601 - Process Control Trainer, Basic

Product Dimensions
Product Dimensions: (L x W x H)
33.5in. x 48in. x 76in (860 x 1220 x 1930 mm)
375lbs. (170kg)

Shipping Dimensions
715lbs. (320kg)

A working, large scale, 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 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. Variable demand and supply disturbances can be inserted using solenoid valves in combination with metered ball valves.

The device includes the capability of establishing cascade, feedforward, 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. Quick-disconnects are provided allowing the training aid to be connected to other similar units or a temperature process trainer, facilitating more complex process systems.

The trainer can be configured to create one complex process loop, accommodating two students, which addresses pressure, level, and flow. Alternately, the device can be outfitted to address each of these three variables individually. Standard, user-supplied, or user-specified instruments of any brand can be easily installed, either on a mounting stanchion or on a built-in, 19in. instrument rack.
Four, 4" diameter casters, two with locks.
Integral, 19" x 70" high, instrument mounting rack, with silk-screened instrument and controller panels.
Rack-mounted, locking storage box for accessories.
Front panel faces fabricated from marine-grade 1/2" plywood and covered with a .040" thick, high-durability, surface treatment.
Clear, 1/2" diameter, PVC piping components throughout.
Clear acrylic tank, 3 gallon capacity.
Primary reservoir, 20 gallon capacity.
Centrifugal pump, 1/2 HP.
Circuit breaker with GFI circuit protection.
Two solenoid valves, allowing for the creation of flow supply and demand disturbances both at the tank outlet and in a bypass surrounding the control valve.
Power distribution panel, mounted in instrument rack including on/off power switch, GFI receptacle, fuses for all circuits, and 12 electric "free line" connections to the front panel.
Front panel-mounted, operator control panel, including switches and pilot lights for: a pump, and two solenoid valves, as well as control relay connections for equipment, 24 VDC power supply terminals
Master instrument air supply regulator.
24 VDC Power supply.
Five, process quick-disconnect hose fittings allowing for connection to other process trainers, and pump down.
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, pneumatic control valve.
Pipe stanchion, allowing for attachment of differential pressure transmitters and pressure transmitters at varying heights.
High-durability, powder coated surfaces throughout.
Provision for attachment to the Instrumentation and Calibration Bench.
Provision for integration with temperature trainer.
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.
#600-008B - 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.
#600-023 - Capacitance-type level detector/transmitter.
#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)
#600-033F - 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
#600-055 - 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).
#600-097 - Descrete/Analog Allen-Bradley SLC-500 PLC Package (2 analog channels)
#600-098 - Descrete/Analog Allen-Bradley SLC-500 PLC Package (4 analog channels)
#600-101 - Deadweight tester, (optional test instrument).
#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)
#600-132 - Supplementary Gauge and Meter Panel
#600-201 - Smart field communicator (for Honeywell ST 3000 Transmitters).
#600-205 - Digital multimeter/process calibrator (alternate calibration instrument).
#600-310 - Chart recorder supply pack, 12/pens/20 rolls, supplemental.
#600-501 - Textbook series, 4-part, on process measurement and control (General Physics).
#601-001EH - Standard Instrument and Control Package (3-Variable) (Endress & Hauser Preference).
#601-001F - Standard Instrument and Control Package (3-Variable) (Foxboro Preference).
#601-001H - Standard Instrument and Control Package (3-Variable) (Honeywell Preference).
#601-001R - Standard Instrument and Control Package (3-Variable) (Rosemount Preference).
#601-002 - Standard Instrument and Control Package (flow)
#601-003 - Standard Instrument and Control Package (level)
#601-004 - Standard Instrument and Control Package (pressure)
#601-012 - Heat Exchanger Assembly
#601-500 - Use/Exercise Guide (additional).
#601-PAC - PROCESS CONTROL TRAINER, BASIC, Quick-Start Package (includes: #601, #601EH, #600-006A, #600-007, #600-010, #600-022)
* Twenty, 36in. Test leads. * Twenty, 60in. Test leads. * 150', 1/4in. Diameter instrument connection tubing, of two colors. * Fifteen, quick-disconnect nipples. * Ten, tubing tees. * Ten, tubing couplers. * 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, Basic * 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.