Fault Finding in Control Systems Trainer
(CT-033)
  • Simulation to real-life industrial process systems
  • Familiarization with different heat transfer equipment
  • Reading and understanding of industrial flow diagrams
  • Simulation to faults that may occur through the system
  • Controlling of three different variables
  • Demonstration of different control loops and their function
  • Familiarization with variables measuring and controlling devices
  • Illustration of hazards resulting from such systems and how to mitigate these hazards using safety devices
  • Familiarization with the master and slave controllers in cascade loop systems
  • Tanks
    • Stirred tank with scale: approx. 10L
    • Collecting tank: approx. 80L
  • Main circuit centrifugal pump
    • Max. flow rate: approx. 4500L/h
    • Max. head: approx. 14m
  • 2 pumps, cooling circuit and refrigeration system
    • Max. flow rate: approx. 2800L/h
    • Max. head: approx. 4m
  • Heater power output: approx. 2kW Refrigerant: R134A or equivalent
    • Filling volume: 2200g
    • 3 integrated controllers P, PI or PID controller
  • Measuring ranges
    • Level: 1x 0…600mm
    • Flow rate: 1x 0…2300L/h
    • Temperature: 4x 0…100°C
    • Pressure: 1x 0…2,5bar
  • PLC Type
    • 1 x SIMATIC S7-1200, CPU 1214C
    • 14 Digital Inputs
    • 10 Digital Outputs
    • 8 Analog Inputs
    • 4 Analog Outputs
  • HMI Screen Type
    • 1 x SIMATIC HMI KTP700 Basic
    • Fully graphical color display.
    • Touch screen.
    • Resolution: 800 x 480 pixels.
    • Ethernet Port: PROFINET.
    • Operating voltage: 24 V DC.
  • Fault finding in Control Systems - (CT - 033)
  • BEDO Software + USB cable
  • Hard copy user manual
  • Laboratory PC
  • Compressed Air: 2…4bar; 25…50L/min

Fault finding in control systems trainer enables the trainees to experiment the control of the most common three variables in industrial processes and getting familiar with the faults that may occur in these systems. Training system features a simulation to a real industrial process of refrigeration system. The system setup includes pipes , a tank , a pump , valves , control sensors , PLC controller with HMI. Data acquisition software for monitoring, analyzing different parameters is provided. System values can be displayed on PC.

                                     
  • The educational unit simulates an industrial process that can be found in real life in order to experiment with different system disturbances and control more than one variable at once (Temperature, Flowrate, liquid level)
  • The unit consists of refrigeration system, stirred tank with heater, pump, heat exchanger and different controllers
  • The system demonstrates three types of heat transfer equipment, the first one is cooling using refrigerant, the second one is heating using coiled heater while the last one is heat integrating between both systems in a heat exchanger.
  • Water circulates through the system using different pumps.
  • The system is supplied with different sensors to measure temperature and flow of the streams.
  • The system is supplied with different controllers (Flow, level and temperature controllers) to give signals to the final control elements.
  • The system is supplied with different valves acting as the final control elements, valves open or close depending on signals received from the PLC to regulate the flow.
  • A valve is placed in the outlet of the tank to provide the process with disturbance variable in level control
  • The system is supplied with cascade controllers to improve process performance by reducing or nearly eliminating the outer disturbances
  • Cascade control can be found in the system where it controls the level of the fluid by means of flowrate control, the master controller. or to control temperature depending on flowrate controller as well.
  • The system is aided with safety devices to protect the system against possible hazards e.g., Explosions
  • The educational system can simulate different faults e.g., failure of sensors or cable breaks
  • All of the sensor readings and operation states can be read off a HMI touch screen.
  • All of the measured values can be saved in the PLC controller, analyzed using BEDO software and displayed on PC.
  • Trainees will also be able to control the process thorough the HMI screen (Touchscreen) besides monitoring the parameters.
    • Testing
    • Testing
    • Testing
  • Testing Bullets
  • The PLC system is supplied with WLAN with an integrated router/ LAN connection which enables the user to connect the training system to an end device such as external PC, or tablet in order to monitor and control the process.