Practical mastery of closed loops I

05.08.2008 Folie 1Jürgen Helmich

Practical mastery of closed loops I

Module 2: Commissioning a basic closed-loop control system

MPS® PA Compact Workstation


Outcome of Module 2 – Commissioning a closed-loop control system

The participant

can commission a basic closed-loop control system

— ensure supply

— install controller

— setup wiring

Detailed competencies needed:

able to identify components

able to read a circuit diagram or wiring schematic

able to connect components according to a circuit diagram or wiring schematic

Reason why:

In order to maintain a closed-loop control system in their production line the participant must understand the components and circuit of a closed-loop.

set up training system for following exercises/modules.


Module 2 - Contents

Overview components of MPS® PA Compact Workstation

sensors

actuators

I/O-board

control possibilities

Commissioning and testing with Simulation box, digital/analogue

Commissioning and testing with Easyport, digital/analogue and FluidLab-PA


Training system for process automation – MPS® PA Compact Workstation

Process technology is not only simple like basic

principles of a water treatment process or

production of food. It can be as highly complex as

a technical processes.

No matter the complexity of process technology –

to learn about the fundamentals of open and

closed-loop control technology is always the first

step.

This is why MPS® PA Compact Workstation

is great to learn about closed-loop control.


What´s new ?

The MPS® PA Compact Workstation has new technical features:

tanks with scaling 0-10 L, new form drains completely, without adhesive joint

screw-on tank cover with filling flap and fixed section, → parts as pipes and sensors are firmly mounted, → connecting cables or pipes are not moved, → no re-connection at commissioning necessarynew clearly laid out piping system

new proportional valve with larger diameter DN7 (higher flow rate)

pluggable pressure sensor for flexible usage in piping system, e.g. before or after the proportional valve

19“-frame with integrated ground fault circuit interrupter for heating element

2-row ER-frame

pressure tank connected to upper tank, therefore better visibility of inspection pipe

5 cm less head room

design MPS-PA conform


Components

tank

pump

flow rate sensor

controller

trolley

profile plate

proportional valve

ultrasonic sensor

I/O-board

2-wayball valve

pressure sensor heating

temperature sensor


• Two capacitive sensors at the rear of the lower

tank are monitoring the level of the water. The

sensors can be mechanically adjusted on an

aluminum profile.

• sensors detect the water level through the tank

wall.

• The binary 24 V signal output of the sensors is

wired to the I/O terminal in the form of an input.

Capacitive level sensors „see“ through the container wall

Datasheet → 690588


Float switch housing for lateral installation

• Depending on assembly position, the float

switch can be used either to switch at

increasing or decreasing water level.

• The binary 24 V signal is wired to the I/O

terminal as an input.

• connecting cables with plug/socket for easy

wiring or maintenance.



Float switch housing for heating safety

• The float switch is monitoring the decreasing

filling level in the tank. The heating is switched

off if the filling level sinks below the heating.

The heating must be surrounded completely by

the fluid. It is connected in line to the digital

output for activating the heating.

• connecting cables with plug/socket for easy

wiring or maintenance.

Datasheet → BE.EL.0162


• The binary 24 V signal is wired to the I/O

terminal (input at SysLink interface)

• also can be used as a safety limit switch to

switch off the pump by means of a safety relay.

• The switching solenoid is located in a

transparent float housing for easy visibility.

Float switch in tank cover



• Ultrasonic sensor, 50-300 mm / standard current signal 4-20 mA

• sensor detects distance to a surface, signal characteristic is modified to “falling”

• dead range < 50 mm, no defined measure value• Current to voltage transducer

4-20 mA → 0-10 V DC

Level detection with ultrasonic sensor

Datasheet → BE.SI.0193



Ultrasonic sensor with “falling” signal characteristic



L = E - D

D = • vst 2

t = sonic duration timevs = sonic speedBD = block distanceE = empty distanceD = measured distance to level surfaceL = level

E

D

BD

L

ultra sonicsensor measuring

transformer

Sour

ce: E

ndre

ss+H

ause

r


Actual value of flow rate is detected by

an opto-electronic vane sensor.

Frequency signal

0,3-9,0 l/min / 40-1200Hz

signal amplitude ~24 V DC

for PLC fast counter inputs

Impulse height 8-24 V DC

Frequency to voltage transducer

0-1000 Hz → 0-10 V DC

Flow rate measuring

Datasheet → 170711170711


Flow rate measuring

liquid product strikes the front edge of the rotor blades

low-pressure area is produced between the upstream cone and the rotor hub

Fluid flowing through the meter impacts an angular velocity to the turbine rotor blades

degree of the angular velocity or number of revolutions per minute of the turbine rotor is proportional to the flowing stream of the liquid

turbine rotor is hydraulically balanced on its axis

minimum flow rate of a turbine flow meter becomes a factor of viscosity versus the degree of accuracy

cavitation in a turbine flow meter will take place when the local pressures fall close to or below the vapor pressure of the liquid product


Pressure sensor

Pressure sensor, ceramic measurement cell

measure range 0…400 mbar

signal output 0-10 V DC

pluggable connector for flexible usage

in piping system

Datasheet → BE.EL.0600


Ceramic pressure cell

Suitable for:

compressed air, oxygen

water, sea water

fuel oil, diesel oil, fuel

hydraulic oil, brake fluid

aggressive media

pasty mediaSo

urce

: BD

Sen

sors


Temperature measuring

PT100 sensor

platinum resistance thermometer with

interchangeable measuring element.

Measuring range -50 °C ... +150 °C



Platinum resistance thermometer

1

2

3

1 Screw

2 Shield tube

3 Thermo element


• centrifugal pump with delivery rate of approx.

5 l/min ensures continuous flow of water.

• continuous control of the pump, pump motor

speed can be varied by means of a motor

controller with a voltage signal:

input 0-10 VDC, output 0-24 VDC.

• ON/OFF control of the pump motor with a

digital output/relay circuit.

Centrifugal pump



Centrifugal pump

1 rotor

2 rotor axis


• Flow control of fluids with directly actuated

proportional 2/2-way valve.

A solenoid coil current lifts the valve piston

continuously from its seat.

• An external standard signal is converted into a

pulse width modulated (PWM) signal. The

orifice of the valve is infinitely adjustable. The

frequency of the PWM signal can be modified.

• Standard signal 0-10VDC

(also: 0-20mA and 4-20mA)

Proportional valve



Proportional valve

1 return spring

2 seat sealing

3 plunger

4 seat

5 valve body

6 glide ring

flow


2-way ball valve for water process with:

• rotary pneumatic quarter turn actuator SYPAR,

scotch yoke principle

• 5/2 way pneumatic valve

with port pattern to NAMUR

direct mounted onto rotary drive

• electrical signal box

with two micro-switches for position feedback

CLOSED/OPEN

2-way ball valve with pneumatic rotary drive

ball valve → 534304

actuator → 533417

valve → 535987

signal box → 534469


Quarter turn actuator SYPAR – Double acting function

Process valve opensPistons move towards the end caps

Process valve closesPistons move toward the shaft


I/O-board wiring with measuring transducers and motor controller

Syslink I/O module, 20 pin Centronix

analogue 15pin Sub-D terminal block

top-hat rail relays

motor controller for the pump motor0-10V DC → 0-24 V DC, max. 3,5 A

measuring transducersC→ V, f → V, PT100 → V

current limiter, max. 2A

mechanical adaptation with ER-frame clips


19“- and ER-frame

ground fault circuit interrupter for heating element

2 ER-rows for I/O-board, EduTrainers, touch panels or control panel

optional: with power supply 24 V DC/4,5 A


PLC control

Siemens S7-300

CPU 313C

PC control

Festo EasyPort,

digital/analog

Closed-loop control

Industrial controller

Siemens Sipart DR19

Control possibilities

Commissioning/testing

Festo simulation box

digital/analog PLC control

Festo CPX-FEC

Closed-loop control

Industrial controller

Jumo Imago 500

PLC control

Siemens Logo

PLC control

Allen-Bradley

Micrologix 1500


Commissioning and testing with Simulation box, digital/analog

Station training:

Commissioning the station and check the digital and analog I/O signals.

Display of analog values

Connect Simulation box, digital/analog with crossover digital and analog Syslink cable to station I/Os


Connecting Simbox, digital/analogue

Connect Simulation box, digital/analog with crossover digital and analog Syslink cable to station I/Os


Compact Workstation

PC control with FluidLab-PA

PCstudy 1

Station training:

Basic training for measuring, control

and closed-loop control.

Connect a PC with RS232 cable to EasyPortDA (station I/O) using FluidLab-PA

PTP RS232


Connecting Easyport digital, analogue

PC


Compact Workstation

PLC control with Simatic S7-300 – CPU313C/CPU314C-2DP

PCstudy 1

PLC training:

Basic and advanced training for open and

closed-loop control.

Advanced training for

network communication

and visualization.

Programming with PC and Step7. Connect a PLC with digital and analogue Syslink cable to station I/Os

COM1 MPI

RS232


PLC control with Simatic S7-300 – CPU313C/CPU314C-2DP

19“- and ER-frame for multiple use

19“ control panel

19“ground fault circuit interrupter

EduTrainer for ER-frame


Compact Workstation

PLC control with Festo CPX-FEC

PCstudy 1

PLC training:

Basic and advanced training for open and

closed-loop control.

Advanced training for

network communication

and visualization.

Programming with PC and FSTV4.1 or higher. Connect a PLC with digital and analogue Syslink cable to station I/Os.

Visualization with FED120 and making projectwith FED Designer.

Ethernet


PLC control with Festo CPX-FEC

19“- and ER-frame for multiple use

19“ control panel

19“ground fault circuit interrupter

EduTrainer for ER-frame


Compact Workstation

Closed-loop control with industrial controller – Sipart DR19

PCstudy 1

Industrial controller training:

Basic operation training for industrial controller.

Advanced training

for closed-loop control.

Configuration and setup of parameters with PC and Simatic PDM V5.2 or higher. PC card CP5611 for Profibus-DP recommended. Connect a PLC with digital and analogue Syslink cable to station I/Os.

Profibus-DP


• Station size

w x d x h = 700 x 700 x 935 mm

d + approx. 100 mm for PLC or controller

towards the rear

• Station weight approx. 45 kg

• Voltage supply 24 VDC, 4,5 A

• Compressed air supply approx. 6 bar

General technical data


Getting started – commissioning a basic closed-loop control system

Which tasks have to be maintained ?

1. Prepare components following equipment list.

2. Visual check.

3. Make cable and pneumatic connections.

4. Arrange supply for voltage and pressurized air.

5. Fill the water tank if empty.

6. Deairate pipe system.

7. Start controller.

8. Operate controller.

Prepare work station

Visual check

Cable connections

Pneumatic connection

Commissioning Closed-loop control system

Operate controller

Runing closed-loop

Voltage supply

Filling tank

Deaeration pipe system

Start controller

Practical mastery of closed loops I

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