Applications for Process Control

Product Overview

The Applications for Process Control, allows the student to design, assemble and configure various control systems, apart from studying the fundamentals of the control engineering on which they are based.

Technical Specifications

ATENG 12656 � Applications for Process Control

FLOW

APC-FC. Computer Controlled Flow Regulation Application.

In the �APC-FC� application, a variable speed pump impels the water flow from a supply tank to a proportional valve and two flow sensors.

The control of the system is done through the �APC-FC-KAC� software.

• The elements included in the �APC-FC� application are:
• SU-H/S. Small Size Hydraulic Supply Unit.

Module designed to pump water to the other devices of the application. The variable speed pump included can be used as actuator

of the system.

• The elements included in the �SU-H/S� module are:
• Variable speed pump: 8 l/min approx.
• Plastic tank: 4 l approx.

Manual valve.

• N-ALI20. Power Supply Module for Control Circuits Module.
• Supply voltage (single-phase): 230 VAC, L+N+G.

Removable ON/OFF key switch.

• N-M-F-T/S. Turbine Type Sensor for Low Flow Rates.
• Maximum flow rate: 3 l/min approx.
• N-P-F-WR/S. Rotameter for Low Flow Hydraulic Circuit.
• Maximum flow rate: 4 l/min approx.
• APC-FC-KAC. Acquisition Kit and Control Software for APC-FC.
• The elements included in the �APC-FC-KAC� kit are:

USB Acquisition Card.

Data Acquisition and Control Software.

• The main functions of this software, based on LabVIEW, are:

? Process signal visualization.

? Data management and data storage.

? ON/OFF and PID controls via software.

? Tuning of the controller parameters.

• N-V-PR-W/S. Electromagnetic Proportional Valve for Low Flow Hydraulic Circuits.

Proportional valve that can be used to introduce disturbances in the system or as control device.

For the �APC-FC� application, there is available the optional �APC-FC-SIM�, Simulation Software for �APC-FC�. The �APC-FC-SIM�

• software is design to simulate the complete process of the application: the plant, the sensor and the controller. In order to simulate the

complete close control loop to adjust the controller in the software to understand the real process of the unit.

• APC-FC-SIM. Simulation Software for APC-FC.
• The main functions of this software, based on LabVIEW, are:

? Process simulation.

? Open loop system simulation.

? Close loop system simulation.

? PID controller simulation.

? PID controller tuning of the close loop system simulation.

The elements recommended to extend the functionality of the �APC-FC� application are indicated in the table of available modules found

at the end of the document. In addition to the modules related to the flow control, it is possible to add modules related to other variables

to obtain multivariable control systems.

• Some practical possibilities of the �APC-FC� application:
• Design and assembly of the control system:
• Familiarization with the main components of a control system: sensor, actuator and controller.
• Preparation of the piping and instrumentation diagram (P&ID) of a flow control system.
• Preparation of connection, circuits, wiring and terminals diagrams of a flow control system.
• Assembly of the hydraulic circuit of a flow control system.
• Wiring of the control and measurement signals and the power supply of a flow control system.
• Analysis of the system and design of control strategies:
• Response of a flow control system to a step input.
• Simulation of a flow control system in open and closed loop (with optional �APC-FC-SIM�, Simulation Software for APC-FC).
• Effect of the parameters of a PID controller.
• PID control of a flow control system with the variable speed pump.
• PID control of a flow control system with the proportional valve.
• Response of the controlled system to disturbances and changes of the reference signal.
• Disturbance compensation through feedforward control.

3

AVAILABLE APPLICATIONS

FLOW

APC-FIC. Flow Regulation Application with Industrial Controller.

In the �APC-FIC� application, a pump impels water through a hydraulic circuit consisting of a supply tank, a rotameter and a motorized

valve. The control of the system is done through an industrial controller. In addition, a ball valve with scale is included to introduce

disturbances.

• The elements included in the �APC-FIC� application are:
• SU-H. Hydraulic Supply Unit.

Module designed to pump water to the other devices of the application. It is recommended for simple control applications, with only

one variable.

• The elements included in the �SU-H� module are:
• Centrifugal pump: 80 l/min approx.
• Stainless steel tank: 15 l approx.

Manual valve.

• N-ALI20. Power Supply Module for Control Circuits Module.
• Supply voltage (single-phase): 230 VAC, L+N+G.

Removable ON/OFF key switch.

• N-M-F-P. Paddlewheel Flow Sensor.
• Maximum flow rate: 50 l/min approx.
• N-V-MO. Motorized Control Valve.
• N-P-F-WR. Hydraulic Circuit Rotameter.
• The elements included in the �N-P-F-WR� module are:
• Rotameter: 50 l/min.

Regulation valve.

• N-IC. Industrial Controller.

USB Communication.

• Display: full-color LCD 9 cm (3.5 inches) with built-in backlight.

Configurable sample rate chart (1 second to 5 minutes).

• Control parameters:
• Control type:

? ON/OFF control.

? P, PI, PID control.

? P, PI, PID control with gain scheduling (up to 3 set of PID parameters).

? Predictive control (dead-time compensation).

? Adaptive control.

? P, PI and PID control with feedforward.

? Cascade control.

? Cascade control with feedforward.

? Ratio controller.

? Ratio station.

• Control output type:

? Analog output.

? Time proportioning output.

? ON/OFF output.

? Motorized valve with feedback.

? Motorized valve without feedback.

? Split output with combinations of relay, digital output and current outputs.

• Autotune function:
• ? On - demand calculation of control settings.
• Set points:

? Configurable through the front panel or the computer.

? Up to four local set points, all selectable via digital inputs or front panel.

8 Blocks math functions.

8 Blocks of logic functions.

2 Blocks of totalizer functions.

8 Blocks process alarms.

• 4 Analog inputs with 125 ms of sample rate.
• 2 Analog outputs.

4 Relays.

6 Digital I/O.

4

AVAILABLE APPLICATIONS

FLOW

• IC-KSS-SOF. Acquisition, Control and Controllers Configuration Software.
• The main functions of this software, based on LabVIEW, are:
• The following process variables can be visualize and managed via software:

? Set point (SP) of the first and second control loop, output process (O/P) of the first and second control loop, process

variable (PV) of the first and second control loop.

Data visualization, data management and data storage of all process variables involved in the control loops.

• The following process parameters can be adjustable via software:

? ON/OFF controller parameters, PID controller parameters of the one control loop or two control loops, set point values

bias and slope ratio and Feedforward gain.

Besides, if other applications with industrial controllers are connected, the �IC-KSS-SOF� software can supervise all applications

connected, forming a distributed control system.

• N-V-H-S. Ball Valve with Scale.

Metering ball valve.

Scale from 90� (closed) to 0� (open).

The elements recommended to extend the functionality of the �APC-FIC� application are indicated in the table of available modules found

at the end of the document. In addition to the modules related to the flow control, it is possible to add modules related to other variables

to obtain multivariable control systems.

• Some practical possibilities of the �APC-FIC� application:
• Design and assembly of the control system:
• Familiarization with the main components of a control system: sensor, actuator and controller.
• Preparation of the piping and instrumentation diagram (P&ID) of a flow control system.
• Preparation of circuits, wiring, terminals and connection diagrams of a flow control system.
• Assembly of the hydraulic circuit of a flow control system.
• Wiring of the control and measurement signals and the power supply of a flow control system.
• Configuration of the system devices:
• Configuration of an industrial controller.
• Analysis of the system and design of control strategies:
• Manual control of the system with an industrial controller (open loop).
• Effect of the parameters of a PID controller.
• Obtaining the PID parameters automatically by auto-tuning.
• Adjustment and optimization of a PID controller.
• Response of the controlled system to disturbances and changes of the reference signal.

5

AVAILABLE APPLICATIONS

LEVEL

APC-LC. Computer Controlled Level Regulation Application.

In the �APC-LC� application, a variable speed pump impels water from a supply tank to an upper tank (process tank) where the level is

measured. The application includes a control valve, which can be configured in different points of the hydraulic circuit to regulate the

system or introduce disturbance. The control of the system is done through the �APC-LC-KAC� software.

• The elements included in the �APC-LC� application are:
• SU-H/S. Small Size Hydraulic Supply Unit.

Module designed to pump water to the other devices of the application. The variable speed pump included can be used as actuator

of the system.

• The elements included in the �SU-H/S� module are:
• Variable speed pump: 8 l/min approx.
• Plastic tank: 4 l approx.

Manual valve.

• N-ALI20. Power Supply Module for Control Circuits Module.
• Supply voltage (single-phase): 230 VAC, L+N+G.

Removable ON/OFF key switch.

• N-M-P-W/S. Pressure Sensor for Low Water Levels.
• Maximum pressure: 30 mbar approx.
• N-P-L-TT/S. Small Size Transparent Tank.

Transparent tank with graduated scale.

• Maximum level: 250 mm approx.
• APC-LC-KAC. Acquisition Kit and Control Software for APC-LC.
• The elements included in the �APC-LC-KAC� kit are:

USB Acquisition Card.

Data Acquisition and Control Software.

• The main functions of this software, based on LabVIEW, are:

? Process signal visualization.

? Data management and data storage.

? ON/OFF and PID controls via software.

? Tuning of the controller parameters.

• N-V-PR-W/S. Electromagnetic Proportional Valve for Low Flow Hydraulic Circuits.

Proportional valve that can be used to introduce disturbances in the system or as control device.

For the �APC-LC� application, there is available the optional �APC-LC-SIM�, Simulation Software for �APC-LC�. The �APC-LC-SIM�

• software is design to simulate the complete process of the application: the plant, the sensor and the controller. In order to simulate the

complete close control loop to adjust the controller in the software to understand the real process of the unit.

• APC-LC-SIM. Simulation Software for APC-LC.
• The main functions of this software, based on LabVIEW, are:

? Process simulation.

? Open loop system simulation.

? Close loop system simulation.

? PID controller simulation.

? PID controller tuning of the close loop system simulation.

The elements recommended to extend the functionality of the �APC-LC� application are indicated in the table of available modules found

at the end of the document. In addition to the modules related to the level control, it is possible to add modules related to other variables

to obtain multivariable control systems.

• Some practical possibilities of the �APC-LC� application:
• Design and assembly of the control system:
• Familiarization with the main components of a control system: sensor, actuator and controller.
• Preparation of the piping and instrumentation diagram (P&ID) of a level control system.
• Preparation of circuits, wiring, terminals and connection diagrams of a level control system.
• Assembly of the hydraulic circuit of a level control system.
• Wiring of the control and measurement signals and the power supply of a level control system.
• Analysis of the system and design of control strategies:
• Response of a level control system to a step input.
• Simulation of a level control system in open and closed loop (with optional �APC-LC-SIM�, Simulation Software for APC-LC).
• Effect of the parameters of a PID controller.
• PID control of a level control system with the variable speed pump.
• PID control of a level control system with the proportional valve.
• Response of the controlled system to disturbances and changes of the reference signal.
• Disturbance compensation through feedforward control.

6

AVAILABLE APPLICATIONS

LEVEL

APC-LPRIC. Level Regulation Application with Industrial Controller and Proportional Valve.

In the �APC-LPRIC� application, a pump impels water through a hydraulic circuit consisting of a supply tank, a transparent tank with scale

and a proportional valve. The control of the system is done through an industrial controller. In addition, a ball valve with scale is included

to introduce disturbances.

• The elements included in the �APC-LPRIC� application are:
• SU-H. Hydraulic Supply Unit.

Module designed to pump water to the other devices of the application. It is recommended for simple control applications, with only

one variable.

• The elements included in the �SU-H� module are:
• Centrifugal pump: 80 l/min approx.
• Stainless steel tank: 15 l approx.

Manual valve.

• N-ALI20. Power Supply Module for Control Circuits Module.
• Supply voltage (single-phase): 230 VAC, L+N+G.

Removable ON/OFF key switch.

• N-M-P-W. Level Measurement Pressure Sensor.
• Maximum pressure: 100 mbar approx.
• N-V-PR-W. Electromagnetic Proportional Valve for Hydraulic Circuits.
• N-P-L-TT. Transparent Tank.

Transparent tank with graduated scale.

• Maximum level: 600 mm approx.
• N-IC. Industrial Controller.

USB Communication.

• Display: full-color LCD 9 cm (3.5 inches) with built-in backlight.

Configurable sample rate chart (1 second to 5 minutes).

• Control parameters:
• Control type:

? ON/OFF control.

? P, PI, PID control.

? P, PI, PID control with gain scheduling (up to 3 set of PID parameters).

? Predictive control (dead-time compensation).

? Adaptive control.

? P, PI and PID with feedforward.

? Cascade control.

? Cascade control with feedforward.

? Ratio controller.

? Ratio station.

• Control output type:

? Analog output.

? Time proportioning output.

? ON/OFF output.

? Motorized valve with feedback.

? Motorized valve without feedback.

? Split output with combinations of relay, digital output and current outputs.

• Autotune function:
• ? On - demand calculation of control settings.
• Set points:

? Configurable through the front panel or the computer.

? Up to four local set points, all selectable via digital inputs or front panel.

8 Blocks math functions.

8 Blocks of logic functions.

2 Blocks of totalizer functions.

8 Blocks process alarms.

• 4 Analog inputs with 125 ms of sample rate.
• 2 Analog outputs.

4 Relays.

6 Digital I/O.

7

AVAILABLE APPLICATIONS

LEVEL

• IC-KSS-SOF. Acquisition, Control and Controllers Configuration Software.
• The main functions of this software, based on LabVIEW, are:
• The following process variables can be visualize and managed via software:

? Set point (SP) of the first and second control loop, output process (O/P) of the first and second control loop, process

variable (PV) of the first and second control loop.

Data visualization, data management and data storage of all process variables involved in the control loops.

• The following process parameters can be adjustable via software:

? ON/OFF controller parameters, PID controller parameters of the one control loop or two control loops, set point values

bias and slope ratio and Feedforward gain.

Besides, if other applications with industrial controllers are connected, the �IC-KSS-SOF� software can supervise all applications

connected, forming a distributed control system.

• N-V-H-S. Ball valve with Scale.

Metering ball valve.

Scale from 90� (closed) to 0� (open).

The elements recommended to extend the functionality of the �APC-LPRIC� application are indicated in the table of available modules

found at the end of the document. In addition to the modules related to the level control, it is possible to add modules related to other

variables to obtain multivariable control systems.

• Some practical possibilities of the �APC-LPRIC� application:
• Design and assembly of the control system:
• Familiarization with the main components of a control system: sensor, actuator and controller.
• Preparation of the piping and instrumentation diagram (P&ID) of a level control system.
• Preparation of circuits, wiring, terminals and connection diagrams of a level control system.
• Assembly of the hydraulic circuit of a level control system.
• Wiring of the control and measurement signals and the power supply of a level control system.
• Configuration of the system devices:
• Configuration of an industrial controller.
• Analysis of the system and design of control strategies:
• Manual control of the system with an industrial controller (open loop).
• Effect of the parameters of a PID controller.
• Obtaining the PID parameters automatically by auto-tuning.
• Adjustment and optimization of a PID controller.
• Response of the controlled system to disturbances and changes of the reference signal.

8

AVAILABLE APPLICATIONS

LEVEL

APC-LPNIC. Level Regulation Application with Industrial Controller and Pneumatic Valve.

In the �APC-LPNIC� application, a pump impels water through a hydraulic circuit consisting of a supply tank, a transparent tank with scale

and a pneumatic valve. The control of the system is done through an industrial controller. In addition, a ball valve with scale is included to

introduce disturbances and a signal recorder.

• The elements included in the �APC-LPNIC� application are:
• SU-H. Hydraulic Supply Unit.

Module designed to pump water to the other devices of the application. It is recommended for simple control applications, with only

one variable.

• The elements included in the �SU-H� module are:
• Centrifugal pump: 80 l/min approx.
• Stainless steel tank: 15 l approx.

Manual valve.

• N-ALI20. Power Supply Module for Control Circuits Module.
• Supply voltage (single-phase): 230 VAC, L+N+G.

Removable ON/OFF key switch.

• N-M-P-W. Level Measurement Pressure Sensor.
• Maximum pressure: 100 mbar approx.
• N-V-PN-W. Pneumatic Control Valve for Hydraulic Circuits.
• Pneumatic control valve:

Normally closed valve.

Linear plug.

Electro-pneumatic linear positioner.

• Control signals: 3 - 15 psi.
• Actuator: diaphragm type.

DN 20.

• Flow:
• ? Cv: 6.6 (referenced to USGPM and psi units).
• ? Kv: 5.7 (referenced to m3/h and bar units).
• Pressurized air inlet required: 2.5 bar.
• 2 Manometers:
• Pressure range: 0 - 10 bar.

Manual ball valve.

• N-ATC01: Air Filter and Pressure Regulator with Manometer Module.
• Air pressure inlet admitted range: 0 - 12 bar.
• Output pressure: 2.5 bar.
• Drain capacity: 12 cm3.
• N-P-L-TT. Transparent Tank.

Transparent tank with graduated scale.

• Maximum level: 600 mm approx.
• N-IC. Industrial Controller.

USB Communication.

• Display: full-color LCD 9 cm (3.5 inches) with built-in backlight.

Configurable sample rate chart (1 second to 5 minutes).

• Control parameters:
• Control type:

? ON/OFF control.

? P, PI, PID control.

? P, PI, PID control with gain scheduling (up to 3 set of PID parameters).

? Predictive control (dead-time compensation).

? Adaptive control.

? P, PI and PID control with feedforward.

? Cascade control.

? Cascade control with feedforward.

? Ratio controller.

? Ratio station.

9

AVAILABLE APPLICATIONS

LEVEL

• Control output type:

? Analog output.

? Time proportioning output.

? ON/OFF output.

? Motorized valve with feedback.

? Motorized valve without feedback.

? Split output with combinations of relay, digital output and current outputs.

• Autotune function:
• ? On - demand calculation of control settings.
• Set points:

? Configurable through the front panel or the computer.

? Up to four local set points, all selectable via digital inputs or front panel.

8 Blocks math functions.

8 Blocks of logic functions.

2 Blocks of totalizer functions.

8 Blocks process alarms.

• 4 Analog inputs with 125 ms of sample rate.
• 2 Analog outputs.

4 Relays.

6 Digital I/O.

• IC-KSS-SOF. Acquisition, Control and Controllers Configuration Software.
• The main functions of this software, based on LabVIEW, are:
• The following process variables can be visualize and managed via software:

? Set point (SP) of the first and second control loop, output process (O/P) of the first and second control loop, process

variable (PV) of the first and second control loop.

Data visualization, data management and data storage of all process variables involved in the control loops.

• The following process parameters can be adjustable via software:

? ON/OFF controller parameters, PID controller parameters of the one control loop or two control loops, set point values

bias and slope ratio and Feedforward gain.

Besides, if other applications with industrial controllers are connected, the �IC-KSS-SOF� software can supervise all applications

connected, forming a distributed control system.

• N-V-H-S. Ball Valve with Scale.

Metering ball valve.

Scale from 90� (closed) to 0� (open).

• This application needs compressed air. The following accessory is recommended:
• SU-P. Large Pneumatic Supply Unit.

Module designed to supply compressed air to the rest of devices of the application.

• The elements included in the �SU-P� module are:
• Air compressor: 8 bar approx.

The elements recommended to extend the functionality of the �APC-LPNIC� application are indicated in the table of available modules

found at the end of the document. In addition to the modules related to the level control, it is possible to add modules related to other

variables to obtain multivariable control systems.

• Some practical possibilities of the �APC-LPNIC� application:
• Design and assembly of the control system:
• Familiarization with the main components of a control system: sensor, actuator and controller.
• Preparation of the piping and instrumentation diagram (P&ID) of a level control system.
• Preparation of circuits, wiring, terminals and connection diagrams of a level control system.
• Assembly of the hydraulic circuit of a level control system.
• Wiring of the control and measurement signals and the power supply of a level control system.
• Configuration of the system devices:
• Configuration of an industrial controller.
• Configuration of a signal recorder.
• Analysis of the system and design of control strategies:
• Manual control of the system with an industrial controller (open loop).
• Effect of the parameters of a PID controller.
• Obtaining the PID parameters automatically by auto-tuning.
• Adjustment and optimization of a PID controller.
• Response of the controlled system to disturbances and changes of the reference signal.

10

AVAILABLE APPLICATIONS

PRESSURE

APC-PHYC. Computer Controlled Pressure Regulation Application in a Hydraulic Circuit.

In the �APC-PHYC� application, a variable speed pump impels water from a supply tank to a pressurized upper tank where the pressure is

measured. The outlet of the process tank has a solenoid valve to regulate the system or introduce disturbances. The control of the system

is done through the �APC-PHYC-KAC� software.

• The elements included in the �APC-PHYC� application are:
• SU-H/S. Small Size Hydraulic Supply Unit.

Module designed to pump water to the other devices of the application. The variable speed pump included can be used as actuator

of the system.

• The elements included in the �SU-H/S� module are:
• Variable speed pump: 8 l/min approx.
• Plastic tank: 4 l approx.

Manual valve.

• N-ALI20. Power Supply Module for Control Circuits Module.
• Supply voltage (single-phase): 230 VAC, L+N+G.

Removable ON/OFF key switch.

• N-M-P-A/S. Compressed Air Low Pressure Sensor.
• Maximum pressure: 1 bar approx.
• N-P-L-PT/S. Small Size Pressurized Transparent Tank.

Pressurized transparent tank with graduated scale for level and pressure applications.

• Maximum level: 250 mm approx.
• APC-PHYC-KAC. Acquisition Kit and Control Software for APC-PHYC.
• The elements included in the �APC-PHYC-KAC� kit are:

USB Acquisition Card.

Data Acquisition and Control Software.

• The main functions of this software, based on LabVIEW, are:

? Process signal visualization.

? Data management and data storage.

? ON/OFF and PID controls via software.

? Tuning of the controller parameters.

• N-V-SO/S. Solenoid Valve for Low Flow Rates.

Solenoid valve that can be used to introduce disturbances in the system or as control device.

For the �APC-PHYC� application, there is available the optional �APC-PHYC-SIM�, Simulation Software for APC-PHYC. The �APC-PHYC

• SIM� software is design to simulate the complete process of the application: the plant, the sensor and the controller. In order to simulate

the complete close control loop to adjust the controller in the software to understand the real process of the unit.

• APC-PHYC-SIM. Simulation Software for APC-PHYC.
• The main functions of this software, based on LabVIEW, are:

? Process simulation.

? Open loop system simulation.

? Close loop system simulation.

? PID controller simulation.

? PID controller tuning of the close loop system simulation.

The elements recommended to extend the functionality of the �APC-PHYC� application are indicated in the table of available modules

found at the end of the document. In addition to the modules related to the pressure control, it is possible to add modules related to other

variables to obtain multivariable control systems.

• Some practical possibilities of the �APC-PHYC� application:
• Design and assembly of the control system:
• Familiarization with the main components of a control system: sensor, actuator and controller.
• Preparation of the piping and instrumentation diagram (P&ID) of a pressure control system.
• Preparation of circuits, wiring, terminals and connection diagrams of a pressure control system.
• Assembly of the hydraulic circuit of a pressure control system.
• Wiring of the control and measurement signals and the power supply of a pressure control system.
• Analysis of the system and design of control strategies:
• Response of a pressure control system to a step input.
• Simulation of a flow control system in open and closed loop (with optional �APC-PHYC-SIM�, Simulation Software for APC-PHYC).
• Effect of the parameters of a PID controller.
• ON/OFF control of a pressure control system with the solenoid valve.
• PID control of a pressure control system with the variable speed pump.
• Response of the controlled system to disturbances and changes of the reference signal.

11

AVAILABLE APPLICATIONS

PRESSURE

APC-PPNC. Computer Controlled Pressure Regulation Application in a Pneumatic Circuit.

In the �APC-PPNC� application, a variable speed gas pump fills a tank with compressed air. The outlet of the tank has a valve to introduce

disturbances. The control of the system is done through the �APC-PPNC-KAC� software.

• The elements included in the �APC-PPNC� application are:
• N-ALI20. Power Supply Module for Control Circuits Module.
• Supply voltage (single-phase): 230 VAC, L+N+G.

Removable ON/OFF key switch.

• N-SU-P/S. Small Size Pneumatic Supply Unit.

Module designed to pump air to the other devices of the application. The variable speed pump included can be used as actuator of

the system.

• The elements included in the �N-SU-P/S� module are:

Variable speed gas pump.

• ? Maximum flow: 3 l/min approx.

Manual valve.

• N-M-P-A/S. Compressed Air Low Pressure Sensor.
• Maximum pressure: 1 bar approx.
• N-P-P/S. Small Size Air Tank.
• The elements included in the �N-P-P/S� module are:
• Air tank: 400 ml approx.
• Manometer: 1 bar approx.

2 x relief valve.

• APC-PPNC-KAC. Acquisition Kit and Control Software for APC-PPNC.
• The elements included in the �APC-PPNC-KAC� kit are:

USB Acquisition Card.

Data Acquisition and Control Software.

• The main functions of this software, based on LabVIEW, are:

? Process signal visualization.

? Data management and data storage.

? ON/OFF and PID controls via software.

? Tuning of the controller parameters.

• N-V-SO/S. Solenoid Valve for Low Flow Rates.

Solenoid valve that can be used to introduce disturbances in the system or as control device.

For the �APC-PPNC� application, there is available the optional �APC-PPNC-SIM�, Simulation Software for APC-PPNC. The �APC-PPNC-SIM�

• software is design to simulate the complete process of the application: the plant, the sensor and the controller. In order to simulate the

complete close control loop to adjust the controller in the software to understand the real process of the unit.

• APC-PPNC-SIM. Simulation Software for APC-PPNC.
• The main functions of this software, based on LabVIEW, are:

? Process simulation.

? Open loop system simulation.

? Close loop system simulation.

? PID controller simulation.

? PID controller tuning of the close loop system simulation.

The elements recommended to extend the functionality of the �APC-PPNC� application are indicated in the table of available modules

found at the end of the document. In addition to the modules related to the pressure control, it is possible to add modules related to other

variables to obtain multivariable control systems.

• Some practical possibilities of the �APC-PPNC� application:
• Design and assembly of the control system:
• Familiarization with the main components of a control system: sensor, actuator and controller.
• Preparation of the piping and instrumentation diagram (P&ID) of a pressure control system.
• Preparation of circuits, wiring, terminals and connection diagrams of a pressure control system.
• Assembly of the pneumatic circuit of a pressure control system.
• Wiring of the control and measurement signals and the power supply of a pressure control system.
• Analysis of the system and design of control strategies:
• Response of a pressure control system to a step input.
• Simulation of a pressure control system in open and closed loop (with optional �APC-PPNC-SIM�, Simulation Software for APC

PPNC).

• Effect of the parameters of a PID controller.
• PID control of a pressure control system.
• Response of the controlled system to disturbances and changes of the reference signal.

12

AVAILABLE APPLICATIONS

PRESSURE

APC-PIC. Pressure Regulation Application with Industrial Controller.

In the �APC-PIC� application, the main compressed air circuit consists of a pneumatic valve and two tanks. The control of the system is

done through an industrial controller. In addition, a valve is included to introduce disturbances.

• The elements included in the �APC-PIC� application are:
• N-ALI20. Power Supply Module for Control Circuits Module.
• Supply voltage (single-phase): 230 VAC, L+N+G.

Removable ON/OFF key switch.

• N-M-P-A/L. Compressed Air Pressure Sensor for High Levels.
• Supply voltage: 24 VDC.
• Pressure range: 0 - 6 bar.
• Output voltage: 0 - 10 V.
• N-V-PN-A. Pneumatic Valve for Pneumatic Circuits.

Pneumatic regulation valve.

• 2 x N-ATC01: Air Filter and Pressure Regulator with Manometer Module.
• Air pressure inlet admitted range: 0 - 12 bar.
• Output pressure: 2.5 bar.
• Drain capacity: 12 cm3.
• 2 x N-P-P/L. Large Air Tank.
• The elements included in the �N-P-P/L� module are:
• Compressed air tank: 10 l approx.
• Manometer: 12 bar approx.

Needle valve.

• N-IC. Industrial Controller.

USB Communication.

• Display: full-color LCD 9 cm (3.5 inches) with built-in backlight.

Configurable sample rate chart (1 second to 5 minutes).

• Control parameters:
• Control type:

? ON/OFF control.

? P, PI, PID control.

? P, PI, PID control with gain scheduling (up to 3 set of PID parameters).

? Predictive control (dead-time compensation).

? Adaptive control.

? P, PI and PID control with feedforward.

? Cascade control.

? Cascade control with feedforward.

? Ratio controller.

? Ratio station.

• Control output type:

? Analog output.

? Time proportioning output.

? ON/OFF output.

? Motorized valve with feedback.

? Motorized valve without feedback.

? Split output with combinations of relay, digital output and current outputs.

• Autotune function:
• ? On - demand calculation of control settings.
• Set points:

? Configurable through the front panel or the computer.

? Up to four local set points, all selectable via digital inputs or front panel.

13

AVAILABLE APPLICATIONS

PRESSURE

8 Blocks math functions.

8 Blocks of logic functions.

2 Blocks of totalizer functions.

8 Blocks process alarms.

• 4 Analog inputs with 125 ms of sample rate.
• 2 Analog outputs.

4 Relays.

6 Digital I/O.

• IC-KSS-SOF. Acquisition, Control and Controllers Configuration Software.
• The main functions of this software, based on LabVIEW, are:
• The following process variables can be visualize and managed via software:

? Set point (SP) of the first and second control loop, output process (O/P) of the first and second control loop, process

variable (PV) of the first and second control loop.

Data visualization, data management and data storage of all process variables involved in the control loops.

• The following process parameters can be adjustable via software:

? ON/OFF controller parameters, PID controller parameters of the one control loop or two control loops, set point values

bias and slope ratio and Feedforward gain.

Besides, if other applications with industrial controllers are connected, the �IC-KSS-SOF� software can supervise all applications

connected, forming a distributed control system.

• This application needs compressed air. The following accessory is recommended:
• SU-P. Large Pneumatic Supply Unit.

Module designed to supply compressed air to the rest of devices of the application.

• The elements included in the �SU-P� module are:
• Air compressor: 8 bar approx.

The elements recommended to extend the functionality of the �APC-PIC� application are indicated in the table of available modules found

at the end of the document. In addition to the modules related to the pressure control, it is possible to add modules related to other

variables to obtain multivariable control systems.

• Some practical possibilities of the �APC-PIC� application:
• Design and assembly of the control system:
• Familiarization with the main components of a control system: sensor, actuator and controller.
• Preparation of the piping and instrumentation diagram (P&ID) of a pressure control system.
• Preparation of circuits, wiring, terminals and connection diagrams of a pressure control system.
• Assembly of the pneumatic circuit of a pressure control system.
• Wiring of the control and measurement signals and the power supply of a pressure control system.
• Configuration of the system devices:
• Configuration of an industrial controller.
• Analysis of the system and design of control strategies:
• Manual control of the system with an industrial controller (open loop).
• Effect of the parameters of a PID controller.
• Obtaining the PID parameters automatically by auto-tuning.
• Adjustment and optimization of a PID controller.
• Response of the controlled system to disturbances and changes of the reference signal.

14

AVAILABLE APPLICATIONS

TEMPERATURE

APC-TPRIC. Temperature Regulation Application with Industrial Controller and Proportional Valve.

The �APC-TPRIC� application consists of a hot water circuit, a cold water circuit and an exchanger that transfers the heat between both

circuits. In the hot water circuit, a pump impels the water from the supply tank to the exchanger, passing through a heating element and

a control valve. From the exchanger, the water returns to the supply tank, closing the circuit. Tap water is used as cold water source. Both

circuits include rotameters and valves to adjust the flow rate.

The modular design of the �APC-TPRIC� application makes it possible to measure and control the temperature in different points of the

system. Besides, a valve with scale introduces disturbances.

• The elements included in the �APC-TPRIC� application are:
• SU-H. Hydraulic Supply Unit.

Module designed to pump water to the other devices of the application. It is recommended for simple control applications, with only

one variable.

• The elements included in the �SU-H� module are:
• Centrifugal pump: 80 l/min approx.
• Stainless steel tank: 15 l approx.

Manual valve.

• N-ALI20. Power Supply Module for Control Circuits Module.
• Supply voltage (single-phase): 230 VAC, L+N+G.

Removable ON/OFF key switch.

• N-M-T-PT100. Pt100 Temperature Sensor.
• Range: -50 - 400 �C.
• N-H-2K. 2 kW Heating Module.
• Heating resistance:
• Supply voltage (single-phase): 220 VAC.
• Maximum power: 2 kW.

Safety temperature switch.

• Safety temperature sensor:
• Transducer type: thermocouple type �J�.
• Temperature range: -100 - 900 �C.
• Accuracy: � 1 �C.

Safety low level switch.

• Safety relief valve:
• Pressure setting: 3 bar.

Discharge line.

Additional manual opening system.

• Manometer:
• Pressure range: 0 - 4 bar.

Automatic air vent valve.

Control module box.

• 2 kW power control driver.

Based on Solid State Relay (SSR).

• 24 VDC Digital input.
• Safety temperature controller:

? ON/OFF control.

• ? Set temperature: 65 �C.

Safety stop input for low level switch.

• N-P-T-WW. Water-Water Heat Exchanger.
• The elements included in the �N-P-T-WW� module are:

Heat exchanger.

• ? Type: plate heat exchanger.

2 Manual ball valves.

• 2 Analog flow meter:
• ? Flow range: 0 - 2 l/min.
• 4 N-M-T-JT: �J Type� thermocouple.
• ? Transducer type: thermocouple type �J�.
• ? Temperature range: -100 - 900 �C.
• ? Accuracy: � 1 �C.
• 4 Temperature analogs:
• ? Temperature range: 0 - 120 �C.
• ? Accuracy: � 1 �C.

15

AVAILABLE APPLICATIONS

TEMPERATURE

• N-IC. Industrial Controller.

USB Communication.

• Display: full-color LCD 9 cm (3.5 inches) with built-in backlight.

Configurable sample rate chart (1 second to 5 minutes).

• Control parameters:
• Control type:

? ON/OFF control.

? P, PI, PID control.

? P, PI, PID control with gain scheduling (up to 3 set of PID parameters).

? Predictive control (dead-time compensation).

? Adaptive control.

? P, PI and PID control with feedforward.

? Cascade control.

? Cascade control with feedforward.

? Ratio controller.

? Ratio station.

• Control output type:

? Analog output.

? Time proportioning output.

? ON/OFF output.

? Motorized valve with feedback.

? Motorized valve without feedback.

? Split output with combinations of relay, digital output and current outputs.

• Autotune function:
• ? On - demand calculation of control settings.
• Set points:

? Configurable through the front panel or the computer.

? Up to four local set points, all selectable via digital inputs or front panel.

8 Blocks math functions.

8 Blocks of logic functions.

2 Blocks of totalizer functions.

8 Blocks process alarms.

• 4 Analog inputs with 125 ms of sample rate.
• 2 Analog outputs.

4 Relays.

6 Digital I/O.

• IC-KSS-SOF. Acquisition, Control and Controllers Configuration Software.
• The main functions of this software, based on LabVIEW, are:
• The following process variables can be visualize and managed via software:

? Set point (SP) of the first and second control loop, output process (O/P) of the first and second control loop, process

variable (PV) of the first and second control loop.

Data visualization, data management and data storage of all process variables involved in the control loops.

• The following process parameters can be adjustable via software:

? ON/OFF controller parameters, PID controller parameters of the one control loop or two control loops, set point values

bias and slope ratio and Feedforward gain.

Besides, if other applications with industrial controllers are connected, the �IC-KSS-SOF� software can supervise all applications

connected, forming a distributed control system.

16

AVAILABLE APPLICATIONS

TEMPERATURE

• N-V-H-S. Ball Valve with Scale.

Metering ball valve.

Scale from 90� (closed) to 0� (open).

• N-V-PR-W. Electromagnetic Proportional Valve for Hydraulic Circuits.

The elements recommended to extend the functionality of the �APC-TPRIC� application are indicated in the table of available modules

found at the end of the document. In addition to the modules related to the temperature control, it is possible to add modules related to

other variables to obtain multivariable control systems.

• Some practical possibilities of the �APC-TPRIC� application:
• Design and assembly of the control system:
• Familiarization with the main components of a control system: sensor, actuator and controller.
• Preparation of the piping and instrumentation diagram (P&ID) of a temperature control system.
• Preparation of circuits, wiring, terminals and connection diagrams of a temperature control system.
• Assembly of the hydraulic circuit of a temperature control system.
• Wiring of the control and measurement signals and the power supply of a temperature control system.
• Configuration of the system devices:
• Configuration of an industrial controller.
• Analysis of the system and design of control strategies:
• Manual control of the system with an industrial controller (open loop).
• Effect of the parameters of a PID controller.
• Obtaining the PID parameters automatically by auto-tuning.
• Adjustment and optimization of a PID controller.
• Response of the controlled system to disturbances and changes of the reference signal.

17

AVAILABLE APPLICATIONS

TEMPERATURE

APC-TFAIC. Temperature Regulation Application with Industrial Controller and Fan.

In the �APC-TFAIC� application, a pump impels water through a hydraulic circuit consisting of a heating device, which heats water, and an

air-water exchanger, which cools the fluid down with a fan. Both the fan and the heating element can be used to control the temperature.

The application includes three thermocouples to measure the temperature in various points of the circuit and a system of tubes to study

delays. In addition, a valve with scale introduces disturbances.

• The elements included in the �APC-TFAIC� application are:
• N-SU-H-HW. Hot Water Pumping Unit.

Water pumping unit designed for temperature control applications.

• The elements included in the �N-SU-H-HW� module are:
• Circulation pump:
• ? Supply voltage: single-phase 230 VAC.
• ? Nominal power: 103 W.
• ? Nominal flow: 10 - 63.2 l/min.
• ? Maximum operating pressure: 10 bar.

N-V-H-S. Ball Valve with Scale.

? Metering ball valve.

? Scale from 90� (closed) to 0� (open).

• N-ALI20. Power Supply Module for Control Circuits Module.
• Supply voltage (single-phase): 230 VAC, L+N+G.

Removable ON/OFF key switch.

• N-M-T-JT. �J type� Thermocouple.
• Transducer type: thermocouple type �J�.
• Temperature range: -100 - 900 �C.
• Accuracy: � 1 �C.
• N-H-2K. 2 kW Heating Module.
• Heating resistance:
• Supply voltage (single-phase): 220 VAC.
• Maximum power: 2 kW.

Safety temperature switch.

• Safety temperature sensor:
• Transducer type: thermocouple type �J�.
• Temperature range: -100 - 900 �C.
• Accuracy: � 1 �C.

Safety low level switch.

• Safety relief valve:
• Pressure setting: 3 bar.

Discharge line.

Additional manual opening system

• Manometer:
• Pressure range: 0 - 4 bar.

Automatic air vent valve.

Control module box.

• 2 kW power control driver.

Based on Solid State Relay (SSR).

18

AVAILABLE APPLICATIONS

TEMPERATURE

• 24 VDC Digital input.
• Safety temperature controller:

? ON/OFF control.

• ? Set temperature: 65 �C.

Safety stop input for low level switch.

• N-P-T-AW. Air-Water Heat Exchanger.

The fan of the air-water exchanger included may be used as actuator of the system.

• The elements included in the �N-P-T-AW� module are:

Air-water heat exchanger with fan.

2 x needle thermometer of 80 �C approx.

• N-IC. Industrial Controller.

USB Communication.

• Display: full-color LCD 9 cm (3.5 inches) with built-in backlight.

Configurable sample rate chart (1 second to 5 minutes).

• Control parameters:
• Control type:

? ON/OFF control.

? P, PI, PID control.

? P, PI, PID control with gain scheduling (up to 3 set of PID parameters).

? Predictive control (dead-time compensation).

? Adaptive control.

? P, PI and PID control with feedforward.

? Cascade control.

? Cascade control with feedforward.

? Ratio controller.

? Ratio station.

• Control output type:

? Analog output.

? Time proportioning output.

? ON/OFF output.

? Motorized valve with feedback.

? Motorized valve without feedback.

? Split output with combinations of relay, digital output and current outputs.

• Autotune function:
• ? On - demand calculation of control settings.
• Set points:

? Configurable through the front panel or the computer.

? Up to four local set points, all selectable via digital inputs or front panel.

8 Blocks math functions.

8 Blocks of logic functions.

2 Blocks of totalizer functions.

8 Blocks process alarms.

• 4 Analog inputs with 125 ms of sample rate.
• 2 Analog outputs.

4 Relays.

6 Digital I/O.

19

AVAILABLE APPLICATIONS

TEMPERATURE

• IC-KSS-SOF. Acquisition, Control and Controllers Configuration Software.
• The main functions of this software, based on LabVIEW, are:
• The following process variables can be visualize and managed via software:

? Set point (SP) of the first and second control loop, output process (O/P) of the first and second control loop, process

variable (PV) of the first and second control loop.

Data visualization, data management and data storage of all process variables involved in the control loops.

• The following process parameters can be adjustable via software:

? ON/OFF controller parameters, PID controller parameters of the one control loop or two control loops, set point values

bias and slope ratio and Feedforward gain.

Besides, if other applications with industrial controllers are connected, the �IC-KSS-SOF� software can supervise all applications

connected, forming a distributed control system.

• N-DELAY. Delay Time Module.

The elements recommended to extend the functionality of the �APC-TFAIC� application are indicated in the table of available modules

found at the end of the document. In addition to the modules related to the temperature control, it is possible to add modules related to

other variables to obtain multivariable control systems.

• Some practical possibilities of the �APC-TFAIC� application:
• Design and assembly of the control system:
• Familiarization with the main components of a control system: sensor, actuator and controller.
• Preparation of the piping and instrumentation diagram (P&ID) of a temperature control system.
• Preparation of circuits, wiring, terminals and connection diagrams of a temperature control system.
• Assembly of the hydraulic circuit of a temperature control system.
• Wiring of the control and measurement signals and the power supply of a temperature control system.
• Configuration of the system devices:
• Configuration of an industrial controller.
• Configuration of a signal recorder.
• Analysis of the system and design of control strategies:
• Manual control of the system with an industrial controller (open loop).
• Effect of the parameters of a PID controller.
• Obtaining the PID parameters automatically by auto-tuning.
• Adjustment and optimization of a PID controller.
• Effect of the delay time.
• Response of the controlled system to disturbances and changes of the reference signal.

20

AVAILABLE APPLICATIONS

pH

APC-PHIC. pH Regulation Application with Industrial Controller.

In the �APC-PHIC� application, an alkali is added to the tap water by a dosing pump and the pH is measured. Then, a second dosing

pump adds an acid to the solution.

The control of the system is done through an industrial controller that acts on one of the pumps. Disturbances can be introduced into the

system with the other pump or with a valve at the water inlet. In addition, a manual pH meter is included to remove the products and a

signal recorder.

• The elements included in the �APC-PHIC� application are:
• 2 x N-SU-C. Chemicals Supply Unit.

Module designed to pump reagents to the other devices of the application. The variable speed pump included can be used as actuator

of the system.

• The elements included in the �N-SU-C� module are:
• Dosing pump: 2 l/h approx.
• Plastic tank: 5 l approx.

Manual valve.

• N-ALI20. Power Supply Module for Control Circuits Module.
• Supply voltage (single-phase): 230 VAC, L+N+G.

Removable ON/OFF key switch.

• 2 x N-M-PH. pH Sensor.
• Range: 1 - 12.
• N-P-PH. Tanks for pH Measurement.
• The elements included in the �N-P-PH� module are:

2 x transparent tanks for pH measurement.

2 x mixing nozzles.

• Rotameter: 4 l/min.

Regulation valve.

Tank for chemical products.

• N-IC. Industrial Controller.

USB Communication.

• Display: full-color LCD 9 cm (3.5 inches) with built-in backlight.

Configurable sample rate chart (1 second to 5 minutes).

• Control parameters:
• Control type:

? ON/OFF control.

? P, PI, PID control.

? P, PI, PID control with gain scheduling (up to 3 set of PID parameters).

? Predictive control (dead-time compensation).

? Adaptive control.

? P, PI and PID control with feedforward.

? Cascade control.

? Cascade control with feedforward.

? Ratio controller.

? Ratio station.

• Control output type:

? Analog output.

? Time proportioning output.

? ON/OFF output.

? Motorized valve with feedback.

? Motorized valve without feedback.

? Split output with combinations of relay, digital output and current outputs.

• Autotune function:
• ? On - demand calculation of control settings.
• Set points:

? Configurable through the front panel or the computer.

? Up to four local set points, all selectable via digital inputs or front panel.

21

AVAILABLE APPLICATIONS

pH

8 Blocks math functions.

8 Blocks of logic functions.

2 Blocks of totalizer functions.

8 Blocks process alarms.

• 4 Analog inputs with 125 ms of sample rate.
• 2 Analog outputs.

4 Relays.

6 Digital I/O.

• IC-KSS-SOF. Acquisition, Control and Controllers Configuration Software.
• The main functions of this software, based on LabVIEW, are:
• The following process variables can be visualize and managed via software:

? Set point (SP) of the first and second control loop, output process (O/P) of the first and second control loop, process

variable (PV) of the first and second control loop.

Data visualization, data management and data storage of all process variables involved in the control loops.

• The following process parameters can be adjustable via software:

? ON/OFF controller parameters, PID controller parameters of the one control loop or two control loops, set point values

bias and slope ratio and Feedforward gain.

Besides, if other applications with industrial controllers are connected, the �IC-KSS-SOF� software can supervise all applications

connected, forming a distributed control system.

• N-SR-2. Two-channel Signal Recorder Module.
• 2 x N-DD. Digital Display.
• N-M-PH-HH. Handheld pH Meter.
• Required consumables (not included):
• Caustic soda 45 % (NaOH).
• Hydrochloric acid 30 % (HCl).

The elements recommended to extend the functionality of the �APC-PHIC� application are indicated in the table of available modules found

at the end of the document. In addition to the modules related to the pH control, it is possible to add modules related to other variables

to obtain multivariable control systems.

• Some practical possibilities of the �APC-PHIC� application:
• Design and assembly of the control system:
• Familiarization with the main components of a control system: sensor, actuator and controller.
• Preparation of the piping and instrumentation diagram (P&ID) of a pH control system.
• Preparation of circuits, wiring, terminals and connection diagrams of a pH control system.
• Assembly of the hydraulic circuit of a pH control system.
• Wiring of the control and measurement signals and the power supply of a pH control system.
• Configuration of the system devices:
• Configuration of an industrial controller.
• Analysis of the system and design of control strategies:
• Manual control of the system with an industrial controller (open loop).
• Effect of the parameters of a PID controller.
• Obtaining the PID parameters automatically by auto-tuning.
• Adjustment and optimization of a PID controller