601D - Process Control Trainer, Downsized

Product Dimensions
(L x W x H) 81" x 22" . x 44" (2050 x 550 x 1110 mm)
350lbs. (159kg)

Shipping Dimensions
(L x W x H) 88" x 42" x 58" (2240 x 1070 x 1480 mm)
720lbs. (327kg)

A working, large scale, yet economical, fluid process system allowing for hands-on training relating to the measurement and control of process variables including level, pressure and flow. The device allows for the creation of simple 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. Variable supply disturbances can be inserted using solenoid valves in combination with metered ball valves. The device includes the capability of establishing several control schemes.

Primary instruments and controls are mounted on an independent, tethered, 19in., control rack. Additional or alternate instruments can be easily added using the rack or supplemental instrument racks.

Designed as a basic process trainer, the device through its construction features and modular pipe spool arrangement, can easily be modified to allow for experiments relating to the flow of fluids through fittings or a pipe network using manufacturer-supplied or user-supplied components.

Standard Instruments:
•  One, differential pressure transmitter. (Honeywell, Model ST3000, Series 900).
•  One, I/P converter (Control Air, Model IP-500-APC).
•  One, industrial PID controller, 1/4 DIN, expanded (Honeywell, Model UDC 3500).
•  Two, orifice plates.
•  One, 3-Valve manifold.
7-Gauge, formed-steel baseplate.
Four, 4" diameter casters, with locks.
Welded and assembled modular framework using 1-1/2" square, 14-gauge steel tubing.
Laminate-covered front panel face.
Independent 19" x 26-1/4" high instrument mounting rack and control assembly, with silk-screened and powder coated panels.
Transparent, schedule 80, PVC piping and fittings throughout.
Provision for interchangeable, horizontal pipe spools for experiments related to flow of liquids through pipe fittings, piping networks, and using optional flow instruments.
Modular pipe spools with unions, allowing for installation of orifice plate/flange assembly, optional pitot tube or alternate, optional, flow instruments.
Clear acrylic closed tank, 6 gallon capacity, with valved drain and metered secondary outlet.
Baseplate-mounted, pressure switch, allowing on/off control at tank.
Two, tank-mounted level switches, with associated banana-jack connections.
Two, t-slotted device mounting pads on baseplate.
Transmitter mounting stanchion (re-positionable).
Primary reservoir, 14 gallon capacity, polyethylene.
Centrifugal pump, 1/2HP jet pump.
Solenoid valves, allowing for the creation of flow supply disturbances at bypass surrounding the control valve and at secondary metered tank drain.
Control assembly power panel including power switch, pilot light, instructor key switch, switches and pilot lights for: pump, solenoid valves, (both with control relay connections), 24 VDC power supply terminals, GFI device, and conversion resistor bank.
24 VDC industrial power supply, 1.2 A.
Control/instrument panel, including industrial PID controller and provision for optional strip chart recorder and ACdrive controller.
Base-mounted air supply panel including master 0-60 psi. gauge and regulator, and secondary 0-30 psi. instrument air gauge, regulator and filter.
Quick-disconnect fittings located throughout, allowing for attachment of instruments.
Variable-area flow meter.
Two orifice plates and associated flanges, with tubing connections.
Industrial-quality, diaphragm-operated control valve.
Powder coated surfaces throughout.
Packaging for shipment via motor freight.
#080-467-2 - Video on pressure measurement (ISA).
#080-467-3 - Video on level measurement (ISA).
#080-467-4 - Video on flow measurement (ISA).
#464-003 - Basic DC/AC/Analog Allen-Bradley SLC-500 PLC 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). - Analog Combination card (2 inputs, 2 outputs). - Power supply, 5A.
#464-009 - On-line/Off-line Programming Software w/Comp. Interface
#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.
#600-006A - Standard Test and Calibration Equipment Package, Hand-held, Economy
#600-008B - Storage/Lockbox Accessory
#600-010 - Optional AC variable speed drive module (for varying pump speed for control).
#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.
#600-024 - Orifice plate set, 3-piece (Supplemental)
#600-025 - Vortex-type flow meter.
#600-031 - Pitot tube flow assembly.
#600-032 - Venturi tube flow assembly.
#600-033 - Coriolis effect flow meter, Hart (Emerson, MicroMotion)
#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).
#600-036 - Magnetic flow measurement assembly/transmitter (Rosemount).
#600-036A - Magnetic Flow Meter Assembly, Economy (4-20 mA Output)
#600-040 - Valve Positioner, Pneumatic
#600-041 - Control valve positioner, electro-pneumatic.
#600-041F - Valve Positioner, Digital, FIELDVIEW
#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
#600-053 - Square root extractor, panel mounted (requires #940F or #600-005).
#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).
#600-060 - Industrial PID controller w/panel (Honeywell UDC-3500,1/4 DIN).
#600-102 - Function generator, (optional test instrument).
#600-102E - Function Generator, Economy
#600-104 - Differential pressure gauge, low range (0-200in. H2O) (Dwyer).
#600-106 - U-tube manometer (-36in. - 0 - 36in. range).
#600-121 - Supply pressure regulator, upgrade, w/filter, oiler.
#600-130 - Pressure Gauge, Pipe-Mounted (0-30 psig)
#600-201 - Smart field communicator (for Honeywell ST 3000 Transmitters).
#600-205 - Digital multimeter/process calibrator (alternate calibration instrument).
#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-D07 - PLC control interface panel w/frame.
#600-D65 - Bubbler (dip tube) assembly.
#600-D80 - Pipe spool assortment (supplemental).
#600-D96 - Support frame/caster assembly (30in. height).
#601-003 - Standard Instrument and Control Package (level)
#601-D10 - AC-drive/3-phase motor option.
#601-D33 - Coriolis Effect Flow Assembly/Transmitter
#601D-PAC - PROCESS CONTROL TRAINER, DOWNSIZED, Quick-Start Package (includes: #601D, #600-006A, #601-D10, #600-022, #600-051, #600-D96)
•  One test lead holder.
•  Eight, 36in. test leads.
•  Twenty-one, 60in. test leads.
•  1/4in. diameter instrument connection tubing, of two colors (160').
•  Twelve, quick-disconnect nipples.
•  Six, tubing tees.
•  Six, tubing unions.
•  Tubing cutter.
•  Use/Exercise Guide
•  110/230 VAC, 50/60 Hz, water source, instrument air source.
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, Downsized   •  Review of process instrumentation terms, abbreviations and designations.   •  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 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 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 control in a pressure process.   •  Closed loop control in a level process.   •  Closed loop control in a flow process.   •  Open loop proportional plus integral controller characteristics.   •  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 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 pressure process.   •  Open loop tuning of a level process.   •  Open loop tuning of a flow 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.