an orifice plate. •  Calibration of a flow transmitter. •  Calibration of a square root extractor. •  Installation and calibration of an electronic flow measurement channel. •  Review of process control theory, terms, abbreviations and designations. •  Introduction to the Honeywell UDC 3300 universal digital controller. •  Introduction to the Foxboro 762 digital controller. •  Determining a temperature process' operating characteristics. •  Determining a pressure process' operation characteristics. •  Determining a level process' operating characteristics. •  Determining a flow process' operating characteristics. •  Open loop integral controller characteristics. •  Closed loop integral control in a temperature process. •  Closed loop integral control in a pressure process. •  Closed loop integral control in a level process. •  Closed loop integral control in a flow process. •  Open loop proportional controller characteristics. •  Closed loop proportional control in a temperature process. •  Closed loop proportional control in a pressure process. •  Closed loop proportional control in a level process. •  Closed loop proportional control in a flow process. •  Open loop proportional plus integral controller characteristics. •  Closed loop proportional plus integral control in a temperature process. •  Closed loop proportional plus integral control in a pressure process. •  Closed loop proportional plus integral control in a level process. •  Closed loop proportional plus integral control in a flow process. •  Open loop proportional plus integral plus derivative controller characteristics. •  Closed loop proportional plus integral plus derivative control in a temperature process. •  Closed loop proportional plus integral plus derivative control in a pressure process. •  Closed loop proportional plus integral plus derivative control in a level process. •  Closed loop proportional plus integral plus derivative control in a flow process. •  Notch tuning of a pressure process. •  Notch tuning of a level process. •  Notch tuning of a flow process.& •  Ultimate tuning of a pressure process.& •  Ultimate tuning of a level process. •  Ultimate tuning of a flow process. •  Open loop tuning of a temperature process. •  Open loop tuning of a pressure process. Open loop tuning of a level process. •  Open loop tuning of a flow process. •  Cascade control of a temperature process. •  Cascade control of a level process. • 


In accordance with DAC’s established policy of continuous improvement, these specifications and product descriptions are subject to change without notice. This information is the latest technical information as of the time of viewing or printing.