38-004 Pron Pressure Process Manual v2p0 CD

Electricity & Electronics
Control & Instrumentation
Pressure Process Control

Reference Manual
38-004
Process Control
Mechatronics
Telecommunications
Electrical Power & Machines
Technology Training for tomorrows world
Procon Pressure Process

38-004
Feedback Instruments Ltd, Park Road, Crowborough, E. Sussex, TN6 2QR, UK.
Telephone: +44 (0) 1892 653322,
Fax: +44 (0) 1892 663719.
email: feedback@feedback-group.com website: http:// www.feedback-group.com
Manual produced from software version: v2.0
Date: 19/10/2010
Feedback Part No. 116038004
Preface
THE HEALTH AND SAFETY AT WORK ACT 1974

We are required under the Health and Safety at Work Act 1974, to make available to users of this equipment certain information
regarding its safe use.+
The equipment, when used in normal or prescribed applications within the parameters set for its mechanical and electrical
performance, should not cause any danger or hazard to health or safety if normal engineering practices are observed and they are used
in accordance with the instructions supplied.
If, in specific cases, circumstances exist in which a potential hazard may be brought about by careless or improper use, these will be
pointed out and the necessary precautions emphasised.
While we provide the fullest possible user information relating to the proper use of this equipment, if there is any doubt whatsoever
about any aspect, the user should contact the Product Safety Officer at Feedback Instruments Limited, Crowborough.
This equipment should not be used by inexperienced users unless they are under supervision.
We are required by European Directives to indicate on our equipment panels certain areas and warnings that require attention by the
user. These have been indicated in the specified way by yellow labels with black printing, the meaning of any labels that may be fixed to
the instrument are shown below:
CAUTION RISK OF
DANGER
CAUTION RISK OF
ELECTRIC SHOCK
CAUTION ELECTROSTATIC
SENSITIVE DEVICE
Refer to accompanying documents
PRODUCT IMPROVEMENTS
We maintain a policy of continuous product improvement by incorporating the latest developments and components into our equipment,
even up to the time of dispatch.
All major changes are incorporated into up-dated editions of our manuals and this manual was believed to be correct at the time of
printing. However, some product changes which do not affect the instructional capability of the equipment, may not be included until it is
necessary to incorporate other significant changes.
COMPONENT REPLACEMENT
Where components are of a Safety Critical nature, i.e. all components involved with the supply or carrying of voltages at supply
potential or higher, these must be replaced with components of equal international safety approval in order to maintain full equipment
safety.
In order to maintain compliance with international directives, all replacement components should be identical to those originally
supplied.
Any component may be ordered direct from Feedback or its agents by quoting the following information:
1.
Equipment type
2.
Component value
3.
Component reference
4.
Equipment serial number
Components can often be replaced by alternatives available locally, however we cannot therefore guarantee continued performance
either to published specification or compliance with international standards.
38-004
Preface
OPERATING CONDITIONS
WARNING:
This equipment must not be used in conditions of condensing humidity.
This equipment is designed to operate under the following conditions:

Operating Temperature
10C to 40C (50F to 104F)
Humidity
10% to 90% (non-condensing)
DECLARATION CONCERNING ELECTROMAGNETIC COMPATIBILITY

Should this equipment be used outside the classroom, laboratory study area or similar such place for which it is designed and sold then
Feedback Instruments Ltd hereby states that conformity with the protection requirements of the European Community Electromagnetic
Compatibility Directive (89/336/EEC) may be invalidated and could lead to prosecution.
This equipment, when operated in accordance with the supplied documentation, does not cause electromagnetic disturbance outside
its immediate electromagnetic environment.
COPYRIGHT NOTICE
Feedback Instruments Limited

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any
means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of Feedback Instruments Limited.
ACKNOWLEDGEMENTS
Feedback Instruments Ltd acknowledge all trademarks.
IBM, IBM - PC are registered trademarks of International Business Machines.
MICROSOFT, WINDOWS 7, WINDOWS VISTA, WINDOWS XP, WINDOWS 2000, WINDOWS NT, WINDOWS ME, WINDOWS 98,
WINDOWS 95, WINDOWS 3.1 and Internet Explorer are registered trademarks of Microsoft Corporation.
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Chapter 1
Pressure Rig Introduction

Objectives
To learn how to navigate the Discovery software

To familiarise the student with the Pressure rig and how to pressurise the system.
38-004

Introduction
Chapter 1
Pressure Rig
Practical 1: Navigating the Discovery Software

Objectives and Background
Although the Discovery Laboratory environment is very easy to operate, these notes will
help you use all its facilities more quickly.
If there is a demonstration assignment, slider controls in the software perform functions
that would normally be performed on the hardware. In normal assignments, if the any of
the hardware systems fail to initialise the system reverts to demonstration mode. This
means that none of the test equipment is available.
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Chapter 1
Practical 1: Navigating the Discovery Software

Perform Practical
This Practical requires no patching connections and there are no measurements to be
taken.
The assignment window opens when an assignment is launched. The assignment window
consists of a title bar across the top, an assignment side bar at the right-hand edge, and
the main working area. By default, the overall assignment objectives are initially shown in
the main working area whenever an assignment is opened. The assignment window
occupies the entire screen space and it cannot be resized (but it can be moved by
dragging the title bar, and it can be minimised to the task bar). The title bar includes the
name of the selected assignment. The side bar contains the Practicals and any additional
resources that are relevant for the selected assignment. The side bar cannot be
repositioned from the right-hand edge of the assignment window. An example of an
assignment window is shown below.
The precise appearance of the assignment window will depend on the skin that has been
selected by your tutor. However, the behaviour of each of the buttons and icons will
remain the same, irrespective of this.
The clock (if you have one active) at the top of the side bar retrieves its time from the
computer system clock. By double clicking on the clock turns it into a stop watch. To start
the stop watch single click on the clock, click again to stop the stop watch. Double clicking
again will return it to the clock function.
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Introduction
Chapter 1
Pressure Rig
There are a number of resource buttons available in the assignment side bar. These are
relevant to the selected assignment. In general, the resources available will vary with the
assignment. For example, some assignments have video clips and some do not. However,
the Technical Terms, Help and Auto Position buttons have identical functionality in every
assignment. You can click on any resource in any order, close them again, or minimise
them to suit the way you work.
Practicals are listed in numerical order in the side bar. When you hover the mouse over a
Practical button, its proper title will briefly be shown in a pop-up tool-tip. There can be up
to four Practicals in any assignment. You can have only one Practical window open at any
time.
To perform a Practical, left-click on its button in the assignment side bar. The assignment
objectives, if shown in the main working area, will close, and the selected Practical will
appear in its own window initially on the right-hand side of the main working area, as
shown below. You can move and resize the Practical window as desired (even beyond the
assignment window) but its default size and position allows the test equipment to be
displayed down the left-hand side of the main working area without overlapping the
instructions for the Practical.
Again, the precise appearance of the Practical window can be determined by your tutor
but the behaviour of each of the buttons and icons will remain the same, irrespective of
this. Whatever it looks like, the Practical window should have icons for the test equipment,
together with buttons for Objectives & Background, Make Connections, Circuit Simulator
and Test Equipment Manuals. These resources are found in side bar, located on the righthand edge of the Practical window. The resources will depend on which Practical you
have selected. Therefore not all the resources are available in every Practical. If a
resource is unavailable, it will be shown greyed out. To open any resource, left-click on its
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Chapter 1
icon or button. Note that when you close a Practical window, any resources that you have
opened will close. You may open any resource at any time, provided it is available during
the Practical. The Circuit Simulator will only be available if you have one loaded.
Note that if the hardware is switched off, unavailable, or its software driver is not installed,
all the test equipment is disabled. However, you can open any other window. If you switch
on the hardware it will be necessary to close the assignment window and open it again to
enable the test equipment.
Resource Windows
These are standard, browser-like windows that may be moved, resized and scrolled. You
may minimise or maximise them. The system defaults to Auto Position, which means that
as you open each resource window it places it in a convenient position. Most resource
windows place themselves where the main lab window opens out. Each one lays over the
previous one. You can select which one is on top by clicking the tab at the top of each
window. You can see how many windows you have open from the number of tabs. If you
want to see several at once then drag them to where you wish on the screen. If you close
a window it disappears from the resources tab bar.
If you want to return all the windows to their default position simply click the Auto Position
button in the assignment side bar.
Make Connections Window

This movable and resizable window shows the wire connections (4mm patch leads) you
need to make on the hardware to make a practical work. The window opens with no
connections shown. You can show the connections one by one by clicking the Show Next
button or simply pressing the space bar on the keyboard. If you want to remove the
connections and start again click the Start Again button. The Show Function button
toggles the appearance of the block circuit diagram associated with the Practical.
Test Equipment
The test equipment will auto-place itself on the left of the screen at a default size. You
may move it or resize it at any time. Note that below a useable size only the screen of the
instrument will be shown, without the adjustment buttons. Each piece of test equipment
will launch with default settings. You may change these settings at any time. There is an
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Introduction
Chapter 1
Pressure Rig
auto anti-alias feature that prevents you setting time-base or frequency settings that may
give misleading displays.
You may return to the default settings by pressing the Default button on each piece of test
equipment. If you wish to return all the equipment to their original positions on the left of
the screen click Auto Position on the side bar of the assignment window.
Note that if you close a piece of test equipment and open it again it returns to its default
position and settings.
If you want more information on how a piece of test equipment works and how to interpret
the displays, see the Test Equipment Manuals resource in the Practical side bar.
On slower computers it may be noticeable that the refresh rate of each instrument is
reduced if all the instruments are open at once. If this is an issue then only have open the
instrument(s) you actually need to use.
Test Equipment Cursors

If you left click on the display of a piece of test equipment that has a screen, a green
cursor marker will appear where you have clicked. Click to move the cursor to the part of
the trace that you wish to measure. If you then move the mouse into the cursor a tool-tip
will appear displaying the values representing that position. Note if you resize or change
settings any current cursor will be removed.
Perform Practical Window

This window contains the instructions for performing the practical, as well as a block, or
circuit, diagram showing the circuit parts of the hardware board involved in the Practical.
On the diagram are the monitoring points that you use to explore how the system works
and to make measurements. The horizontal divider bar between the instructions and the
diagram can be moved up and down if you want the relative size of the practical
instruction window to diagram to be different. Note that the aspect ratio of the diagram is
fixed.
Information Buttons on Practical Diagrams
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Chapter 1
On many of the symbols on the diagram you will find a button that gives access to new
windows that provide more information on the circuit that the symbol represents. Note that
these windows are modal, which means that you can have only one open at a time and
you must close it before continuing with anything else.
A Further Information point looks like this
Probes
The practical diagram has probes on it, which start in default positions. These determine
where on the hardware the signals are being monitored.
Selecting and Moving the Probes
Probes are indicated by the coloured icons like this

If this probe is the selected probe it then looks like this
probe). You select a probe by left clicking on it.
.
(notice the black top to the
Monitor points look like this

If you place the mouse over a monitor point a tool-tip will show a description of what signal
it is.
You can move the selected probe by simply clicking on the required monitor point. If you
want to move the probe again you do not have to re-select it. To change which probe is
selected click on the probe you want to select.
You can also move a probe by the normal drag-and-drop method, common to Windows
programs.
Probes and Test Equipment Traces

The association between probes and traces displayed on the test equipment is by colour.
Data from the blue probe is displayed as a blue trace. Yellow, orange and green probes
and traces operate in a similar way. Which piece of test equipment is allocated to which
probe is defined by the practical.
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Introduction
Chapter 1
Pressure Rig
Note that the phasescope shows the relative phase and magnitude of the signal on its
input probe using another probe as the reference. The reference probe colour is indicated
by the coloured square to the top left corner of the phasescope display.
Practical Buttons
On some Practicals there are buttons at the bottom of the diagram that select some
parameter in the practical. These can be single buttons or in groups. Only one of each
button in a group may be selected at one time.
Slider Controls
Where slider controls are used you may find you can get finer control by clicking on it and
then using the up and down arrow keys on your keyboard.
38-004
Chapter 1
Practical 1 Introduction
The successful design and operation of industrial plant requires the optimum choices of
instrumentation and control equipment together with the ability to commission, monitor
and maintain such equipment.
Technicians and engineers need to be trained in these skills, particularly in view of the
rapid advances in the use of electronics and microcomputers in process control.
This range of specially designed equipment allows practical appreciation and
understanding of the whole spectrum of process control technology from the
characteristics of individual components to complex control loops operating on real
processes.
This assignment describes the 38-714 Pressure Process Rig, which is part of the Procon
range of equipment designed to introduce and demonstrate the principles of process
measurement and control.
The system includes those pneumatic control components of interest to the process
industries. The design allows study of component operation and connection to electrical
control devices through the use of pressure/current transducers.
A photograph of the Pressure Process Rig 38-714 is shown below:
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Introduction
Chapter 1
Pressure Rig
The front panel of the rig incorporates a schematic diagram of the equipment which
identifies the major components and relevant connections in standard pneumatic notation.
The unit consists of a pipeline on which are mounted a Pneumatic Control Valve, Orifice
Block and pressure tappings.
The flow discharges directly to atmosphere or via an Air Receiver to vary the process lag.
The valve is operated from a Current to Pressure Converter, and sensors for direct and
differential pressure facilitates measurement of pressure and flow respectively.
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Practical 1
Chapter 1
Introduction to the Pressure Rig
Perform Practical
This Practical requires no patching connections and there are no measurements to be
taken.
Process Rig Controller
The square root extraction facility of the 38-300 Process Controller is used with the
Current to Pressure Converter (I/P) to provide a linear signal. Both sensors are provided
with conditioners. The pipework and fittings are mounted on a support frame which is
designed to stand on a bench top.
The unit is designed to operate with the 38-200 and 38-300 Process Interface and
Process Controller to configure open or closed loop control circuits. These are explored
in greater detail within a later assignment.
Compressed air for the pneumatic instrumentation and process is connected to a common
inlet. Air for the instrumentation is regulated by a Regulator R1 and the operating pressure
is indicated on a Gauge G1. Air for the process is regulated by a Regulator R2 and the
operating pressure is indicated on Gauge G3.
The pneumatic instrumentation comprises an I/P Converter and Pneumatic Control
Valve. The I/P Converter accepts a 4-20mA control signal from the 38-200 Process
Interface and converts this to a 3-15psi pneumatic signal which operates the control valve.
Rig Control Valves
The control valve comprises a diaphragm actuator which positions the stem of a plug
type valve. An indicator on the valve stem shows the actual position of the valve.
A gauge G2 indicates the pneumatic signal applied to the control valve by the I/P
Converter. The 4-20mA input to the I/P Converter can be connected to the 38-200
Process Connections or the Servo Valve connection.
The air flowing through the process pipe passes through the Pneumatic Control Valve and
an Orifice Block assembly before discharging to atmosphere via a Diffuser.
A set of manual valves V1, V2 and V3 allow a rear-mounted air receiver to be connected
in series or parallel with the process pipe to change the response of the system (to vary
the process lag). The Air Receiver incorporates a pressure relief valve.
Step changes may be applied to the process by bleeding air through an additional Diffuser
by opening and closing the Valve V4, V5 and V7.
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Introduction
Chapter 1
Pressure Rig
This rig incorporates pneumatic control components of great interest to the process
industries. The design allows study of component operation and connection of control
devices through the use of current to pressure converters.
Process Controller and Interface
This Discovery software contains an integral data logger and configuration program.
This software automatically configures the 38-300 Process Controller, through a serial port
allowing it to be immediately used with each practical.
Before attempting any of the practicals:
Ensure that the Process Controller is connected to the serial port of your computer.
Communication Port 3 (Com3) is used by default. If you connect your Process Controller
to a different Com port, the Com port the software uses can be changed to the appropriate
Com port using the supplied Discovery 3 Com Port Changer software.
Ensure that the controller is given the identity '1'. If you are unsure about how to check this
value, please refer to the ABB manual that is supplied with your controller.
Ensure that the switches on the rear of the controller are correctly set up. If they are
switched incorrectly, the computer will not be able to communicate to the controller.
When you start certain practicals, a small delay will occur while the computer sets the
process controller parameters.
You will be presented with different controls depending upon the assignment and practical
that is being studied.
38-004
Chapter 1
Practical 2 System Pressurisation

This practical instructs how to set-up the 38-714 Pressure Process Rig and its associated
components.
38-004

Introduction
Practical 2
Chapter 1
Pressure Rig
System Pressurisation
Perform Practical
The Pressure Rig is made up of the following components:
Pneumatic Control Valve, this contains a 'diaphragm actuator'.
Gauge G2. This shows the pneumatic signal applied to the Control Valve by the I/P
Converter.
I/P Converter. This component accepts a 4-20mA signal from the Process Interface and
converts this to a 3-15psi signal.
Gauge G1. Displays the operating pressure which is controlled by a regulator.
Regulator R1. This control is used to control the pressure going into the I/P converter.
Air Filter. Source of Compressed air for the whole process rig. Arrow indicates direction
of flow.
Regulator R2. Used to control the pressure to parts of the process rig.
Gauge G3. Used to display the operating pressure.
Flowmeter. An instrument used to determine the rate of flow.
Gauge G4.
Orifice Block.
Gauge G5.
Valve V1. When connected to a rear-mounted air receiver, allows you to vary the
response of the system (by changing the process lag).
Gauge G6. Measures the pressure in air receiver.
Valve V2. Allows air to be transferred into the air receiver.
Valve V3. Allows air to be transferred into the air receiver.
Valve V4. Changes in the behaviour of the process can be performed by bleeding air
through a diffuser.
Valve V5. Changes in the behaviour of the process can be performed by bleeding air
through a diffuser.
Valve V6 + V7. Changes in the behaviour of the process can be performed by bleeding
air through the valve and adjustable diffuser.
Pressure Sensors. The Differential Pressure Sensor and the Pressure Sensor are used to
take measurements across the orifice block. This information can then be used by the
process controller.
Representation of Process Rig. On the bottom lies a schematic representation of all the
components of the Pressure Process Rig. Identify all the parts that have been displayed.
Practical
Connect a supply of clean compressed air to the inlet using a reinforced air hose. The
supply must be capable of providing the required volume of compressed air at the
operating pressure, otherwise flow and pressure in the system will be inadequate for
satisfactory demonstrations.
38-004
Chapter 1
Warning !!
The maximum supply pressure should not exceed 40psi. Supply pressure should be
adequately and reliably regulated prior to presentation to the Pressure Process Rig.
Identify all the relevant gauges and valves on the Pressure Rig. Open valve V1 and V3
adjacent to the air tank connection, close valves V2, V4, V5 and V6.
Adjust instrumentation pressure regulator R1 to give 25psi at G1. Pull the collar out to
adjust the regulator. Turn the collar clockwise to increase the downstream pressure and
anticlockwise to reduce the pressure. Push the collar back into place after adjustment.
Adjust process pressure regulator R2 to give 10psi at G3. Air will flow through the system,
pressurising the pipes and Air Receiver to 10 psi.
38-004

Introduction
Chapter 1
Pressure Rig
38-004
Chapter 2
Pressure Rig Familiarisation

Objectives
To familiarise the student with the Pressure Rig and demonstrate how to calibrate the
various components.
38-004

Familiarisation
Chapter 2
Pressure Rig
Practical 1 Current Source Calibration

This practical demonstrates the procedure that should be employed when calibrating the
Process Interface 38-200 Current Source
38-004
Block Diagram
Make Connections Diagram
38-004
Chapter 2

Familiarisation
Chapter 2
Pressure Rig
38-004
Practical 1
Chapter 2
Current Source Calibration
Perform Practical
Use the "Make Connections" diagram to make the required connections on the hardware.
Calibrate the Process Interface 38-200 Current Source as follows.
Connect the Current Source to the Digital Display Module 38-490 as shown in the "Make
Connections" diagram
Turn on the 38-200 Process Interface.
Turn the Current Source control fully anticlockwise to reduce the output to the minimum.
The display should read 4mA or 0%. If it does not, adjust the zero control using a small
screwdriver or trim tool until the display shows 4mA or 0%.
Turn the Current Source control fully clockwise to increase the output to the maximum.
The display should read 20mA or 100%. If it does not, adjust the span control.
The Current Source is now calibrated.
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Familiarisation
Chapter 2
Pressure Rig
Practical 2 I/P Converter and Pneumatic Control Valve Operation

The aim of this practical is to understand the operation of the I/P converter, and how it
controls the pneumatic control valve.
38-004
Block Diagram
38-004
Chapter 2

Familiarisation
Practical 2
Chapter 2
Pressure Rig
I/P Converter and Pneumatic Control Valve Operation
Perform Practical
Check operation of I/P Converter and Pneumatic Control Valve.
The Pressure Sensors are very delicate instruments. They may be damaged if presented
with differential pressures in excess of 30psi.
Connect the I/P Converter to the 38-200 4-20mA supply by making the connections shown
in the "Make Connections" diagram.
Turn on the 38-200 and pressurise the system as per the pressurisation practical
Set the Current Source Output to minimum (4mA) by turning the adjusting knob fully
anticlockwise. Gauge G2 should indicate 3 psi with control valve fully open. The indicator
on the valve stem should be in the raised position.
Set the Current Source Output to maximum (20mA) by turning the adjusting knob fully
clockwise. Gauge G2 should indicate 15 psi with control valve fully closed. The indicator
on the valve stem should be in the lowered position.
Note that the indicator on the valve stem provides only an approximate indication of valve
position.
Note: If the pressures indicated on G2 differ from the values stated above it will be
necessary to recalibrate the I/P Converter. This procedure is detailed in the I/P Converter
Assignment.
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Chapter 2
Practical 3 Pressure Sensor and Transmitter

In this practical you will learn the method of checking the operation of the Pressure Sensor
and Transmitter.
38-004

Familiarisation
Chapter 2
Pressure Rig
Block Diagram
38-004
38-004
Chapter 2

Familiarisation
Practical 3
Chapter 2
Pressure Rig
Pressure Sensor and Transmitter
Perform Practical
Checking the operation of the Pressure Sensor and Transmitter.
Pressurise the System as in the pressurisation practical
Drain all pressure from the system by fully closing R2 and fully opening V2, V4 and V5.
After a minute or two the system will be at atmospheric pressure throughout. The Digital
Display Module should show 4mA or 0%. If it does not, adjust the zero control until the
desired reading is obtained.
Pressurise the Air Receiver by opening V1 and closing V2, V4 and V5 then adjusting R2 to
produce a reading 0.7 bar or 10psi on G3. After a few moments the Air Receiver pressure
gauge G6 will read 10psi.
The Digital Display Module should read 20mA or 100%. If it does not, adjust the span
control until the desired reading is obtained. Repeat the above process checking readings
of 0% at atmospheric pressure and 100% at 10psi.
38-004
Chapter 2
Practical 4 Differential Pressure Sensor and Transmitter

In this practical you will learn the method of checking the operation of the Differential
Pressure Sensor and Transmitter.
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Familiarisation
Chapter 2
Pressure Rig
Block Diagram
38-004
38-004
Chapter 2

Familiarisation
Practical 4
Chapter 2
Pressure Rig
Differential Pressure Sensor and Transmitter
Perform Practical
Checking operation of Differential Pressure Sensor and Transmitter.

Pressurise the System as in the pressurisation practical
Open valves V2, V4, V5, V6 and V7. Close valves V1 and V3 (ensure V7 is fully open).
Drain all pressure from the system by fully closing R2 and fully opening V2. After a few
moments the system will be at atmospheric pressure throughout. The Digital Display
Module should show 4mA or 0% to indicate the zero flow condition. If it does not, adjust
the zero control until the desired reading is obtained.
Create a full flow condition by adjusting R2 until a 10psi difference is shown between the
reading on G4 and the reading on G5. This should easily be achieved. The Digital Display
Module should show 20mA or 100%. If it does not, adjust the span control until the desired
reading is obtained. When G4 indicates 10psi and G5 indicates zero the flow meter will
show a flow of approx 24 litres/min.
38-004
Chapter 3
Controller Familiarisation
Objectives
To familiarise the student with the process controller and demonstrate how to setup
various parameters including the serial communications with a PC..
To learn about control systems and automatic control systems.
38-004

Familiarisation
Chapter 3
Controller
38-300 Process Controller

The Process Controller (38-300) unit is powered by the Process Interface (PI) and
includes the ABB Kent-Taylor Commander 350 process controller and labelled inputs
and outputs, to and from the Process Interface (PI).
The ABB Commander 350 is a universal digital microprocessor-based single loop
programmable controller, that measures, displays and controls temperature, pressure,
liquid level, flow and other process parameters.
For this reason, the controller accepts a large variety of input signal types:
Thermocouple (THC)
Resistance thermometer (RTD)
Linear voltage or current
Resistance
Non-linear voltage or current from temperature transmitters
and other variables transduced to a suitable voltage or current.
In your case, since the 38-300 will control the Process Interface (PI), its process inputs
and control outputs are of the 4-20mA loop current type. The 38-300 features local,
remote or dual set-point, and retransmission of set-point or process variable. In addition,
according to the user requirements, there are four logic inputs (one on the rear) and four
time proportioned, voltage activated relays, labelled n.o (normally open) and n.c (normally
closed).
The industry standard serial communication RS485 and RS232 interfaces are included as
standard on the rear panel of the 38-300, so that a personal computer (PC) can
communicate with it and control of the process carried out using the Discovery software
package.
The 38-300 is equipped with control algorithms for various types of control, including;
On/Off
PID
Ramp/Soak (profile sequencing with up to 9 programs)
Dual Output (Heat/Cool)
Current Proportioning
Time Proportioning
Position Proportioning
Automatic bumpless transfer from manual to auto mode and vice versa
An autotune facility is provided, which can analyse the requirements of a process under
control, and select suitable control parameters for optimum performance.
38-004
Chapter 3
Anti-reset windup is a technique included to prevent a large control effort building up when
attempting to eliminate a deviation caused by a physical problem.
Each of these features will be explained fully as it arises through the increasing use of the
38-300 in this and further assignments. Instrument set up is restricted to authorised users
through multiple levels of security.
Users can select the instrument functionality required, from menus, using the eight tactile
membrane keys and the three high intensity seven-segment displays plus the deviation
bar graph. Configuration data is stored in non-volatile memory.
The controller is equipped with control algorithms for various types of control that were
mentioned earlier. These will be illustrated in later assignments, so that you become
familiar with the full capabilities of the 38-300.
The 38-300 contains analogue-to-digital and digital-to-analogue converters. The sample
time of these devices must be faster than the dynamics of the process for the controller to
operate the system reliably.
The sample time of the 38-300 for both converters is 125 ms, which is much faster than
any dynamics that exist in this process; fluids, pipes, tanks, pumps and servo valves are
relatively slow elements in terms of time response and disturbance introduction.
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Familiarisation
Chapter 3
Controller
The Pneumatic Control Valve

The plug-type valve provides a fine adjustment of flow through the valve and is ideal for
the purpose of pressure control.
A 4-20mA control signal may be used to open or close a valve to any intermediate
position. This facility to operate a valve remotely allows a process to be controlled
automatically when the valve is connected to an appropriate sensor and controller.
Although the Pneumatic Control Valve supplied does not have a truly linear
characteristic, it is satisfactory for control purposes at the operating pressure suggested.
As the pressure is increased, the relationship becomes less linear.
The control valve must be carefully selected to give the correct characteristics over the
normal range of operation.
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Automatic Control Systems

The control of an industrial process by automatic rather than human means is called
automation.
In its modern usage, automation can be defined as a technology that uses programmed
commands to operate a given process, combined with feedback of information to
determine that the commands have been properly executed. This kind of automation is
provided by the digital PID process controller Commander 350.
Modern control systems are self-organising, adaptive, robust, able to learn about a
process, and can optimise control.
Automation is often used for processes that were previously operated by humans.
When automated, the process can operate without human assistance or interference. In
fact, most automated systems are cabable of performing their functions with greater
accuracy and precision, and in less time, than humans are able to do.
However, semi-automated (hybrid, or human-robot) processes that incorporate human
workers and robots (computer controlled machines) and manually controlled systems, still
exist, since some tasks are best carried out by humans.
Automatic Control Systems - Classes
Control systems are sometimes divided into two classes.
If the object of the control system is to maintain the physical variable at some constant
value in the presence of disturbances, the system is called a regulator.
One example of a regulator control system is the speed-control system on the ac
generators of power utility companies. The purpose of this control system is to maintain
the speed of the generators at the constant value that results in the generated voltage
having a frequency of 50 Hz in the presence of varying electrical power loads.
Another example of a regulating process control system is the biological system that
maintains the temperature of the human body at approximately 36oC in an environment
that usually has a different temperature.
The second class of control systems is the servomechanism (sometimes called a Kinetic
control system). Although this term was originally applied to a system that controlled a
mechanical position or motion, it is now often used to describe a control system in which a
physical variable is required to follow, or track, some desired time function.
An example of this type of system is an automatic landing system, in which the aircraft
follows a 'ramp' trajectory to the desired touchdown point.
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A second example is the control systems of a robot, in which the robot 'hand' is made to
follow some desired path in space.
Different types of control can be carried out by the Process Controller (38-300), depending
on the requirements of the process and the desired output.
All types are covered thoroughly in their own assignments, but an introduction to each is
given in this theory. Each type is shown by applying it to a simple level control problem,
and by doing this you will gain an insight into the types of control that are available.
A tank is holding liquid to feed a process. The process being supplied requires a constant
head of liquid and so a control system is required to keep the tank level constant. A valve
is located in the tank inlet to vary the flow rate.
The diagram below illustrates the situation.
Open-loop Operation
The simplest strategy is to calibrate the inlet valve. By experimentation, a relationship
between tank level and position of the handwheel can be obtained.
If the outflow is constant, a position of the handwheel can be found that keeps the level
constant. If the valve is opened a little more, so that more water is coming into the tank
than is going out, then the level will rise. Conversely if the valve is closed a little, so that
more water is going out than is coming in, then the level will fall.
Now, if a different level is required, the handwheel can be changed to increase or
decrease the flow until the new level is reached.
This method is Open-Loop Operation. It is simple and will work well, provided there is no
change in the outflow of the liquid, and all other parameters affecting the level in the tank
remain constant.
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There is no electrical or mechanical feedback path, so the system is open loop, but
feedback is being provided through the user. He/she is deciding if the actual level is
above or below the desired level, and adjusting the actuator accordingly.
Feedforward Control
The major cause of disturbances affecting the tank level is likely to be changes in the tank
outflow rate. An increased outflow will cause the tank level to drop. Therefore, a more
reasonable approach is to produce calibration curves for a number of outflow rates.
By monitoring the outflow rate, the correct position of the handwheel can be determined
by examining the calibration curve for the new flow.
The handwheel is then adjusted to keep the tank at the required level.
This technique is Feedforward Control, and requires a measurement of the outflow rate
in order to calculate the change in the position of the inlet valve.
Feedforward Control - Disadvantages
Although feedforward control is an improvement over open-loop operation, it does have
disadvantages that restrict its usefulness.
One of these disadvantages is the calibration curves between the handwheel position,
outflow and level.
These must be accurate for the process to function correctly. Another is that the process
may vary with time, or disturbances occur that are not included in the calibration curves or
are not monitored. Under these circumstances, feedforward control will not be successful.
Feedback Control
We could carry out more measurements to compensate for the errors that can occur in
feedforward control.
However, the obvious solution to keep the level in the tank constant, is to monitor the level
itself. If it deviates from the desired value, the inlet valve is adjusted by an amount
dependent on the difference between the actual level and the desired level. This control
strategy is called Feedback Control.
Feedback control is error driven in that the control effort is a function of the difference
between the desired and the actual levels. The relationship between the error and the
control effort is called the control law.
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Feedback level control does require a more elaborate level measurement technique, and
an accurate valve actuator. It also requires a signal related to the actual level (i.e a level
transmitter). In addition, the valve actuator must be able to hold the valve in any position,
and to also change its position gradually and smoothly.
The diagram below illustrates how this may be implemented for the situation described
earlier.
The important characteristic of feedback control is that it is capable of providing a range of

control effort, that is, it can produce small as well as large corrections.
An appropriate control law must be designed or selected to produce a satisfactory
performance.
Control Law
The control law represents the action of the controller. Common control law types are the
P-type (proportional), I-type (integral) and D-type (derivative), or a combination of these,
i.e PI, PID.
Examples of feedback control systems can be found in nature, one of which is the
temperature-control of the human body.
This control system attempts to maintain the body temperature at a constant value.
Generally, the environment tends to vary the body temperature.
The body responds to a difference in temperature by perspiring, by increasing or
decreasing blood flow, by shivering, and so on.
This control system has one characteristic that control systems designed by humans do
not often have : it normally operates in a satisfactory manner for seventy years or more.
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Another characteristic of this system, and one that is usually present in control systems
that we design, is that if the magnitude of the error becomes too large, the system fails.
On/Off Feedback Control
A simplification of the general feedback control type is On/Off Feedback Control.
The level in our example would now only have two states; either above the desired level or
below it. Monitoring can now be carried out by a float switch, mounted at the desired level.
The switch produces a binary (on/off) signal that indicates whether the level is above or
below the desired value. The signal can then be used to operate the inlet valve directly.
When the level is above the reference value, the inlet valve is closed, and when below, it
is opened. The control law in on/off control is kept simple, it switches the control effort
between two extremes, depending on the sign of the error.
The diagram below illustrates the control method in the context of the equipment set-up.
Whatever the cause of the change in level, provided the deviation is large enough to
activate the switch, then control action will be applied to correct the situation.
On/Off Feedback Control - Disadvantages
By using on/off control our equipment requirements have been simplified. However, there
are several problems associated with on/off control.
One problem concerns the abrupt fluctuations in flow as the valve switches between fully
open and fully closed.
Another problem is that the precision of on/off control depends heavily on delays
associated with the switch, the inlet valve and the rate of change of flow. With lengthy
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delays, overflow could occur if the valve is not shut as soon as the desired level is
reached.
The answer is not just to make the switch quick and sensitive as this can lead to
unnecessary switching caused by waves or ripples.
The type of control chosen for a particular situation will depend on the accuracy required,
cost of equipment, maintenance (the simpler the system, the easier it will be to maintain),
disturbances expected and the degree of disturbance rejection expected, degree of
human intervention required, health and safety (how dangerous is an overflow of the
process in question?), and so on.
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Practical 1 Serial Communication

Practical 1 will take you through the steps that must be carried out before you can
attempt any practical that uses the Process Controller (38-300) and a personal computer
together. It is vital that these steps are completed successfully to allow the 38-300 to
communicate with your personal computer.
Steps 1 and 2 concern the physical link between the 38-300 and your personal computer.
They ensure that the cable supplied to link the two devices is connected to the correct
ports, and that the 38-300 is terminated correctly. It is possible to use more than one 38300 if a practical demands it, and in such a case the controllers form a chain from the
computer. This is when the termination of the serial lines is important.
Step 3 deals with the parameters that must be set up in the 38-300 to allow it to
communicate with your personal computer. The parameters are the speed of
communication (or Baud rate), the identity of the 38-300 (to allow more than one to be
used), the type of parity checking and the block check character enable (the last two are
both error checking facilities). These four amount to the 'language' that is being spoken, if
they are set up incorrectly the 38-300 will not understand the messages being sent by
your personal computer.
Questions
Why is it vital that this practical is completed before any others

that involve the Process Controller (38-300) and a personal
computer?
The first two steps deal with the physical link between the 38-300
and a computer, what does the third deal with? What would be
the effect of incorrectly completing this step?
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Practical 1
Serial Communication
Perform Practical
This practical has no patching diagram as its aim is to get you familiar with the procedure
that must be followed before any other practical that uses the 38-300 Controller.
Essentially the completed practical is the patching diagram for serial communication,
although it includes steps that are not only hardware links (wires and plugs and the like)
but parameter assignments in the 38-300.
Step 1: Link
There is a serial lead supplied with your equipment to connect the Process Controller (38300) to your computer. This is plugged into the port marked RS-232 on the rear of the 38300 and to a COM Port on the rear of your computer. An adapter is commonly used to
change the 25-way connector to a 9-way connector that many modern computers use. If
there are no available serial ports on the PC then a USB to serial adaptor can be used.
The Discovery 3 software is setup to use COM port 3.
Step 2: Termination
There are two switches on the rear of the 38-300, marked Termination and Connection,
that deal with the communication lines to the 38-300. You will be using it as a single
controller linked to your computer, so both of these switches must be ON.
Step 3: Serial Parameters
Plug the 38-300 power lead into one of the ac supply sockets on the rear of the Process
Interface (not the switched ac supply), turn both on and observe the LED Displays.
Practical Setting the Serial Parameters
Press and hold the Page Advance and the Increase buttons together for three seconds.
It is helpful to press the Page Advance button first, then with another finger, press the Up
button.
Parameter Advance Button
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Up Button
until the RED 38-300 LED display shows LEV.6.
User interface of the controller is divided into a number of levels. Each level contains a
number of related parameters that can be adjusted. Pressing those two buttons together
sets the controller on the first of the configuration levels, the Basic Configuration level.
Press the Raise button to increase to higher levels. Press the Raise button seven times
until LEV.d, the Serial Configuration Level is displayed. If a higher level is selected, press
the Lower button.
Raise Button
Lower Button
Use the Page Advance to move between individual parameter settings. Use the Up and
Down buttons to adjust each parameter.
Up Button
Down Button
Ensure that the controller is configured with the values shown in the below table.
Parameter
S.CFG
Value
4
PrtY
Addr
none
1
Description
Whether 2 or 4 wire serial connection
and baud rate. Value 4 indicates a 4
wire connection, running at 9600
baud.
Parity error checking. Default is none.
Unique address of this controller. This
is defined as a part of the MODBUS
protocol that the controller uses to
communicate to the PC. This must be
set to 2 if you are configuring a
second controller.
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When all parameters have been set, press the Alarm button:
Alarm Button
Pressing this button will return you to the Operating Display where you can observe the
Process Variable, Set Point and Controller Output.
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Practical 2 Navigating the 38-300

Practical 2 considers the 38-300 in much greater detail, and explains the control panel
and how it functions, but this practical must be completed first. Although you may not fully
understand all of the steps yet they will become clear in the next practical. It is sufficient
just to follow them for now.
The reason for keeping this in a separate practical is that it can now be referenced at any
time very easily. Linking the 38-300 to a computer is accomplished by completing this
practical.
The following diagram shows the configuration of the front control panel of the ABB
Commander 350 controller.
The buttons used on the controller are described in more detail on the following pages.
Controller Controls
Raise
Lower
Raise is used to increase a parameter value, or step up through a selection of parameters.

Lower is used to decrease a parameter value or step down through a selection of
parameters.
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Continued pressure on these buttons causes the rate of change of the displayed variable
to increase. To make small adjustments, press the keys momentarily.
Parameter Advance
The various configuration options are held in a number of different 'levels', each level
containing a set of related parameters.
When a level has been selected, as shown within the Process Variable Display, pressing
the Parameter Advance moves between different controller Frames within a level.
If a parameter has changed within a level, pressing the Parameter Advance button will
store the value within the controllers memory.
Auto/Manual
This button is used to change the controller operation mode between automatic and
manual.
In manual mode, the displays automatically revert to control output (bottom display) and
the process variable values (top display), and the Raise and Lower buttons can be used to
alter the control output. When in automatic mode this facility is disabled, since the output
is calculated by the controller.
When the controller is in manual operation, a small M can be seen in the output display.
Up
Down
When the controller is in manual operation, these buttons allow the changing of the
controller output.
When the controller is being configured, these allow specific controller parameters to be
changed.
Alarm
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During normal controller operation, this button allows the controller user to acknowledge
an alarm, a state that a process may have entered into, requiring user intervention. When
an alarm occurs, an alarm symbol will be seen within the bottom output panel.
When the controller is being configured, this button is used to return to the Operating
Display.
Controller Levels
The controller contains two types of Level, operation levels and configuration levels.
Operation levels allow the operator to change simple operational characteristics of the
controller during normal functioning, while the configuration levels allow more
sophisticated settings to be adjusted.
This section describes the controllers Operational Levels, whereas the next describes the
controllers Configuration Levels.
Level 1 : Operator Level
Normal day to day operation of the controller, depending upon which Control Template
has been selected.
Level 2 : Tuning
Allows the setting of important control parameters used to control a process. Key
parameters include Proportional Band, Integral Action time and Derivative Action
Time. These concepts are explored and studied in future assignments and practicals.
This level should be accessed to manually adjust operating parameters.
Level 3 : Set Points
The Commander 350 has the ability to support a number of different Set Points, giving the
controller flexability. This allows Set Point variables to be configured. This Level is not
explored within the software.
Level 4 : Alarm Trip Points
Allows the configuration of conditions under which Alarms can occur.
Level 5 : Valve Setup
This level is not applicable to the Procon training software. It is used in conjunction with
special types of motorised valve.
Levels labelled 6 though E allow the controller to be configured.
For safety reasons, there are many controller settings that have to be configured through
these level using the front panel of the controller, rather than the controllers RS485
communications port.
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Warning! Only change the configuration parameters if you are sure they need to be
changed. Changing the configuration parameters without fully understanding what they
are may cause your controller to enter a state which is not compatible with the Procon
assignments and practicals! If you are in doubt, do not change!
Level 6 : Basic Configuration
The basic configuration level allows the operator to select a required Template, choose
the type of Control Output and set the Control Action.
For some Procon Practicals, the Control Action setting is required to be changed. Control
Action can be set to two different modes, Direct Action or Reverse Action.
The type of mode depends entirely upon the type of actuators that are used in the Procon
rig. The Basic Process Rig servo valve requires Direct Action, whereas other actuators
within the Pressure Rig requires the setting of Reverse Action.
Level 7 : Analogue Inputs
The controller is designed to be flexible, lending itself to a number of different control
situations and needs. Subsequently, the controller can be configured to use different types
of signalling.
Analogue Inputs also allows the operator to configure the number of Decimal Places,
operational Engineering Range, amongst other settings.
Level 8 : Alarms
Level 8 is dedicated to the setting up of Alarms. This level contains setting for alam type,
alarm trip level and hysteresis settings. It also allows alarms to be associated to relays,
allowing audible warnings to alert operators.
The concept of an alarm is explored within a number of Procon assignments.
Level 9 : Set Points
The Commander 350 supports 4 different set points. This level allows the selection of set
points and the choosing of local or remote set points in process control. It also allows Set
Point Tracking, a useful control facility to start and stop processes, to be configured.
Level A : Control Configuration
Level A contains general controller configuration settings, such as what should occur
following a power failure and the defining of controller Output limits.
Level B : Operator Configuration
In an industrial environment, it is useful to prevent access to the controller to those who do
not require it. Within safety critical systems and processes, this is particularly important.
The Operator Configuration level allows the enabling or disabling of certain keys, such as
the Auto/Manual key, Local/Remote Set Point key and the Alarm Acknowledge Key.
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Level C : Output Assignments

The Commander 350 provides both Analogue (Proportional) and Digital (On/Off) Outputs.
This level allows the output facilities of the controller to be configured. Since the Procon
Process Rigs only use a small fraction of the controllers overall abilities, this level should
rarely be accessed.
Level D : Serial Communication
Setting of the type of serial cable used, and the baud rate. This level is described in the
previous practical. One of the most important parameters in this level is the Modbus
address.
Level E : Calibration
The controller is calibrated before it is used in the Procon system. Provision is made to
adjust the controller settings. This level is described for completeness and should not
have be to accessed.
The following documentation is supplied with the controller:
User Guide
Modbus Communication Guide
It is useful to reference these manuals when carrying out practicals involving the
controller. The user guide is especially useful, since it describes each level in detail.
Questions
When controlling the PI, of what type are the process inputs and
outputs of the Process Controller (38-300)? What input signals
does the 38-300 accept?
What is the major restriction when using the 38-300 controller in

terms of monitoring process variables? What is the major
restriction when using the 38-300 controller in terms of
monitoring process variables?
What sort of control can be implemented using this controller,
and so how many variables can be controlled?
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Considering the operations carried out before the parameters on

the Control and Set Point pages were recorded, and the
information given in the background to this practical (2) on
computer initialisation, what do you suggest is the reason for the
differences in the two sets of parameter values recorded?
As well as saving time and effort, what is another advantage of

using a computer to initialise the 38-300 before attempting a
practical?
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Block Diagram
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Practical 2
Navigating the 38-300
Perform Practical
In a similar way to the previous practical, this practical has no patching diagram.
Its aim is for you to become familiar with the Commander 350 controller, its keys and
displays, its parameters and pages, and the use of a personal computer and the controller
together.
Set up the Process Controller (38-300) in exactly the same way as you did in the first
practical, so that the 38-300 and your computer are able to communicate. Please go
through that practical again if you are unsure.
When the 38-300 is switched on it will perform a self-test, show the version of the
controller operating system that is installed and the date, followed by the main operating
display.
If a practical is selected and the controller is switched off an error message will be
produced on screen as shown below. Close the practical and switch on the controller then
restart the practical.
To begin, ensure that the controller is set in Manual operation mode. When the controller
is running in manual operation mode, parameters can be set using the front panel or by
the computer. To change the controller operation mode, press the:
Automatic/Manual Button
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If the Process Controller is not set to manual mode, the controller will not accept new
settings from the computer. An error message will be produced on screen as shown below
if the controller is in Automatic mode when a practical is selected.
Always ensure that the controller has been set to Manual mode before a practical is
started.
Step 1 : Configuration Setting 1
Pressing the configuration 1 button below begins to transmit commands from the
controller from the computer, changing a number of key parameters. The transmission
takes approximately 2 seconds.
Press and hold the Parameter Advance keys on the control panel until CodE is
displayed. Press Parameter Advance twice more to move to the first level of the
configuration displays. Press the Raise button so LEV.2 is displayed. This is the tuning
level.
Use the Up and Down to move between individual parameters. Record all the settings
within this level. When you have done, return to the top of the level (LEV.2), and change
to level 1, the operating level. Press the Parameter Advance to return to the main
operating display.
Step 2 : Configuration Setting 2
Press the configuration 2 button to transmit a different configuration to the controller.
Using the previous instructions, record the same parameters as you did earlier and
compare the two sets of values.
Press Page Advance and then Enter to return to the operating page, and press
Parameter Advance once to display output, shown by OP 100.0. The output can be
decreased and increased with Lower and Raise. Check this. Pressing Auto/Manual will
disable this facility, the output is set automatically. The L.E.D. is off, showing Auto
operation.
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Practical 3 Using the 38-300

In this practical you shall make use of some of the facilities of the Process Controller (38300) that are available for different modes of control.
This practical is kept simple. It introduces a number of basic features of the controller,
including manual control of controller output and the use and purpose of alarms.
As the assignments develop, so too will the use of the 38-300 and more of its full capacity
shall be seen.
Manual Control
Initially you will control the output of the 38-300 using the Up and Down keys on the
control panel.
The 38-300 will take the place of the current source on the Process Interface (PI), and the
Up/Down keys will carry out the same function as the current source control knob on the
PI.
You will be the operator of the process, manually controlling its operation, and it is a very
simple matter to set the level of the tank.
Here the manual control effort, Um, is you, changing the output at will. The actuator is the
servo valve, and the measurement section is also you watching the level in the tank.
Disturbance is normally included in this sort of situation to account for any fluctuations that
are out of your control (environmental changes can affect the flow for example).
Transfer between Automatic and Manual Control
When switching control modes (manual-auto or auto-manual) a problem can arise when
the automatic set-point and the measured operating point are not equal. Normally a
controller will start in manual mode, where the automatic set-point is adjusted until it is
equal to the required operating point.
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The controller output will then be adjusted until the deviation between set-point and actual
operating point is zero, and the controller switched to auto mode. This ensures that the
plant is operating steadily at the desired operating point at the instant of switching.
If the actual operating point is changed (using the manual controls) but the set-point is not,
when the plant has reached steady state and is switched to auto there will be a deviation
(because the measured operating point is not equal to the set-point), and the automatic
controller will attempt to correct this.
This will cause a bump and will drive the plant away from the operating point set manually
by the operator. The same effect can occur when switching from auto to manual, if the
manual output control is not equal to the actual automatic controller output.
The way to avoid this is to employ automatic bumpless transfer, which is a facility most
modern controllers include.
When using the 38-300, if there is a deviation between the desired operating point (as set
by the manual controls) and the automatic set-point at the time of switching from manual
to auto, the plant will continue at its desired operating point (with no bump).
This is slightly anomalous as there will be a (possibly large) deviation and an incorrect setpoint, but it has prevented bumps.
Although bumpless transfer is available on modern controllers, it is good engineering
practice to ensure no deviation in operating points (automatic set-point and actual
measured operating point) before switching modes, rather than rely on this facility.
Alarms
The ABB Commander 350 like other industry process controllers, is capable of triggering
alarms should certain predefined conditions be met.
Up to 8 different alarms can be used, numbered 1 through to 8. Each alarm can be
programmed separately.
On the control panel of the Commander 350, an alarm LED will appear in green at the
bottom of the middle LED display. The LED will flash to show that an alarm has been
triggered but not acknowledged.
Each alarm can be assigned a Type, a Trip Level and a Hysteresis setting.
Alarm Types
The alarm Type describes the situation that the alarm is watching for and it can be one of
the following;
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High or Low Process Value

High or Low Output
High or Low Deviation
High or Low calculated mathematical value
The trip level is the level of the selected type that should trigger the alarm. For example,
alarm A can be set to 'high output' with a trip level of 80%. If the output of the Controller is
increased to 80% or above, an alarm will be triggered.
The hysteresis setting is another way of checking process parameters.
The hysteresis setting is operational when an alarm is active, and it is specified as a
percentage or in engineering units.
It is best shown with the above example; alarm A has been triggered by the output of the
controller increasing above 80%, and the hysteresis setting is 5%. The output is lowered,
but it must decrease below 75% (80% trip level - 5% hysteresis setting) before the alarm is
turned off.
The output must move into the safe region by an amount equal to the hysteresis setting.
Viewing Alarm Settings
When you are carrying out this practical, after the alarms have been set, the alarm
settings can be seen on the Alarms Trip Point page.
Press and hold the Parameter Advance key to change to the configuration mode, then
press the button again twice to move to LEV.1, the operational level.
Finally, press the Raise keys to move to LEV.4, the alarms level. Use the Up and Down
keys to observe the parameters
Configuring Alarms
The practical requires the operator to configure two of the controllers alarms.
When the display shows LEV.4, press and hold the Raise key to move to the higher
configuration levels. The alarm level is situated at level 8, as shown by the display AL_S.
Use the controls on the controller to view the parameters that can be set at this level. Note
particularly the tyP.n setting, where n refers to the alarm number.
With the tyP.1 parameter displayed, change the setting by pressing the Raise and Lower
keys. This manual control practical uses alarms to indicate control output that is too high,
indicated by the letters HO, and the control output is too low, indicated by LO.
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All available parameters are described in the following table for completeness. Do not
worry about understanding them all. Only a small fraction of the available alarm types are
used.
Alarm Settings
Display
NONE
HPU and
LPU
HLP and LLP
Hd and Ld
HPn and LPn
HO and LO
Lbn and Hbn
Description
No alarm currently assigned.
High and Low Process Variable values
High and Low Latch Process Variable
High and Low Deviation
High and Low Input values, where n refers to
different inputs
High and Low Process Output settings, potentially
used to prevent actuators going beyond preset limits.
Programmable mathematical calculations, high and
low settings.
Alarms are set either by using the front panel or by the ABB configurator software, rather
than using the main serial communications link for security purposes. This prevents the
likelihood of software accidentally changing the alarm operation that could be used to
indicate potentially hazardous process states.
Since the alarms are used in a number of different ways, they will be have to be
reconfigured during a number of practicals. Always remember that the alarm settings can
be found at Level 8.
When all alarms have been configured, the trip levels for all alarms that have been
enabled, can be set using the Alarms Trip Point page. Press and hold the Parameter
Advance key to change to the configuration mode, then press the button again twice to
move to LEV.1, the operational level. Finally, press the Raise keys to move to LEV.4, the
alarms level. Use the Up and Down keys to observe the parameters.
If no alarms have been enabled, no parameters can be changed.
Now that alarms are familiar, select the practical page to begin to use and configure the
controller.
Questions
1
Hysteresis, with regard to the 38-300 alarms, is the difference

between the switch-on level and the switch-off level of the
variable assigned to the alarm. Did you find your experimental
results were the same as the values set up in the controller?
38-004

Familiarisation
Chapter 3
Controller
When is hysteresis operational, and when using it, what can be

said about the variable as it moves inside the trip level?
When transferring between modes of the 38-300, what is a

'bump' and what are the conditions that would cause a bump?
What steps should be carried out to prevent bumps, and what
facility is available on modern controllers to prevent bumps?
What is the anomalous situation that can occur if care is not
taken when transfering modes in a modern controller?
Considering what you have learnt in this and previous

assignments about automatic and manual control systems, split
the following into Automatic Control and Manual Control: (a) A
heater with a thermostat. (b) A refrigerator. (c) Filling a bath tub,
(d) A burglar alarm which has been set, (e) Traffic lights at a
road junction, (f) A pedestrian crossing with traffic lights, (g) A
washing machine once it is turned on, (h) A petrol-driven
lawnmower once it has been turned on.
38-004
Block Diagram
38-004
Chapter 3

Familiarisation
Chapter 3
Controller
38-004
Chapter 3
Practical 3
Using the 38-300
Perform Practical
Please ensure that you have completed the first practical!
Ensure that the controller is set to manual operation. You can change the mode of
operation by pressing the Automatic/Manual button on the front of the controller.
Initialise the 38-300 by clicking on the Setup button below to set the controller to some
default operation values.
For safety and security reasons, the controller alarms have to be set manually.
Press the Page Advance button to go to the operational setting level, LEV.1, then press
the Raise button until LEV.8 is displayed. When on Level 8, set the following parameters:
Parameter
tyP.1
trP.1
Hy5.1
tyP.2
Value
LO
25.0
40.0
HO
trP.2
Hy5.2
80.0
20.0
Description
Alarm 1 Type: Controller Output Low
Alarm 1 Trip Level
Alarm 1 Hysteresis
Alarm 2 Type: Controller Output
High
Alarm 2 Trip Level
Alarm 2 Hysteresis
The Pressure Sensors are very delicate instruments. They may be damaged if presented
with differential pressures in excess of 30psi.
Turn on the 38-200 and pressurise the system as per the pressurisation practical 3 in the
Pressure Rig Introduction assignment.
Increase and decrease the output by pressing the Up and Down keys. Use the whole
range of output; 0%-100%.
What is the DDM showing?
What are the units of the output being displayed by the 38-300?
Notice the operation of the alarms.
Experiment with the Alarm Acknowledge button, and consider how it works.
38-004

Familiarisation
Chapter 3
Controller
Use LEV.4, the Alarm Trip Points level to adjust the trip level and observe the alarm
behavior. Try changing the hysteresis value using LEV.8.
Change the operation of the controller between automatic and manual mode by pressing
the Automatic/Manual button.
Return to LEV.8 and set all alarm types to NONE so you are ready for the next practical.
38-004
Chapter 4
Controller Calibration
Objectives
To further explore the 38-300 process controller, its settings and how to read data from
the controller using the Discovery software.
38-004
Chapter 4
38-300 Process Controller

The Process Controller (38-300) unit is powered by the Process Interface (PI) and
includes the ABB Kent-Taylor Commander 350 process controller and labelled inputs
and outputs, to and from the Process Interface (PI).
The ABB Commander 350 is a universal digital microprocessor-based single loop
programmable controller, that measures, displays and controls temperature, pressure,
For this reason, the controller accepts a large variety of input signal types:
Thermocouple (THC)
Resistance
and other variables transduced to a suitable voltage or current.
In your case, since the 38-300 will control the Process Interface (PI), its process inputs
and control outputs are of the 4-20mA loop current type. The 38-300 features local,
remote or dual set-point, and retransmission of set-point or process variable. In addition,
according to the user requirements, there are four logic inputs (one on the rear) and four
time proportioned, voltage activated relays, labelled n.o (normally open) and n.c (normally
closed).
The industry standard serial communication RS485 and RS232 interfaces are included as
standard on the rear panel of the 38-300, so that a personal computer (PC) can
communicate with it and control of the process carried out using the Discovery software
package.
The 38-300 is equipped with control algorithms for various types of control, including;
On/Off
PID
Ramp/Soak (profile sequencing with up to 9 programs)
Dual Output (Heat/Cool)
Current Proportioning
Time Proportioning
Position Proportioning
Automatic bumpless transfer from manual to auto mode and vice versa
An autotune facility is provided, which can analyse the requirements of a process under
control, and select suitable control parameters for optimum performance.
Anti-reset windup is a technique included to prevent a large control effort building up when
attempting to eliminate a deviation caused by a physical problem.
38-004
Chapter 4
Each of these features will be explained fully as it arises through the increasing use of the
38-300 in this and further assignments. Instrument set up is restricted to authorised users
through multiple levels of security.
Users can select the instrument functionality required, from menus, using the eight tactile
membrane keys and the three high intensity seven-segment displays plus the deviation
bar graph. Configuration data is stored in non-volatile memory.
The controller is equipped with control algorithms for various types of control that were
mentioned earlier. These will be illustrated in later assignments, so that you become
familiar with the full capabilities of the 38-300.
The 38-300 contains analogue-to-digital and digital-to-analogue converters. The sample
time of these devices must be faster than the dynamics of the process for the controller to
operate the system reliably.
The sample time of the 38-300 for both converters is 125 ms, which is much faster than
38-004
Chapter 4
General Process Controllers

The task of a controller is to maintain the desired system performance despite any
disturbances in the system.
Controllers are usually implemented electronically, either using analogue circuits, or a
digital computer (microprocessor). However pneumatic and hydraulic controllers are still in
use.
In process control, it is unusual to design a specific controller for a particular plant,
because the dynamics of the plant are uncertain and often very dependent on operating
conditions.
Therefore, a general purpose controller is normally implemented, which has a number of
variable parameters that can be set to meet the static and dynamic requirements of the
control system.
The static characteristics of a system are independent of time and the response of the
system depends only on the inputs. The dynamic characteristics of a system depend on
both time and inputs.
Various types of general purpose controllers exist, and each can be characterised by its
actions and methods of controlling a system.
A block diagram of a General Process Control System is shown below:
This shows the plant, and some means of measuring a process variable. This measured
variable is fed back to the controller to determine how well the system is operating.
With the addition of the feedback loop it has now become a closed loop system.
The controller will compare the measured output and the desired output (the Set Point) to
determine the control effort. Um is the manual input, and the manual/auto switch can also
be seen.
With the switch in the manual position the control law has been disconnected from the
process plant and the system is controlled by the operator only (a manual control system,
the type of control we have been implementing so far).
38-004
Chapter 4
With the switch in the automatic position the control law is added to the manual input and
this will determine the behaviour of the process. The process can now be controlled
automatically, provided it is given desired operating levels.
An automatic controller cannot determine how to control a process, it can only carry out
desired control, determined by a third party, you.
We shall be carrying out various types of feedback control in later assignments.
38-004
Chapter 4
Digital Control Systems

The use of digital computers for the control and monitoring of processes is becoming
increasingly important.
Computers offer improved performance, better management of a process, reliability,
flexibility, reduced cost and can perform complex calculations that could not be done by
other analogue means.
Powerful software development tools (programming languages for instance) which can be
run on digital computers, result in reduced development costs for computer-based control
systems.
A number of digital single loop controllers can be used (an example of one of these
controllers being the 38-300), each carrying out the feedback control of a single variable in
a multi-variable process. These controllers are called the slave controllers and are coordinated by a digital controller called the master.
A master controller sends set point information to the slave controllers and receives back
information on the measured variables. This type of control is called set point control and
a major benefit of this type of control is that even in the event of a master controller failure,
the individual slave controllers will continue to operate, and with these operating the
process should continue to run.
The other type of computer control is called Direct Digital Control (DDC). DDC as the
name implies, uses digital controllers to determine the actual control effort applied to the
process or plant.
The digital controllers are microprocessor-based single loop or multi-loop controllers that
control a single- or multi-variable plant, in place of the old analogue, mechanical or
pneumatic controllers.
38-004
Chapter 4
Digital Control Law

The digital control law of a process that determines the control effort can be obtained from
two completely different design techniques.
The simple method is to approximate the analogue control law with a discrete time control
law. In essence we implement the existing analogue controller with a digital controller.
This method has the advantage of familiarity with the analogue concepts and terminology.
However, a major disadvantage is to restrict the vast capabilities of digital computers due
to the digital approximation of the analogue controllers having limited capabilities.
The other method for the design of digital controllers is to design directly in discrete time.
The drawback of this method is that during discrete time (i.e. during the sample times)
very good control may be achieved, but between samples the controlled variable is
effectively in the open loop condition and may oscillate. Design techniques must be must
be accurate and thorough to encompass such eventualities.
The two block diagrams show the analogue and digital discrete time controllers and how
they differ. The control law in the discrete time example is implemented digitally, but the
plant is a continuous analogue system. A digital to analogue converter (DAC) must be
included between the controller output and the plant input, and a corresponding analogue
to digital converter (ADC) between the plant output and the comparator in the feedback
path.
The sampling rate fs of the DAC and ADC will determine how the controller copes with
oscillation and fluctuations. Consequently it must be much faster than the process
dynamics, so that the digital approximation will produce similar results to the conventional
analogue controller.
38-004
Chapter 4
The controller you are provided with is a single loop, digital controller. The DAC and ADC
are integral parts of the controller, and as such they will not concern you through your
practicals.
38-004
Chapter 4
Practical 1 38-300 Calibration

With reference to the 38-300, measurements are carried out to monitor process
parameters and to determine the control effort that should be applied when controlling a
process.
Such measurements ensure the correct operation of the process system. Because of this,
the accuracy of these measurements must be guaranteed by proper calibration of the
controller used.
Calibration consists of comparing the measured value or level of a parameter, as shown
by the controller being calibrated, with the known value or level of the parameter, as
measured by a standard instrument of known accuracy.
Calibration
Calibration guarantees that the accuracy of the input or output reading in a calibrated
controller will be at a certain acceptable level, when used under the environmental
conditions (e.g temperature, humidity, pressure) present during the calibration process.
Outside those conditions, characteristics may change, and so the accuracy of the
instrument will vary to a greater or lesser extent according to its susceptibility to the
modifying inputs inherent in the new environmental conditions.
When a process controller is calibrated against a standard instrument, its accuracy will be
either inside, or outside that required by the application measurement accuracy limits.
If the controller's accuracy is outside the acceptable measurement limits, then its
characteristics should be adjusted by the zero and span parameters provided, until they
are within the specified measurement limits.
Bear in mind that all calibration and measurement procedures should be documented, so
that a record of the calibration history of any instrument will always be available.
Calibration Check of the Process Controller
There is no need to actually calibrate the controller in this practical, not because it does
not need to be accurate, but because the 38-300 has been calibrated to a level of
accuracy much greater than most meters readily available to you.
It has, stored in its memory, settings for the span and zero parameters of its inputs, and
you may reset these to ensure the 38-300 is accurately calibrated.
38-004
Chapter 4
As mentioned in the Interface Calibration Assignment this calibration should now be

carried out before every practical that uses the 38-300. The more often it is carried out the
more familiar you will become with the importance of calibration and the need to carry it
out before every practical.
Before beginning this practical, make sure that your process interface is switched on so
that the 38-300 controller is powered up.
Questions
1
What are the steps that make up the 38-300 pre-practical setup
procedure?
Why is it unnecessary to calibrate the 38-300 in the same way

that the current source on the Process Interface was calibrated?
What devices would be needed to calibrate the 38-300 to an

accuracy level greater than the one it has already been calibrated
to?
38-004
Chapter 4
Practical 1
38-300 Calibration
Perform Practical
This practical has no patching diagram as it only deals with parameters of the 38-300. Its
aim is to show you where and how to reset the 38-300 analogue input configuration
parameters.
You will use the controllers keys to locate the specific parameters and reset them. This is
something that should be done before every practical using the 38-300, to ensure that all
measurements made with it are within a predefined level of accuracy.
Now you have had experience of starting the initialisation process by clicking on an on
screen button in the previous practical, this shall be carried out automatically from now on,
when a practical is started.
Remember: Set the controller in Manual mode before selecting a practical for the
initialisation process to take place.
As mentioned in the background pages and the patching diagram associated with this
practical, you will check the analogue input settings of the 38-300 controller.
The Commander 350 provides three analogue inputs. Two analogue inputs are universally
configurable, allowing the controller to accept Thermocouple, Resistance Thermometer,
mV, Volts, mA and resistance signals. The third analogue input signal can only accept mA
and mV signals.
Level 7 (LEV.7), the Analogue Input Level allows the input type (tyP.1), decimal point
(dP.1) settings, engineering ranges (EN1.H), (EN1.L), Broken sensor drive (bSd.1) and
Input Filter Time Constant (FLt.1) to be configured for all three inputs. To go to the
Analogue Input Level, press and hold the Parameter Advance and press twice more to
jump to the first level. Then press the Raise button until LEV.7 is displayed.
Note: To advance from Level 5 the Raise button must be pressed and held until Level 6
appears.
Parameter
38-004
Value
Description
Chapter 4
tyP.1
dP.1
EN1.H
EN1.L
bSd.1
FLt.1
1
100.0
0.0
nonE
0
Input 1 Setting: 4 to 20mA (Process

Variable)
Input 1 Decimal Places
Input 1 Engineering Unit High
Input 1 Engineering Unit Low
Broken sensor drive.
Input values averaged over seconds.
Ensure that the input settings for analogue inputs 2 and 3 are identical.
The Broken Sensor Drive is a setting that allows an action to be carried out if an invalid
signal is received. This is to ensure that a sensible operation and potentially preventative
operation is performed following a sensor failure. Options include none, up and down.
Return to level 1 (LEV.1) and press the Parameter Advance button so you are ready for
the next practical.
38-004
Chapter 4
Practical 2 Reading the 38-300

In the controller familiarisation assignment you were introduced to the concept of
computer initialisation of the 38-300, via the serial link. This was discussed primarily in
terms of one-way communication, but it is in fact two-way.
When your personal computer sends a command to the 38-300 containing information
about a particular parameter, the 38-300 will acknowledge the reception of this data by
sending a signal back to the computer.
The signal returned to the computer contains the a number of the parameter that has
been set, along with a checksum called a cyclic redundancy check, known as CRC for
short. The computer calculates the same checksum as the one that is transmitted from the
controller. If they do not match, this indicates that an error has occurred during
transmission.
In control systems, it is very important that the correct operational parameters are set and
reported. If an error is present, this may cause problems within the process that is being
controlled, potentially causing a dangerous situation.
Since the communication is two way, rather than tell the 38-300 what a particular
parameter should be, your computer can also ask for a parameter from the process
controller.
In this way, variables monitored by the 38-300 can be displayed by your computer. This
practical will demonstrate the read facility so that you will be familiar with it for later
practicals.
This practical will take the output from the current source on the PI and use it as a process
variable input to the 38-300 controller. Your personal computer will monitor this process
variable continuously, allowing the value of the current (Percentage) to be observed as
you vary it by hand on the data logger.
As the assignments develop and the need to monitor variables increases, the computer,
with its virtual instrumentation, will play a greater and greater part.
As well as the data logger displaying a parameter graphically, there is also a trackbar
facility. This enables you to change a parameter value by varying the position of a bar with
your mouse. The value you set on the control bar is displayed in the small upper window,
and this value is sent to the 38-300.
Both of these display facilities are shown in the practical. Having completed it, you will
then be familiar with a personal computer as a control tool in a process system.
38-004
Chapter 4
The computer offers the following to the user:

It initialises the 38-300 by setting up a number of its parameters.
It reads operational parameters, such as the set point and process variable, displaying
them in a number of ways, depending on requirements
Allow the user to directly alter parameters and observe their effect by observing the
process or by monitoring the process variables using virtual instrumentation.
Note: Not all parameters can be set by computer (for security reasons).
Questions
1
In this practical you have met two virtual instruments that are
used when controlling a process with your computer. Briefly
outline the different facilities that a computer offers to process
control; include which direction communication is passing, and
between whom.
What type of controller is the 38-300, and what is the nature of

the subservient relationship between controller and computer.
Why are there steps in the curve being drawn by the chart
recorder? What are these steps dependent on? How could the
size of the steps be reduced, how could the curve be made
smoother?
38-004
Block Diagram
38-004
Chapter 4
Chapter 4
38-004
Practical 2
Chapter 4
Reading the 38-300
Perform Practical
The controller has been set up automatically. If an error occurs during initialisation, check
the serial communication links and ensure that the controller is set to the manual
operation mode.
Open the data logger and bar display.
The data logger shows the Pressure Transmitter output/controller input (blue), controller
output/current to the DDM (orange) and set point value (yellow).
Slowly, vary the current source output from the PI and observe the response on the data
logger display (blue). This is displaying the process variable input to the 38-300.
The upper control trackbar is controlling the set point level of the 38-300 (yellow).
Ensure that the 38-300 is showing the set point in the SP (Green LED) display. Change
this track bar setting and observe its effect on the set point level in the 38-300.
The lower control trackbar is controlling the output of the 38-300 (orange). This output is
being fed to the DDM. Change the setting of this track bar and observe the effect, as read
by the DDM.
From your observations of the data logger, consider whether you need to adjust the 'level
7' settings you have checked within the previous practical.
Note: If the output or set point values are changed using the up/down keys on the 38-300
then the trackbars will remain at the value set when last used although the data logger
display will show the change.
38-004
Chapter 4
38-004
Chapter 5
The Pressure Sensor and Transmitter

Objectives
To learn how to calibrate the pressure sensor and pressure transmitter and to investigate
the linearity and hysteresis of the sensor/transmitter.
38-004

and Transmitter
Chapter 5
The Pressure Sensor

A Pressure Sensor may be used to give a remote reading of pressure in a system. This
feature will be used in later experiments to enable the level to be controlled automatically.
It is necessary to calibrate an electrical sensor (with its conditioning circuit) before use to
provide an output that is meaningful.
The Pressure Sensor may be calibrated to suit the operating range and datum required for
a particular application.
The sensor supplied has an output that changes linearly with change in pressure, and
hysteresis is small. Note that this characteristic will not apply to all Pressure Sensors used
in process control.
Resolution of the Pressure Sensor is much finer than the Bourdon gauge that is
designed for indication of approximate pressure only.
For accuracy in operation, a Pressure Sensor should be calibrated using a manometer or
dead weight calibrator.
38-004
Chapter 5
Practical 1 Pressure Sensor and Transmitter Calibration

This practical demonstrates the procedure used to calibrate the pressure sensor and
transmitter. This procedure should be carried out before using the pressure sensor in any
practical in order to maintain accurate results.
38-004

and Transmitter
Chapter 5
The Pressure Sensor
Block Diagram
38-004
38-004
Chapter 5

and Transmitter
Practical 1
Chapter 5
The Pressure Sensor
Pressure Sensor and Transmitter Calibration
Perform Practical
Set R1 and R2 to closed, V2 open and all other valves closed.
The aim of this experiment is to calibrate the Pressure Sensor and Transmitter to give
the following conditions.
Minimum pressure = 0 psi = 4mA output from the Pressure Transmitter.
Maximum pressure = 10psi = 20mA output from the Pressure Transmitter
Note: The Pneumatic Control Valve is designed to open with lack of air. With R1 closed
and the I/P Converter disconnected, the valve will remain open.
If an accurate Manometer or Digital Pressure Gauge is available this may be connected
underneath the Bourdon gauge (G5) to allow a more precise calibration to be performed.
(Note that the connection is a 1/4 inch push-fitting).
With R2 closed, the pressure in the system will be atmospheric (ie the minimum required,
0 psi on gauge G5 or 0 mm differential on the manometer). Use a small screwdriver or
trim tool to adjust the zero control on the Pressure Transmitter to give a reading of 4mA or
0% on the Digital Display Module.
Open valve V4. Set the pressure in the system to the maximum required (10.0psi on
gauge G5 or 414mm on the manometer) by adjusting valve R2. When the pressure is
steady, adjust the span control on the Pressure Transmitter to give a reading of 20mA or
100% on the Digital Display Module.
Repeat the minimum and maximum settings until no further adjustments of the zero and
span controls is required.
38-004
Chapter 5
Practical 2 Linearity and Hysteresis

Having calibrated the Pressure Sensor and Transmitter in the previous practical, this
practical involves examining the linearity of the output over the operating range from
minimum to maximum pressure.
38-004

and Transmitter
Chapter 5
The Pressure Sensor
Block Diagram
38-004
38-004
Chapter 5
Chapter 5
The Pressure Sensor

and Transmitter
Practical 2
Linearity and Hysteresis
Perform Practical
Print out the blank table found below to record your results.
Pressure (psi)
0
2
4
6
8
10
Rising Pressure
Falling Pressure
Do not exceed a reading of 30psi on Gauge G5 as sensor damage could occur.

Adjust the pressure in the system in steps of 2 psi from 0 psi to 10 psi indicated on gauge
G5. Alternatively, if using a Mercury Manometer, adjust the pressure in steps of 50mm
from 0mm to 515mm differential reading on the manometer. (Note: 1mmHg = 0.01934 psi)
Record the pressure and corresponding output from the Pressure Transmitter at each
step.
Repeat for reducing pressure in the system to investigate the hysteresis in the sensor.
Plot the input pressure versus the output pressure to determine the linearity and
hysteresis.
Perform further experiments by repeating the procedures outlined for different minimum
and maximum pressures in the system.
38-004
Chapter 5
Do not exceed a reading of 30psi on Gauge G5 as sensor damage could occur.

Please refer the Familiarisation Assignment for more information.
38-004
Chapter 6
The I to P Converter
Objectives
To learn how to calibrate the Current/Pressure (I/P) Converter to operate the Pneumatic
Control Valve and investigate the linearity and hysteresis of the converter.
38-004
Chapter 6
A Pneumatic Control Valve requires a current to pressure converter to change the
electrical signal from the control circuit to a corresponding pressure which can actuate the
valve.
It is necessary to calibrate a current to pressure converter before use to provide the
appropriate output to a Pneumatic Control Valve.
In this pneumatic control system, the equivalent of the 4 to 20mA electronic signal is 3 psi
to 15 psi.
The Pneumatic Control Valve should not be used in applications where total shut-off is
required. An additional Isolating or Stop valve should be used. Note that this characteristic
will apply to the majority of proportional control valves used in process control.
The I/P Converter provides a largely linear conversion from current input to pneumatic
output. Hysteresis is small.
38-004
Chapter 6
Practical 1 The I to P Converter

The aim of this experiment is to calibrate the I/P Converter to position the Pneumatic
Control Valve, which is designed to open with lack of air with the following characteristics:
4mA to converter = 3 psi from converter (on G2) = Pneumatic Control Valve open
20mA to converter = 15 psi from converter(on G2) = Pneumatic Control Valve closed
38-004
Chapter 6
Block Diagram
38-004
38-004
Chapter 6
Practical 1
Chapter 6
Perform Practical
Ensure the following is set:
R2, V1, V3, V5 & V6 Closed .
R1, V2 & V4 Open
Adjust R1 to give a reading of 25 psi on gauge G1
For this demonstration the 38-300 Process Controller will be used in Manual operation
mode to operate the I/P Converter.
Calibration of the controller is not required.
This practical requires that the controller is switched on and correctly connected to the
computer.
The controller will have been automatically intialised by starting this practical.
The below track bar control emulates the output control that can be accessed by the
controls on the front of the controller.
To perform the practical, carry out the following steps:
Remove the plastic stoppers which seal the zero and span adjusting controls on the I/P
Converter. Note the span control on the I/P Converter is called Range.
Adjust the zero output on the I/P Converter to give a reading of 3 psi on gauge G2. The
Pneumatic Control Valve should be just on the point of starting to close. This could be
described as a braced position.
Adjust the output from the Process Controller to 100% by using the track bar.
Adjust the span (range) control on the I/P Converter to give a reading of 15 psi on gauge
G2. The Pneumatic Control Valve should be just fully closed.
Replace the plastic stoppers on the zero and span controls.
38-004
Chapter 6
Check the operation of the Pneumatic Control Valve.

With the output from the controller set to 0%, adjust valve R2 until a reading of 10 psi is
indicated on gauge G5. Valve V2 should be open, all other valves should be closed.
Adjust the output from the Process Controller to 100%.
Observe that the pressure in the system falls to zero with the valve closed.
Adjust the output from the controller to intermediate settings (e.g. 40% and 60%) and
observe the change in valve position and the change in pressure on gauge G5.
Note: The Pneumatic Control Valve is not designed to isolate totally when in the closed
position. A small amount of air will leak past the valve seat and from the system.
An Isolation or Stop Valve is required to completely remove leakage. The small amount of
air bleeding through the valve causes the float in the flow meter to attempt to lift very
slightly and a clicking noise can be heard from the flow meter.
38-004
Chapter 6
Practical 2 The I to P Converter Linearity and Hysteresis

The aim of the practical is to investigate the linearity and hysteresis of the I/P Converter.
38-004
Block Diagram
38-004
Chapter 6
Chapter 6
38-004
Practical 2
Chapter 6
The I to P Converter Linearity and Hysteresis
Perform Practical
Ensure the following is set:
R2, V1, V3, V5 & V6 Closed .
R1, V2 & V4 Open
Adjust R1 to give a reading of 25 psi on gauge G1
For this practical the 38-300 Process Controller will be used in Manual operation mode
to operate the I/P Converter.
Calibration of the controller is not required.
This practical requires that the controller is switched on and correctly connected to the
computer.
The below track bar control emulates the output control that can be accessed by the
controls on the front of the controller.
Ensure that the controller output is set to 0% (4mA).
Confirm that the corresponding output from the I/P Converter is 3 psi on gauge G2.
Adjust the controller output from 0% to 100% in steps of 10% and record the
corresponding pressure from the I/P Converter on gauge G2. Repeat for reducing inputs
to the I/P Converter.
Record the observations using the results table found below then plot the input versus the
output for rising and falling inputs to determine the linearity and hysteresis of the I/P
Converter.
Note: The pressure gauge used to perform this experiment has a stated accuracy of only
3% of full scale.
Results Table
Controller Output (%) Increasing G2 psi Decreasing G2 psi
10
38-004
Chapter 6
20
30
40
50
60
70
80
90
100
38-004
Chapter 7

Objectives
To demonstrate manual operation of the Pneumatic Control Valve and to determine its
characteristics (pressure/position).
38-004

Valve
Chapter 7
The Pneumatic Control

The plug-type valve provides a fine adjustment of flow through the valve and is ideal for
the purpose of pressure control.
A 4-20mA control signal may be used to open or close a valve to any intermediate
position. This facility to operate a valve remotely allows a process to be controlled
automatically when the valve is connected to an appropriate sensor and controller.
Although the Pneumatic Control Valve supplied does not have a truly linear
characteristic, it is satisfactory for control purposes at the operating pressure suggested.
As the pressure is increased, the relationship becomes less linear.
The control valve must be carefully selected to give the correct characteristics over the
normal range of operation.
38-004
Chapter 7
Practical 1 Characteristics of the Pneumatic Control Valve

The Pneumatic Control Valve comprises a plug type valve operated by a pneumatic
actuator which receives a 3 to 15 psi pneumatic signal from a Current to Pressure
Converter.
The most useful characteristic of the control valve is the relationship between current input
to the I/P Converter and pressure in the process pipe downstream of the valve.
The relationship between current input and corresponding process variable is relevant in
control applications.
The aim of this practical is to demonstrate how the valve may be opened or closed to any
intermediate position using a 4-20mA current and to obtain the characteristics of pressure
versus position.
38-004

Valve
Chapter 7
Block Diagram
38-004
38-004
Chapter 7

Valve
Practical 1
Chapter 7
Characteristics of the Pneumatic Control Valve
Perform Practical
The Process Controller is factory calibrated in the following way:
Span 100% represents 20mA input or output
Zero 0% represents 4mA input or output
The Pressure Sensor and Transmitter are calibrated in the following way:
0 psi at G5 produces 4mA from Pressure Transmitter, representing 0% of range
10 psi at G5 produces 20mA from Pressure Transmitter, representing 100% of range
Calibration of the controller is not required. This practical requires that the controller is
switched on and correctly connected to the computer.
Complete the following steps:
Set V1, V3 & V6 Closed.
Set V2, V4 & V5 Open.
Adjust R1 to give 25psi on gauge G1.
Adjust R2 to give 10 psi on gauge G5 with the Pneumatic Control Valve open.
Before starting the practical ensure that the controller is operating in manual mode. This is
shown by the orange M displayed in the bottom LED display of the controller.
Open the data logger and bar display. These display the PV value from the process
controller (blue) and the output from the controller (yellow).
The Pneumatic Control Valve should now be fully open as the control output is 0%.
Observe the bottom LED display which should show 0.
38-004
Chapter 7
To perform the practical, complete the following steps:

Check that the maximum pressure is 100% on the process variable display of the
controller (10 psi on gauge G5). If not adjust R2.
Close the Pneumatic Control Valve by setting the controller output to 100% (20mA).
Check that the process variable falls to 0% (0 psi on gauge G5).
Adjust the position of the valve in steps of 10% from 0% to 100% by adjusting the
controller output manually.
At each position of the valve record the corresponding pressure on the process variable
display, data logger or bar display.
Repeat the procedure for the valve opening in steps of 10% to determine any hysteresis.
Record the observations using the results table below.
Results Table
Controller Output (%) Process Variable (%)
38-004

Valve
Chapter 7
Practical 2 Pneumatic Control Valve Characteristics at Different

Pressure Ranges
The aim of this practical is to demonstrate the change in characteristic of the Pneumatic
control valve when operated over a different range of pressures.
38-004
Block Diagram
38-004
Chapter 7

Valve
Chapter 7
38-004
Chapter 7
Practical 1 Pneumatic Control Valve Characteristics at Different

Pressure Ranges
Perform Practical
Calibration of the controller is not required. This practical requires that the controller is
switched on and correctly connected to the computer.
Complete the following steps:
Set V1, V3 & V6 Closed.
Adjust R2 to give 12 psi on gauge G5 with the Pneumatic Control Valve open.
Before starting the practical ensure that the controller is operating in manual mode. This is
shown by the orange M displayed in the bottom LED display of the controller.
The Pneumatic Control Valve should now be fully open as the control output is 0%.
Observe the bottom LED display which should show 0.
The Pressure Sensor may be recalibrated to operate over a different range, e.g. 0 to 12
psi. However, for the purpose of demonstration, the pressures may be read directly on
gauge G5 to avoid the need for recalibration.
Adjust regulator R2 to give a reading of 12 psi on gauge G5 with the Pneumatic Control
Valve fully open.
Close the Pneumatic Control Valve by setting the controller output to 100% (20mA).
Check that the process variable falls to 0% (0 psi on gauge G5).
Adjust the position of the valve in steps of 10% from 0% to 100% by adjusting the
controller output manually.
38-004

Valve
Chapter 7
At each position of the valve record the corresponding pressure on gauge G5.
Repeat the procedure for the valve opening in steps of 10% to determine any hysteresis.
Record the observations using the results table below.
Observe the change in characteristic using the data logger noting that the change from 10
psi to 12 psi operating pressure is a relatively small change.
Results Table
Controller Output (%) Process Variable (%)
0
10
20
30
40
50
60
70
80
90
100
38-004
Chapter 8
System Response and the Air Receiver

Objectives
To determine the system response with and without the Air Receiver by manually
operating the Pneumatic Control Valve.
38-004

the Air Receiver
Chapter 8
System Response and

Proportional adjustment of flow into the process pipe gives a steady pressure at the
required value provided the process characteristics remain constant, ie a change in
conditions in the system necessitates a corresponding change in valve position to
maintain the pressure.
The Pneumatic Control Valve provides proportional adjustment of flow into the process
pipe by remote operation using a 3-15 psi control signal.
Without the Air Receiver, disturbances cause the process variable to change very quickly.
With the Air Receiver in series, changes in process variable are much slower.
The Air Receiver has the effect of changing the response of the process (time constant).
38-004
Chapter 8
Practical 1 System Response without the Air Receiver

In this practical the current output from the Pressure Transmitter should be connected to
the process variable input of the Process Controller to indicate the pressure in the process
pipe as measured by the sensor.
The data logger which is found on the main practical page is used to give a clear
indication of the responses. The changes may best be observed by watching the pressure
indicated on gauge G5 (the digital changes on the process variable display may be too
rapid to observe).
The Process Controller is factory calibrated where Span 100% represents 20mA input or
output and Zero 0% represents 4mA input or output.
The Pressure Sensor and Transmitter are calibrated where 0 psi at G5 produces 4mA
from pressure transmitter, representing 0% of range and 10 psi at G5 produces 20mA
from pressure transmitter, representing 100% of range.
38-004

the Air Receiver
Chapter 8
System Response and
Block Diagram
38-004
38-004
Chapter 8

the Air Receiver
Practical 1
Chapter 8
System Response and
System Response without the Air Receiver
Perform Practical
To prepare for the practical, complete the following steps:
V1, V3, V5 & V6 Closed.
V2 & V4 Open.
Adjust R2 to give 10 psi on gauge G5 with Pneumatic Control Valve open.
Before starting the practical ensure that all connections in the patching diagram have been
carried out and the controller is operating in manual mode. This is shown by the orange M
displayed in the bottom LED display of the controller.
The object of the demonstration is to maintain the pressure of the air in the process pipe
at a preset value.
The output from the controller will have been initially set to 50% (the bottom display will
show 50) and note the corresponding process variable (pressure in the process pipe) on
the data logger and bar display when the system has settled.
Change the output from the controller to 60%. Observe the change in process variable.
Change the output from the controller to 50%. Note that the process variable returns to the
original value.
Adjust the position of the Pneumatic Control Valve to give a process variable reading of
50%, by changing the controller output. Note the output from the controller.
Open valve V5 to give additional outflow and observe the response of the process
variable.
Re-adjust the output from the controller to return the process variable to 50%.
38-004
Chapter 8
Close valve V5 and observe the response of the process variable. Adjust the controller
output to its original value of 50% and observe that the process variable returns to 100%.
38-004

the Air Receiver
Chapter 8
System Response and
Practical 2 System Response with the Air Receiver

This practical is very similar to the previous practical except the system response is
observed whilst using the Air receiver with the system.
38-004
Block Diagram
38-004
Chapter 8

the Air Receiver
Chapter 8
System Response and
38-004
Practical 2
Chapter 8
System Response with the Air Receiver
Perform Practical
To prepare for the practical, complete the following steps:
R1, R2, V1, V3, V5 & V6 Closed.
V2 & V4 Open.
Adjust R2 to give 10 psi on gauge G5 with Pneumatic Control Valve open.
Before starting the practical ensure that all connections in the patching diagram have been
carried out and the controller is operating in manual mode. This is shown by the orange M
displayed in the bottom LED display of the controller.
Fully open valve V1, open V3 and close valve V2 so that the air leaving the process pipe
travels through the Air Receiver before discharging.
The output from the controller will have been initially set to 50% (the bottom display will
show 50) and note the corresponding process variable (pressure in the process pipe) on
the data logger and bar display when the system has settled.
To perform the practical, complete the following steps and observe the slower changes in
response with the Air Receiver in series with the process pipe:
Change the output from the controller to 60%. Observe the change in process variable.
Change the output from the controller to 50%. Note that the process variable returns to the
original value.
Adjust the position of the Pneumatic Control Valve to give a process variable reading of
50% by changing the controller output value. Note the output from the controller.
Open valve V5 to give additional outflow and observe the response of the process
variable.
Re-adjust the output from the controller to return the process variable to 50%.
38-004

the Air Receiver
Chapter 8
System Response and
Close valve V5 and observe the response of the process variable. Adjust the controller
output to its original value and observe that the process variable value.
38-004
Chapter 9
Principles of Proportioning Valve

Objectives
To control pressure in the process pipe using the Pressure Sensor and three-term
Process Controller with 4-20mA proportional output to an I/P Converter and Pneumatic
Control Valve.
38-004

Proportioning Valve
Chapter 9
Principles of
Practical 1 Maintaining Pressure at a Set-Point

Pressure in the process pipe can be controlled using a Pressure Sensor and Process
Controller configured for proportional output (4-20mA) to position a Pneumatic Control
Valve as required.
Proportional control of the Pneumatic Control Valve allows the pressure to be held at the
required set point despite changes in the upstream and downstream conditions.
The pressure in the system may be changed by setting an alternative set point on the
controller. No adjustment to the process or sensor is required provided the inlet and outlet
conditions are compatible with the new setting.
The object of this practical is to maintain the pressure at the set point (50% process
variable on the controller corresponds to 5 psi on gauge G5).
38-004
Block Diagram
38-004
Chapter 9

Proportioning Valve
Chapter 9
Principles of
38-004
Practical 1
Chapter 9
Maintaining Pressure at a Set-Point
Perform Practical
This practical requires the controller control action to be set to Direct Action.
The control action can be checked, and altered if necessary, by using the front panel of
the controller. To set the controller to Direct Action carry out the following steps:
Press and hold the Parameter Advance button three times to change to the Operator
Level (LEV.1).
Press the Up button five times. Between levels 5 and 6, the Up key will have to be
pressed for slightly longer.
Press the Parameter Advance button three times to access the Control Action setting.
This is represented by the display C.ACt.
Change the setting to dIr, inidicating Direct Action.
To exit the configuration level, press and hold the Parameter Advance key to return to the
top of the level, return to Level 1 (LEV.1), then press and hold Parameter Advance once
again to return to the main display.
Many practicals require the controller to operate in Automatic mode. When the controller is
controlling a process in Automatic mode, the properties of the process rig and
characteristics of different control algorithms can be explored.
Changing between Manual and Automatic mode is a simple matter of pressing the
Auto/Manual button.
The object of the demonstration is to maintain the pressure at the set point (50% process
To maintain a steady pressure in the process pipe, the Pneumatic Control Valve must be
opened to the appropriate position by the Process Controller and continually adjusted to
compensate for changes upstream or downstream in the system.
The Air Receiver has been included in the circuit to give a slow response to the process.
To setup the practical, perform the following steps:
Complete the connections shown in the patching diagram.
38-004

Proportioning Valve
Chapter 9
Principles of
R1, R2, V2, V5 & V6 Closed.

V1, V3 & V4 Open.
Adjust R2 to give 10 psi on gauge G5 with Pneumatic Control Valve open (Controller
output set to zero). The Air Receiver pressure will begin to rise towards 10psi.
output/current to pressure converter input 4-20mA loop (yellow) and set point value
(orange).
This practical has initialised the Process Controller, setting the Set Point at 50%, the
Proportional Band to 300%, Integral Action time to 5 Seconds and Derivative Action Time
turned off.
When ready, set the controller to automatic mode, by pressing the automatic/manual
button. The M shown in the bottom display should disappear.
If the set-up is correct, air should be delivered to the process pipe and discharge at the
outlet with the pressure remaining at 50% (process variable).
Observe that the pressure is controlled at the set point.
38-004
Chapter 9
Practical 2 Effects of Disturbance

This practical is the same as the previous but this time a disturbance will be exerted on
the system and the effect of this observed.
38-004

Proportioning Valve
Chapter 9
Principles of
Block Diagram
38-004
38-004
Chapter 9

Proportioning Valve
Practical 2
Chapter 9
Principles of
Effects of Disturbance
Perform Practical
Ensure that you have performed the previous practical.
Level (LEV.1).
Auto/Manual button.
38-004
Chapter 9

V1, V3 & V4 Open.
Adjust R2 to give 10 psi on gauge G5 with Pneumatic Control Valve open. The Air
Receiver pressure will begin to rise towards 10psi.
(orange).
turned off.
Observe that the pressure is controlled at the set point.
Open valve V5 to give an additional outflow from the system.
Observe the response of the system. The Pneumatic Control Valve will open to give the
required additional flow of air to maintain the pressure in the process pipe at the set point.
Close valve V5. Observe the response as the Pneumatic Control Valve closes to maintain
the pressure.
Observe the changes in air flow on the flow meter.
38-004

Proportioning Valve
Chapter 9
Principles of
Practical 3 Changing the Set-Point Remotely

This practical is the same as the previous practicals but this time the set point of the
system is changed remotely by using the track bar provided. The effect of this change
should be observed to understand how the system response to this sudden change.
38-004
Block Diagram
38-004
Chapter 9

Proportioning Valve
Chapter 9
Principles of
38-004
Practical 3
Chapter 9
Changing the Set-Point Remotely
Perform Practical
Ensure that you have performed the previous practical.
Level (LEV.1).
Auto/Manual button.
38-004

Proportioning Valve
Chapter 9
Principles of

V1, V3 & V4 Open.
Adjust R2 to give 10 psi on gauge G5 with Pneumatic Control Valve open. The Air
Receiver pressure will begin to rise towards 10psi.
(orange).
turned off.
In the basic set-up, the pressure is controlled about a mean value of 50% which
corresponds to 5 psi on gauge G5.
Adjust the set point to 70% on the Process Controller using the track bar below.
Observe how the pressure changes to the required setting and the position of the
Pneumatic Control Valve varies to suit the conditions.
Adjust the set point to 40% on the Process Controller.
Once again, observe the changes in the level and the valve operation.
38-004
38-004
Chapter 9
Chapter 10
Proportional only Process Control

Objectives
To demonstrate the characteristics of a Proportional (P) only Process Control and the
response to a change in set point or a disturbance in the process.
38-004

Process Control
Chapter 10
Proportional only

As the process variable deviates from the set point, the output from the controller will
change in an attempt to restore the process variable to the set point.
A small setting of Proportional Band means a large change in controller output (large
movement of the valve) for a small deviation from the set point.
If the setting of the Proportional Band is too small, the control loop will be unstable and
continuous large scale oscillation of the control valve will occur.
If the setting of the Proportional Band is too large, the process variable will be offset from
the set point by a large amount.
The controller centralises the Proportional Band about the set point. If a new set point is
instructed by the operator, the controller will produce an output of 50% (12mA) when the
process variable matches the new set point.
The operator can offset the output to give accurate control of the process by setting the
system up manually before transferring to Automatic Control.
Changing from Automatic to Manual
Changing from Automatic to Manual (operator) control, as described within other
assignments is a simple matter of pressing the Automatic/Manual button located on the
third row, second column of the controller. The M LED will disappear when the controller is
controlling the process.
Any changes in the process (e.g. change in outflow from the process tank) will result in an
offset from the set point. Any offset applied to the controller output will be transferred if a
new set point is instructed, i.e. the output will be centralised about the new set point but
offset by the amount of offset at the previous set point.
The optimum setting of Proportional Band is the smallest setting which will allow the
process to operate with minimum offset while not allowing the system to become unstable.
38-004
Chapter 10
Practical 1 Proportional Control- Removing Offsets

The object of the demonstration is to control the pressure in the process pipe using a Ponly controller to operate the Pneumatic Control Valve.
38-004

Process Control
Chapter 10
Proportional only
Block Diagram
38-004
38-004
Chapter 10

Process Control
Practical 1
Chapter 10
Proportional only
Proportional Control - Removing Offsets
Perform Practical
The controller fitted in the 38-300 has an option for the removal of offsets in proportional
only systems.
This option is known as manual reset and allows the operator to reduce the offsets to
zero by offsetting the proportional band between 0 and 100% in 1% increments.
The Manual Reset option will only function when no Integral Action has been selected.
This would have been set when this practical is fully initialised.
To view the Manual Reset setting on the controller:
Press and hold the Parameter Advance button until CoDE is displayed.
Press twice to move to level 1, the operators setting level, (LEV.1).
Press the green Raise button to move the Tuning level (LEV.2).
Finally, press the Parameter Advance button four times until rSt.1 is displayed. This is
the manual reset value.
This setting is only used when the controller is running in Automatic mode. When set to
manual mode, a default is used.
On the process rig set valves V1, V3 and V6 to closed and valves V2, V4 and V5 to open.
Set G1 to 25psi using R1 and G5 to 10psi using R2
Initialisation has set the Proportional Band to 300% and set the Set Point to 50%, and
turned the Derivative Action off.
Open the data logger and bar display. The data logger shows the Pressure Transmitter
output/controller input (blue), controller output/current to pressure converter input 4-20mA
loop (yellow) and set point value (orange).
To perform the practical and to consider how the manual reset function operates, the
following steps must be followed:
38-004
Chapter 10
Adjust the manual reset option until the measured value is 50%, hence there is no offset.
Change the set point to 40% and observe the effect on offset. Notice the offset has
returned. Hence we have shown the manual reset option only reduces the offset for a
given set point. Moving the set point requires the operator to make an adjustment to the
amount of normal reset.
Return the set point to 50% and observe the offset is removed using the procedure
previously outlined.
Close valve V4 and observe the effect on the offset. Adjust the manual reset until the
offset is reduced to zero. We have shown that when there is a change in demand in the
process the controller requires manual adjustment to reduce the offset in a Proportional
only system.
Reduce the Proportional Band to 200% and observe the effect on the offset. Notice the
offset is unaffected by the changed PB.
Reduce the Proportional Band to 80% and open valve V4 to introduce a step response
on the system. Observe the oscillating response from the process. The effect can be
heard from the noise of the expelled air and seen on the bar display. With these settings
the system may not settle.
Increase the Proportional Band to 400% and close valve V4. Once the system has
settled, open valve V4. Notice how less oscillatory the process is.
38-004

Process Control
Chapter 10
Proportional only
Practical 2 Proportional Control- Effects of Disturbance

The aim if this practical is to control the pressure in the process pipe using a P-only
controller to operate the Pneumatic Control Valve and then introduce a disturbance to the
system and observe the effect of this.
38-004
Block Diagram
38-004
Chapter 10

Process Control
Chapter 10
Proportional only
38-004
Practical 2
Chapter 10
Proportional Control- Effects of Disturbance
Perform Practical
This practical follows on from the previous practical, the Proportional Band has again
been set to 300% and the Set Point set to 50%.
The controller fitted in the 38-300 has an option for the removal of offsets in proportional
only systems.
This option is known as manual reset and allows the operator to reduce the offsets to
zero by offsetting the proportional band between 0 and 100% in 1% increments.
The Manual Reset option will only function when no Integral Action has been selected.
This would have been set when this practical is fully initialised.
To view the Manual Reset setting on the controller:
Press and hold the Parameter Advance button until CoDE is displayed.
Press twice to move to level 1, the operators setting level, (LEV.1).
Press the green Raise button to move the Tuning level (LEV.2).
Finally, press the Parameter Advance button four times until rSt.1 is displayed. This is
the manual reset value.
This setting is only used when the controller is running in Automatic mode. When set to
manual mode, a default is used.
On the process rig set valves V1, V3, V4 and V6 to closed and valves V2 and V5 to open.
Set G1 to 25psi using R1 and G5 to 10psi using R2.
Initialisation has set the Proportional Band to 300% and set the Set Point to 50%, and
turned the Derivative Action off.
Open the data logger and bar display. The data logger shows the Pressure Transmitter
output/controller input (blue), controller output/current to pressure converter input 4-20mA
loop (yellow) and set point value (orange).
When ready ensure the controller is set to automatic mode, by pressing the
automatic/manual button. The M shown in the bottom display should disappear.
38-004

Process Control
Chapter 10
Proportional only
Adjust the manual reset option until the measured value is 50%, hence there is no offset.
Open valve V4 a little to give a disturbance to the process.
Observe the response of the system. The Pneumatic Control Valve will open to give
additional inflow to maintain the pressure at the set point.
Observe the offset from the set point.
Return valve V4 to its original position. Observe the response as the Pneumatic Control
Valve closes to maintain the pressure. Observe that the pressure returns to the set point.
38-004
Chapter 10
Practical 2 Proportional Control - Effects of Changing the Set Point

The aim if this practical is to see the effect of changing the set point whilst in manual and
automatic mode. It should be seen that in manual mode the output can be adjusted so
that no offset is seen between the measured value and a particular set point. When set to
automatic mode this should remain the same, if a new set point is selected whilst in
automatic mode an offset will be observed at the new set point.
38-004

Process Control
Chapter 10
Proportional only
Block Diagram
38-004
38-004
Chapter 10

Process Control
Practical 3
Chapter 10
Proportional only
Proportional Control - Effects of Changing the Set Point
Perform Practical
This practical follows on from the previous practical.
Open data logger and bar display.
(orange).
Initially the Set Point is set to 50%. You are required to change the controller output using
the front panel, and change the controller between Automatic and Manual mode.
To perform this practical, carry out the following steps:
In Automatic mode, adjust the Set Point to 70% on the Process Controller using the track
bar or UP/DOWN keys.
The Pneumatic Control Valve will open to increase the flow into the process pipe to
compensate for the increased pressure requirement. Observe that the pressure does not
achieve the revised set point.
Adjust the Set Point to 30% on the Process Controller. Once again, observe the changes
in the pressure and the valve operation.
Adjust the Set Point to 50% on the Process Controller.
Observe that the pressure returns to the Set Point.
Change the controller to Manual mode. Manually adjust output from the controller to
maintain the process variable at 70%.
Set the controller to Automatic operation and observe that offset from the Set Point is
removed.
38-004
Chapter 10

Observe that the process variable is offset from the Set Point.
38-004

Process Control
Chapter 10
Proportional only
Practical 4 Proportional Control - Effect of Changing the Proportional

Band
This practical explores the effect of changing the Proportional Band. It demonstrates that
offset can be reduced as proportional band is reduced (higher gain) up to a point after
which further reduction causes the system to become unstable.
38-004
Block Diagram
38-004
Chapter 10

Process Control
Chapter 10
Proportional only
38-004
Practical 4
Band
Chapter 10
Proportional Control - Effect of Changing the Proportional
Perform Practical
This practical follows on from the previous practicals.
(orange).
Set the Proportional Band to 200% on the controller using the track bar.
To perform this practical, carry out the following steps and observe the reduction in
offsets:
Adjust the output in manual mode so that the PV is equal to the Set point (50%).
In Automatic mode, adjust the Set Point to 70% on the Process Controller.
The Pneumatic Control Valve will open to increase the flow into the process pipe to
compensate for the increased pressure requirement. Observe that the pressure does not
achieve the revised set point.
Observe that the pressure returns to the Set Point.
Change the controller to Manual mode. Manually adjust output from the controller to
maintain the process variable at 70%.
Set the controller to Automatic operation and observe that offset from the Set Point is
removed.
38-004

Process Control
Chapter 10
Proportional only

Observe that the process variable is offset from the Set Point.
Repeat the steps above but with the Proportional Band set to 150% on the controller and
observe the reduction in offsets.
Repeat the steps above again but with the Proportional Band to 120% on the controller.
Observe that the process has become unstable, i.e. the Proportional Band setting is too
small.
Where an offset is observed try to reduce the proportional band further in small
increments until oscillation is seen. Because no set point change is introduced it should be
possible to use a proportional setting much lower than above, before the process
oscillates.
38-004
Chapter 11
Proportional + Integral Action Process Controller

Objectives
To demonstrate the characteristics of a (P + I) Proportional + Integral Action Process
Controller and the response to a change in set point or a disturbance to the process.
38-004

Action Process Controller
Chapter 11
Proportional + Integral

Integral Action will remove offsets from the set point which occur with Proportional
control.
Correction is applied to the output from the controller while any deviation from the set
point exists.
A short setting of Integral Action Time (IAT) means greater Integral Action effect on the
output from the controller. (The output is corrected more frequently).
The amount of correction applied to the output by the Integral Action is related to the
Proportional Band setting. (A large Proportional Band means a smaller correction due to
the Integral Action).
Increasing the time constant of the system makes the process more oscillatory and
increases the setting time.
Note: Short settings of the Integral Action Time can be used in the pressure control
demonstration to give fast correction of large offsets because the system responds quickly
to changes.
Effects of Integral Action Time
In a process where disturbances take a long time to affect the process variable, the
amount of Integral Action must be limited (ie use longer Integral Action Time) to avoid
problems of saturation.
If the IAT setting is too small, extreme actuation of the control valve will occur before the
process has responded to initial valve adjustments. 38-100 and 38-600 involve processes
with longer response times and may be used to demonstrate this feature.
38-004
Chapter 11
Practical 1 P + I Control and Effects of Disturbance

The object of this practical is to control the pressure in the process pipe using a P+I
controller to operate the Pneumatic Control Valve.
38-004

Chapter 11
Block Diagram
38-004
38-004
Chapter 11

Practical 1
Chapter 11
P + I Control and Effects of Disturbance
Perform Practical
As the Pneumatic Control Valve is open when 4mA is applied to the current/pressure
converter and a pressure below the set point requires the valve to be opened, the Process
Controller should be configured for Direct action.
Level (LEV.1).
Set R1, R2, V1, V3 & V6 to Closed.
Set V2, V4 & V5 to Open.
Adjust R1 to give 25psi on G1.
Adjust R2 to give 10psi on G5 with the Pneumatic Control Valve open.
The controller is initialised for a Proportional Band of 300% and 5 secs Integral Action
Time.
38-004
Chapter 11
(orange).
To perform the practical, carry out the following steps:
Allow the system to settle with no deviation.
Close valve V4 further to give a disturbance to the process.
Observe the response of the system. The Pneumatic Control Valve will close to reduce
the pressure at the set point. Observe that the initial offset from the set point is gradually
removed as the Integral Action moves to the required position.
Now open V4 and observe the system responding by increasing the airflow until the
pressure is returned to the set point.
38-004

Chapter 11
Practical 2 Effects of Changing the Set Point

This practical explores the effect of changing the set point when the system is under
proportional and integral control.
38-004
Block Diagram
38-004
Chapter 11

Chapter 11
38-004
Practical 2
Chapter 11
Effects of Changing the Set Point
Perform Practical
the controller.
To set the controller to Direct Action carry out the following steps:
Level (LEV.1).
The controller is initialised for a Proportional Band of 300% and 5 secs Integral Action
Time.
38-004

Chapter 11

(orange).
When the process has stabilsed:
Observe the initial response due to Proportional Action followed by the gradual
correction due to Integral Action.
Adjust the Set Point to 50% on the Process Controller and allow the process to settle at
the Set Point.
38-004
Chapter 11
Practical 3 Effects of Changing the Integral Action Time

This practical explores the effect of changing the integral action time for the system when
it is under proportional and integral control.
38-004

Chapter 11
Block Diagram
38-004
38-004
Chapter 11

Practical 3
Chapter 11
Effects of Changing the Integral Action Time
Perform Practical
Level (LEV.1).
(orange).
38-004
Chapter 11
In this practical, change the Integral Action Time to 1 second on the controller using the
track bar control. Observe the reduced effect of the Integral Action (the effect is the same
but the time taken to reduce the offset is decreased).
The effect of the Integral Action Time can be observed by following the below steps that
were seen in the previous practical.
Observe the response.
Adjust the Set Point to 30% on the Process Controller. Once again, observe the changes.
Adjust the Set Point to 50% on the Process Controller and allow the process to settle at
the Set Point.
38-004

Chapter 11
Practical 4 Effects of Changing the Proportional Band

This practical explores the effect of changing the proportional action for the system when it
is under proportional and integral control. It should be seen that besides the reduced
offset due to proportional action being reduced (higher gain), that the amount of correction
applied by integral action is increased also.
38-004
Block Diagram
38-004
Chapter 11

Chapter 11
38-004
Practical 4
Chapter 11
Effects of Changing the Proportional Band
Perform Practical
Level (LEV.1).
(orange).
38-004

Chapter 11
Set the Proportional Band to 200% and the Integral Action to 5 seconds on the
controller if they are not already.
Apply a disturbance to the process by changing set point or closing V4 and observe the
response of the process.
Besides the reduced offset due to Proportional Action observe that the amount of
correction applied by Integral Action is increased.
Open valves V1 & V3 and close V2 to connect the air receiver. Observe the effect of this
while repeating the above.
38-004
Chapter 12
Proportional + Derivative Action Process Controller
P + D Control of Pressure
Objectives
To demonstrate the characteristics of a (P + D) Proportional + Derivative Action Process
Controller and the response to a change in set point or a disturbance to the process.
38-004

Derivative Action Process Controller
Chapter 12
Proportional +

Derivative Action cannot reduce offsets from the set point which result with Proportional
control.
Correction is applied to the output from the controller whenever the process variable is
changing. (The faster the process variable changes, the larger the amount of correction
due to Derivative Action).
A short setting of Derivative Action Time means less Derivative Action effect on the
output of the controller. (Any correction applied to the output lasts for a shorter period of
time).
The amount of correction applied to the controller output by the Derivative Action is related
to the proportional Band setting. (A large Proportional Band means a smaller correction
due to the Derivative Action).
Note: Short settings of the Derivative Time may be applied to this pressure process for the
purpose of demonstration provided the setting of the Proportional Band is not too small.
Effects of Derivative Action
If the Derivative Time setting is too long, the corrections to the control valve will be
excessive and the process will be unstable.
Derivative Action is usually applied to processes which have a slow reaction rate,
moderate lags and small changes in load to the process.
The large initial correction to the control valve allows the process to stabilise more quickly.
The 38-100 Basic Process Rig and 38-600 Temperature Process Rig involve processes
with longer response times and may be used to demonstrate this feature.
38-004
38-004
Chapter 12

Chapter 12
Proportional +
Practical 1 Effects of Disturbance

The object of the demonstration is to control the pressure in the process pipe using a P+D
controller to operate the Pneumatic Control Valve and to observe the effect of a
disturbance on the system.
38-004
Chapter 12
Block Diagram
38-004

Chapter 12
Proportional +
38-004
Practical 1
Chapter 12
Effects of Disturbance
Perform Practical
To set-up the equipment for this practical, perform the following steps:
Set R1, R2, V1, V3 & V6 Closed.
(orange).
The controller is set with a Proportional Band of 200% and a Derivative Action Time of
6 seconds from the initialisation of this practical.
Close valve V4 further to give a disturbance to the process.
Observe the response of the system as the Pneumatic Control Valve closes to reduce the
pressure at the set point. Observe the large initial closing of the control valve occurs as
the process variable moves away from the set point followed by an opening of the valve as
the process variable approaches the set point. Note that the offset from the set point is not
removed by the Derivative Action.
Return valve V4 to its initial position. Observe the response as the Pneumatic Control
Valve opens to maintain the pressure. Observe that the large movements of the control
valve as the process variable moves away from and towards the set point.
38-004

Chapter 12
Proportional +
Practical 2 Effect of Changing the Set Point

This practical explores the effect of changing the set point when the system is under
proportional and derivative action control.
38-004
Chapter 12
Block Diagram
38-004

Chapter 12
Proportional +
38-004
Practical 2
Chapter 12
Effect of Changing the Set Point
Perform Practical
(orange).
Adjust the Set Point to 70% on the Process Controller using the track bar.
Observe the initial response due to Derivative Action followed by the conventional
response due to the Proportional action. Note once again that the deviation from the set
point is not corrected.
38-004

Chapter 12
Proportional +
Practical 3 Effects of Changing the Derivative Time

This practical explores the effect of changing the derivative action time when the system
is under proportional and derivative action control. By adjusting the Set Point value the
effect of increasing the Derivative Action (the effect is the same but the time taken for the
valve to return to the position dictated by the Proportional setting is increased) on the
system can be observed.
38-004
Chapter 12
Block Diagram
38-004

Chapter 12
Proportional +
38-004
Practical 3
Chapter 12
Effects of Changing the Derivative Time
Perform Practical
(orange).
Adjust the Derivative Action Time in steps of +1 each time.

Adjust the Set Point values from 70% to 30% and from 30% to 70% to observe the
increased effect of the Derivative Action (the effect is the same but the time taken for the
valve to return to the position dictated by the Proportional setting is increased).
Repeat the steps above until the process becomes unstable. This will happen at a setting
of approximately 8 or 9.
38-004

Chapter 12
Proportional +
Practical 4 Effect of Changing the Proportional Band

This practical explores the effect of changing the proportional band setting has on the
derivative action when the system is under proportional and derivative action control. To
observe the effect a disturbance is introduced to the system by opening valves V6 and V7
or a change of the set point.
38-004
Chapter 12
Block Diagram
38-004

Chapter 12
Proportional +
38-004
Chapter 12
Practical 4 Effect of Changing the Proportional Band

Perform Practical
(orange).
Ensure the Proportional Band is set to 200% and the Derivative Action Time is set to 6
seconds.
Apply a disturbance to the process by opening valves V6 and V7 or change the set point.
Besides the reduced offset due to Proportional Action observe that the amount of
correction applied by Derivative Action as it is increased.
Experiment with the settings to gain a full understanding of the effects of changing the
proportional band on a system under P + D control.
Note: The data logger window may need to be maximised in order to see the full effect.
38-004

Controllers
Chapter 13
Optimising Proportional Integral and Derivative
Optimising Proportional Integral and Derivative Controllers

Objectives
To demonstrate typical procedures for optimising the settings of a three-term controller to
suit a particular process.
To use widely used field methods for optimising the P, I and D settings on the controller to
suit the characteristics of the process.
In this instance the Ultimate Period/Ziegler-Nichols (closed loop) and Reaction Curve
(open loop) methods will be used.
38-004
Chapter 13
Optimising

Proportional Integral and Derivative Controllers
Practical 1 Ultimate Period/Ziegler-Nichols

Techniques exist which allow the settings of a three-term controller to be determined to

suit a particular process.
The settings predicted by these techniques will differ and should be treated as a starting
condition for the setting up of the controller.
Satisfactory control may be obtained from these settings but the commissioning engineer
may need to make fine adjustments to obtain the required operating characteristics.
The object of this experiment is to use one of those widely used field methods for
optimising the P, I and D settings on the controller the suit the characteristics of the
process.
In this case the Ultimate Period/Ziegler-Nichols (closed loop) method will be used.
To carry out the Ziegler-Nichols method all integral and derivative action should be
removed from the control. Then a small disturbance in the loop needs to be created, either
by opening or closing a valve or changing the set point. The proportional action should be
increased and/or decreased, until oscillations are produced that have a constant
amplitude. The value of the gain Kc and period of oscillation Pc should be recorded and
used with the table below to give the settings for either PI or PID control of the closed loop
system.
ZieglerNichols method
Control Type
Kc
TI
TD
2 Pb
PI
2.2 Pb
Pc /1.2
PID
1.7 Pb
Pc / 2
Pc / 8
With the pressure rig it may be found that the oscillations are too fast for the period to be
determined on the data logger.
38-004

Controllers
38-004
Chapter 13

Chapter 13
Optimising
Block Diagram
38-004

Controllers
38-004
Chapter 13

Practical 1
Chapter 13
Optimising
Ultimate Period/Ziegler-Nichols
Perform Practical
To setup this practical, perform the following steps:
Adjust R1 to give 25 psi on G1.
Adjust R2 to give 5 psi on G5 with V2 open and V4 closed.
Open the data logger.
The data logger shows the Pressure Transmitter output/controller input (blue).
Data for the analysis is obtained using the controller configured for Proportional control
only.
Integral and Derivative settings on the controller will have been turned off (zero) when this
practical has initialised.
To complete the practical, perform the following steps:
Allow the process variable to settle then apply a step change to the process by closing
valve V4
As the process variable remains steady, decrease the Proportional Band (Pb) and re-apply
a step change (by opening V4).
Continue adjusting the Proportional Band and applying a step change until the process
variable continually oscillates. Note the setting of the Proportional Band at which continual
cycling occurs.
From the trace obtained on the data logger, measure the Period of the oscillation Pc in
minutes by using the capture option and the delta measuring facility.
The optimum settings for the controller may be calculated using the table below:
38-004
Chapter 13

Controllers
ZieglerNichols method
38-004
Control Type
Kc
TI
TD
2 Pb
PI
2.2 Pb
Pc /1.2
PID
1.7 Pb
Pc / 2
Pc / 8

Chapter 13
Optimising
Practical 2 Reaction Curve Method

The object of this experiment is to use one of the widely used field methods for optimising
the P, I and D settings on the controller the suit the characteristics of the process. In this
instance, the Reaction Curve (open loop) method will be used.
A typical response curve is shown below:
This method requires a straight line be drawn through the point of maximum slope so that
the line intersects the time axis.
Measure the dead time L in minutes. (Time at which step change is applied to time where
straight line intersects time axis). Calculate the maximum slope R
Determine R1 using the equation:
38-004

Controllers
Block Diagram
38-004
Chapter 13

Chapter 13
Optimising
38-004

Controllers
Practical 2
Chapter 13
Reaction Curve Method
Perform Practical
The data logger shows the Pressure Transmitter output/controller input (blue) and
controller output current to the pressure converter input (yellow).
When setup is complete and the practical has started, perform the following steps:
Set the controller for Manual operation.
Adjust the output from the controller to give a steady pressure in the system with the
process variable display showing 50%.
Leave the controller in Manual operation and apply a step disturbance to the process by
changing the position of the Pneumatic Control Valve slightly. This can be done either by
selecting the 60% output button below or by manual entry. Note the step change applied
(M%).
The step change will result in a new pressure in the system. The open loop response may
be analysed from the data logger to determine the optimum settings for P, I & D.
The optimum settings for the controller may be calculated as follows:
P only
PI
PID
38-004
PB = R1 x L
PB = 1.1 (R1 x L)
PB = 0.5 (R1 x L) to
0.8 (R1 x L)
IAT = 3.0 L
IAT = 2.0 L to
2.5 L
DAT = 0.3 L to
0.5 L

Chapter 13
Optimising
Calculate the optimal controller settings using the equations and information from the
background page.
Compare the values obtained with those obtained using the Ziegler-Nichols method. See
the previous practical for details.
38-004

Controllers
Chapter 13
Practical 3 Evaluation of Controller by Introducing a Disturbance

In this practical the operating settings that have been discovered in previous practicals will
be used. The effect on these control settings will be observed to see what occurs when a
disturbance is introduced to the process.
38-004

Chapter 13
Optimising
Block Diagram
38-004

Controllers
38-004
Chapter 13

Practical 3
Chapter 13
Optimising
Evaluation of Controller by Introducing a Disturbance
Perform Practical
For this practical you will need the settings obtained in the previous practical.
Set V1, V3 & V6 to Closed.
Set R1, R2, V2, V4 & V5 to Open.
The data logger shows the Pressure Transmitter output/controller input (blue).
Perform the following steps:
Enter the settings of P, I and D to be evaluated on the Process Controller using the track
bars.
Set the Set Point to 50%.
Set the controller to Manual operation and adjust the valve position to maintain the
required set point (50% process variable, 4 psi on G5).
Set the controller to Automatic operation then apply a disturbance by opening valve V4.
Observe the behaviour of the process.
Repeat the procedure for the settings of the controller suggested by the other technique.
38-004

Controllers
38-004
Chapter 13
Chapter 14
PID Controller with the Air Receiver

Objectives
To demonstrate the effect of the Air Receiver on the response of the process and to
determine the optimum settings for the Process Controller.
38-004

Air Receiver
Chapter 14
PID Controller with the
Practical 1 System Response

In this practical addition of the Air Receiver makes the response of the system
correspondingly slower. (Pressure cannot change as quickly in the process pipe when a
disturbance occurs or a new set point is instructed).
Any change in the response of a process will necessitate a change in the settings of the
three terms on the controller to achieve optimum control.
Where the response of a process will change in operation, the controller must be
configured to give stable control under all operating conditions.
This may necessitate a reduction in performance at some conditions.
38-004
Block Diagram
38-004
Chapter 14

Air Receiver
Chapter 14
38-004
Practical 1
Chapter 14
System Response
Perform Practical
To perform the practical, setup the equipment using the following steps:
Connect the equipment as shown in the patching diagram with the Air Receiver in series
with the process pipe.
Adjust R2 to give 5 psi on G5 with the Pneumatic Control Valve open.
output/current to pressure converter input 4-20mA loop (yellow).
The Set Point of the system has been set to 50%.
Observe the response of the system when valve V4 is opened and closed to give a
disturbance.
Isolate the Air Receiver from the process pipe by opening V2 and closing V1 and V3.
Apply a disturbance to the new configuration and observe the change in response.
38-004

Air Receiver
Chapter 14
Practical 2 Determining Optimum Settings for the Process Controller

In this practical the Ziegler-Nichols and Reaction curve methods of PID control tuning will
be applied to the two systems from the previous practical. It will be shown that the settings
used for the system with the Air Receiver in series produce a unstable system when the
Air Receiver is removed from the system.
38-004
Block Diagram
38-004
Chapter 14

Air Receiver
Chapter 14
38-004
Practical 2
Chapter 14
Determining Optimum Settings for the Process Controller
Perform Practical
Using the techniques described in the previous assignment, determine the optimum
settings for the three-term controller to suit the two systems from the previous practical.
Apply the optimum settings for each system and evaluate their responses using valve V4
to apply a step change to the outflow from the system.
The data logger shows the Pressure Transmitter output/controller input (blue) and
controller output/current to pressure converter input 4-20mA loop (yellow).
Observe that the process becomes unstable if the settings relating to the Air Receiver in
series are applied to the process without the Air Receiver.
38-004

Transmitter
Chapter 15
Calibration of the Differential Pressure Sensor and
Calibration of the Differential Pressure Sensor and Transmitter

Objectives
To calibrate the Differential Pressure Sensor and Differential Pressure Transmitter.
38-004

Chapter 15
Calibration of the
Practical 1 Calibration of the Differential Pressure Sensor and

Transmitter
A Differential Pressure Sensor may be used to give a remote reading of the differential
pressure in a system.
It is necessary to calibrate an electrical sensor before use to provide an output which is
meaningful.
The Differential Pressure Sensor may be calibrated to suit the operating range and datum
required for a particular application.
The readings obtained can be related to actual flow rates from the flowmeter.
The aim of this experiment is to calibrate the Differential Pressure Sensor/Transmitter to
suit the process.
The Differential Pressure Sensor is connected to the tappings upstream and
downstream of an Orifice Block located in the process pipe.
Pressure drop across the Orifice Block is related to the flow of air in the pipe (pressure
drop is proportional to the square of the flow). The aperture in the Orifice Block is 1.5mm
in diameter.
The flowmeter installed on the 38-714 allows the relationship between the actual flow rate
and the output from the sensor to be considered.
The sensor and transmitter can be calibrated to the minimum and maximum conditions of
flow through the pipe so as to be of use in control applications (the corresponding real
values of the flow being known from the flowmeter reading).
38-004

Transmitter
Block Diagram
38-004
Chapter 15

Chapter 15
Calibration of the
38-004

Transmitter
Chapter 15
Practical 1 Calibration of the Differential Pressure Sensor and

Transmitter
Perform Practical
For this set of demonstrations the controller will be used manually to operate the control
valve via the I/P Converter and to monitor the differential pressure in the process pipe.
Set R1, R2, V1, V3, V4 & V5 to Closed.
Set V2, V6 and V7 to fully open.
Adjust R2 to give 15 psi on G4 with the Pneumatic Control Valve open (Set the controller
to Manual operation and open the control valve by setting output to 0%).
Adjust V7 to give 5 psi on G5.
Re-adjust R2 and V7 until G4 reads 15 psi and G5 reads 5 psi.
There should be a pressure difference of 10 psi between G4 and G5.
To perform the calibration, follow the below steps:
The Pneumatic Control Valve is designed to open with lack of air. With 4mA input to the
I/P Converter, the valve will remain open.
The controller should be set to Manual operation and the control valve open with the
output set to 0%.
Adjust the span on the differential pressure transducer to give 100% reading on the
controller.
38-004

Chapter 15
Calibration of the
Increase the controller output to close the control valve until the flow is zero, gauge G5 will
read 0 psi. Use the trim tool supplied with 38-300 to adjust the zero control on the
Differential Pressure conditioning module to give a reading of 4.0mA on the Digital Display
Module.
Set the flow in the system to the maximum required by opening the Pneumatic Control
Valve (pressure process variable should return to 100%). When the flow is steady, adjust
the span control on the Differential Pressure conditioning module to give a reading of
20.0mA on the Digital Display Module.
The Differential Pressure Sensor/Transmitter has now been calibrated to give readings
from 4-20mA (0-100% if used with the Process Controller) corresponding to the range of
flow rates available in the process pipe.
38-004
Chapter 16
Flow Control in the Process Pipe

Objectives
To control flow in the process pipe using a Differential Pressure Sensor/Orifice Block with
square root extractor and three-term Process Controller with a 4-20mA proportional output
to an I/P Converter and Pneumatic Control Valve.
38-004

Process Pipe
Chapter 16
Flow Control in the
Controller Advanced Settings

The ABB Commander 350 process controller contains a large number of features that are
not immediately accessible.
There is a simple reason for hiding some features and making others easily available.
Parameters such as P, I and D will be familiar to all process control engineers.
Using the ABB Commander 350, it is possible to 'fine tune' the controller so that it can
successfully control processes in situations where the input (and output) signals are not
linear.
Advanced users can change the signals that the PID controller receives and produced by
applying a mathematical function. This is achieved using a feature called a 'maths block'.
Normal users of a process controller will want to access common parameters, like the PID
and offset settings. The more intricate settings of the controller are hidden from immediate
view, preventing them to be changed accidentally.
To allow your controller to be configured easily and securely, ABB has created a separate
pathway to the controller settings.
This pathway is separate from the serial communication pathway which is used to obtain
the state of a process and change the main operational parameters.
This separation is made for safety reasons.
A potentially dangerous situation could arise if the linearity setting is changed during the
middle of a process. The issue of safety and security can again be seen in the 'level'
scheme that the controller adopts where only the highest most important levels can be
changed when the controller is in manual mode.
Controller settings can be changed by using a special Configurator program, developed
by ABB.
This software requires a special cable that connects the controller to the computer using
the circular jack plug located at the rear of the controller.
38-004
Chapter 16
Using the Configurator Software

To use the ABB Configurator software a configurator cable is required.
The cable should be connected to a PC Com port (RS232) and the other end to the
controller config connector on the rear of the 38-300 Process Controller.
Follow the manufacturers instructions on installing the Configurator software.
This practical requires the Square Root Lineariser to be used.
This is one of many different linearisers that can be used with the Commander 350
controller.
When the Configurator software has started and has found the Procon controller
(remember to check the number of the communications port if problems arise), select the
Advanced Level option, shown in the bottom right of the display. When the advanced
options are displayed, select the Maths Block option.
A representation of the maths block dialog is shown below.
Ensure that the Maths Block 1 type is set to Square Root, and the Square Root Source
is set to Analogue Input 1. When you are happy with the settings, transfer them to the
controller. Be careful to only change the parameters you need to change.
A skilled process control engineer who is familiar with computer controls will always know
how to return to a known 'good' setting.
Important! The controllers memory is non-volatile, meaning it remembers its settings
when the power is turned off. When you have finished using the practicals within this
38-004

Process Pipe
Chapter 16
Flow Control in the
assignment, the lineariser must be turned off. If you forget to do this, other users may
observe behaviour that may be difficult to understand!
38-004
Chapter 16
Practical 1 Maintaining a flow by using the Control Valve


Flow in the process pipe can be measured using a Differential Pressure Sensor
connected to an Orifice Block.
As the pressure drop across the Orifice Block changes with the square of the velocity, the
output from the Differential Pressure Sensor is highly non-linear. The output from the
Transmitter can be linearised using a square root extractor to provide a signal which is
proportional to flow.
Flow in the process pipe can be controlled using a flow sensor/conditioner and Process
Controller configured for proportional output (4-20mA) and square-root extraction to an I/P
Converter to position a Pneumatic Control Valve as required at the inlet to the pipe.
Proportional control of the pneumatic control valve allows the flow to be held at the set
point without the undue oscillations which are inherent in an on/off control system.
The flow in the pipe may be changed by setting an alternative set point on the controller.
No adjustment to the process or sensor is required provided the inlet and outlet conditions
are compatible with the new setting.
The object of this practical is to maintain the flow at mid range in the process pipe (50%
set point) by adjusting the opening of the Pneumatic Control Valve to allow the required
amount of air to flow through the pipe.
38-004

Process Pipe
Chapter 16
Flow Control in the
Block Diagram
38-004
38-004
Chapter 16

Process Pipe
Practical 1
Chapter 16
Flow Control in the
Maintaining a flow by using the Control Valve
Perform Practical
The Process Controller should be configured to use a square root linariser. To learn
about how to configure the controller to use a lineariser, refer to the concepts and
backgrounds sections, and the controller instruction manual for more information.
If the Process Controller has been configured for the square root linariser ensure the
Configurator software has been closed and the cable disconnected from the Process
Controller.
To prepare for this practical, carry out the following steps:
Complete the connections shown in patching diagram.
Set R1, R2, V1, V3, V4, &V5 Closed.
V2, V6 & V7 (fully open) Open.
Adjust R2 to give 20 L/min on the flow meter with the Pneumatic Control Valve open (Set
the controller to Manual operation and open the control valve fully by setting output to
0%).
Change the controller using the front panel to Automatic mode.
For this demonstration, the Process Controller is configured for three-term control. The
Set Point is set to 50%, and a Proportional Band of 300%, the Integral Time is set to 1
Seconds and the Derivative Time is set to 6 seconds.
(orange).
If the set-up is correct, air should discharge from the main orifice. The flow should remain
at 50% (process variable). Observe that the flow is controlled at the set point.
38-004
Chapter 16
Practical 2 Operation of Square Root Extractor

In the practical the effect of the square root extractor will be demonstrated. The output
from the differential pressure transmitter will be plotted against flow with the square root
option set on the process controller.
38-004

Process Pipe
Chapter 16
Flow Control in the
Block Diagram
38-004
38-004
Chapter 16

Process Pipe
Practical 2
Chapter 16
Flow Control in the
Operation of Square Root Extractor
Perform Practical
To prepare for the practical, perform the following steps:
Open valves V2, V4, V5, V6 & V7 (fully open).
Close valves V1 & V3.
With the control valve fully open (Set the controller to Manual operation and open the
control valve fully by setting output to 0%) adjust the flow rate to 20 L/min. This should
give a pressure drop of about 10 psi across the orifice plate (G4 - G5 = 10 psi).
Set the span on the differential pressure transmitter to 100%.
Reduce the flow to zero and set the zero on the differential pressure transmitter to 0%.
With the controller in manual mode set the o/p to 0%.
(orange).
Increase the output in steps of 10% up to 100%.
Record the process variable display on the controller and the actual flow rate on the flow
meter. Repeat the reading with the square root extraction option turned off. Plot the two
sets of data flow against process variable.
Print out the blank table below to record your results.
Results Table
Table 1
Controller O/P Flow L/min Process Variable %
0
10
20
38-004
Chapter 16
30
40
50
60
70
80
90
100
Table 2
Controller O/P Flow L/min Process Variable %
0
10
20
30
40
50
60
70
80
90
100
38-004

Process Pipe
Chapter 16
Flow Control in the
Practical 3 Changing the Set Point Remotely

In this practical changes in set point value when using the Differential Pressure
Sensor/Orifice Block with square root extractor are investigated.
Also the flow process may be studied in detail by following the procedures detailed in the
Proportional Only to the Three-Term Controller assignment.
Optimum controller settings and effects of the Air Receiver may also be investigated.
38-004
Block Diagram
38-004
Chapter 16

Process Pipe
Chapter 16
Flow Control in the
38-004
Practical 3
Chapter 16
Changing the Set Point Remotely
Perform Practical
In the basic set-up the flow was controlled about a mean value of 50%.
(orange).
Change the controller using the front panel to Automatic mode.
Adjust the Set Point to 60% on the Process Controller by using the track bar control.
Observe how the flow changes to the required setting and the position of the Pneumatic
Control Valve varies to suit the conditions.
in the flow and the valve operation.
If required, the flow process may be studied in detail by following the procedures detailed
in the Proportional Only to the Three-Term Controller assignment.
Optimum controller settings and effects of the Air Receiver may also be investigated.
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Appendices
Using the Test Equipment

General Notes
Any of the instruments can be resized and moved at any time using conventional dragand-drop mouse techniques. If you make an instrument small enough then only the
display area will be shown; you must increase its size again in order to restore the
controls. If you close any of the instruments and open them again they will return to their
default settings. Each instrument has a Defaults button which returns the equipment to its
default settings (equivalent to closing and re-opening the instrument). If you want to return
all the instruments (and any other resource windows) to their default size and position
simply click the Auto Position button in the assignment side bar.
Some instruments allow you to place a cursor (by clicking the mouse) at any position on
their display; the cursor reveals information regarding the point at which it is located. You
will have to reactivate this cursor each time you change the settings, size or position of the
instrument.
The Voltmeter
The meter is simply an ac and dc voltmeter that displays the value in digital form. It can be
used in ac mode by clicking ac p-p, in which case the value represents the peak to peak
value. If the waveform has a high crest factor the results can be slightly surprising. In dc
mode, if there is an ac component present, the average value is displayed.
The Data Logger

This displays as a moving image four channels of data much as a conventional paper data
logger / chart recorder does. The four full scale values are shown in the lower boxes. In
the example shown the full scale is 1.25 volts which means that the display is centred on
zero and the range of voltages shown is plus 1.25 volts to minus 1.25 volts. The X Cal
Rate box shows how many milliseconds between each vertical timing line. In overlay mode
all four channels are displayed on top of each other. If this mode is not selected then the
available screen height is divided separate sections for each trace.
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Appendices
In four channel mode all four channels are shown. If this mode is not selected then only
the first two channels are shown.
In order the measure exact values a capture facility is provided and is activated by the
Capture button. This displays a separate window of stationary data. Successive clicks of
the capture button overlays further traces. The Clear button clears the capture window.
Cursors are available for the capture window. The main cursor simply allows the reading
of both time and amplitude data. If the Delta cursor button is clicked a second cursor
appears and all readings for it are relative to the normal cursor.
The record facility enables the recording of results from each of the four channels. The
results obtained are saved to a .CSV type file.
To record, first select the Set file name button. Select a path where you wish to save the
recording file. Enter a new file name or select one from those available.
Note: Selecting an existing file name and clicking Save will erase the current file and all
data will be lost.
Now select Start to begin recording. Once all the data required has been recorded select
the Stop button. The recording can be restarted by selecting record again. The additional
data will be added to the existing file.
The .CSV file created will contain the name of the product you were using and practical
name and number along with the time and date the recording was started.
The first of the columns contain the time from the point of the recording starting to each of
the timing lines. After the first timing line value they will be spaced approximately by the X
Cal Rate setting.
38-004
Appendices
The other four columns contain the data from each of the channels. If no data was
recorded from a particular channel then all the entries will be zero.
If a recording was stopped and then started again the data will be separated by the name
of the product you were using and practical name and number along with the time and
date that section of the recording was started.
The Bar Display
This simply displays in real time the amplitudes of data connected to its four channels. In
bipolar mode it displays values up to its full scale value either side of zero. If this mode is
not selected it only shows positive values.
If the Show Values box is ticked then the numerical values of the data is displayed
underneath each bar.
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Appendices
Discovery System Help

Although the Discovery environment is very easy to operate, these notes will help you use
all its facilities more quickly.
If there is a demonstration assignment, slider controls in the software perform functions
that would normally be performed on the hardware. In normal assignments, if the any of
hardware systems fail to initialise the system reverts to demonstration mode. This means
that none of the test equipment is available.
The Assignment Window
The assignment window opens when an assignment is launched. If you are reading this
you have already found the help button in the side bar of the assignment window!
The assignment window consists of a title bar across the top, an assignment side bar at
the right-hand edge, and the main working area. By default, the overall assignment
objectives are initially shown in the main working area whenever an assignment is opened.
The assignment window occupies the entire screen space and it cannot be resized (but it
can be moved by dragging the title bar, and it can be minimised to the task bar). The title
bar includes the name of the selected assignment. The side bar contains the practicals
and any additional resources that are relevant for the selected assignment. The side bar
cannot be repositioned from the right-hand edge of the assignment window. An example
of an assignment window is shown below.
The precise appearance of the assignment window will depend on the skin that has been
selected by your tutor. However, the behaviour of each of the buttons and icons will
remain the same, irrespective of this.
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Appendices
The clock (if you have one active) at the top of the side bar retrieves its time from the
computer system clock.
There are a number of resource buttons available in the assignment side bar. These are
relevant to the selected assignment. In general, the resources available will vary with the
assignment. For example, some assignments have video clips and some do not. However,
the Technical Terms, Help and Auto Position buttons have identical functionality in every
assignment. You can click on any resource in any order, close them again, or minimise
them to suit the way you work.
Practicals are listed in numerical order in the side bar. When you hover the mouse over a
practical button, its proper title will briefly be shown in a pop-up tool-tip. There can be up
to four practicals in any assignment. You can have only one practical window open at any
time.
To perform a practical, left-click on its button in the assignment side bar. The assignment
objectives, if shown in the main working area, will close, and the selected practical will
appear in its own window initially on the right-hand side of the main working area, as
shown below. You can move and resize the practical window as desired (even beyond the
assignment window). However, its default size and position is designed to allow the test
equipment to be displayed down the left-hand side of the main working area without
overlapping the instructions for the practical.
Again, the precise appearance of the practical window can be determined by your tutor
but the behaviour of each of the buttons and icons will remain the same, irrespective of
this. Whatever it looks like, the practical window should have icons for the test equipment,
together with buttons for Objectives & Background, Make Connections, Circuit Simulator
38-004
Appendices
and Test Equipment Manuals. These resources are found in side bar, located on the righthand edge of the practical window. The resources will depend on which practical you have
selected. Therefore not all the resources are available in every practical. If a resource is
unavailable, it will be shown greyed out. To open any resource, left-click on its icon or
button. Note that when you close a practical window, any resources that you have opened
will close. You may open any resource at any time, provided it available during the
practical. The Circuit Simulator will only be available if you have one loaded.
Note that if the hardware is switched off, unavailable, or its software driver is not installed,
all the test equipment is disabled. However, you can open any other window. If you switch
on the hardware it will be necessary to close the assignment window and open it again to
enable the test equipment.
Resource Windows
These are windows may be moved, resized and scrolled. You may minimise or maximise
them. The system defaults to Auto Position, which means that as you open each
resource window it places it in a convenient position. Most resource windows initially place
themselves inside the practical window, selectable using tabs. Each one lays over the
previous one. You can select which one is on top by clicking the tab at the top of the
practical window. You can see how many windows you have open from the number of
tabs. If you want to see several windows at once then drag them out of the practical
window to where you wish on the screen. If you close a window it disappears from the
resources tab bar.
If you want to return all the windows to their default size and position simply click the Auto
Position button in the assignment side bar.
Make Connections Window

This movable and resizable window shows the wire connections (2mm patch leads) you
need to make on the hardware to make a practical work. Note that some of the wires
connect the monitoring points into the data acquisition switch matrix. If this is not done
correctly the monitoring points on the practical diagram will not correspond with those on
the hardware. The window opens with no connections shown. You can show the
connections one by one by clicking the Show Next button or simply pressing the space bar
on the keyboard. If you want to remove the connections and start again click the Start
Again button. The Show Function button toggles the appearance of the block circuit
diagram associated with the practical.
Test Equipment
The test instruments will auto-place themselves on the left of the screen at a default size.
You may move or resize any instrument at any time. Note that below a useable size only
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Appendices
the screen of the instrument will be shown, without the adjustment controls. Each piece of
test equipment will launch with default settings. You may change these settings at any
time. There is an auto anti-alias feature that prevents you setting time-base or frequency
settings that may give misleading displays. If auto anti-alias has operated the button turns
red. You can turn off the anti-aliasing feature, but you should be aware that it may result in
misleading displays.
You may return to the default settings by pressing the Default button on each piece of test
equipment. If you wish to return all the equipment to their original positions on the left of
the screen click Auto Position on the side bar of the assignment window.
Note that if you close a piece of test equipment and open it again it returns to its default
position and settings.
If you want more information on how a piece of test equipment works and how to interpret
the displays, see the Test Equipment Manuals resource in the practical side bar.
On slower computers it may be noticeable that the refresh rate of each instrument is
reduced if all the instruments are open at once. If this is an issue then only have open the
instrument(s) you actually need to use.
Test Equipment Cursors

If you left click on the display of a piece of test equipment that has a screen, a green
cursor marker will appear where you have clicked. Click to move the cursor to the part of
the trace that you wish to measure. If you then move the mouse into the cursor a tool-tip
will appear displaying the values representing that position. Note if you resize or change
settings any current cursor will be removed.
Practical Window
This window contains the instructions for performing the practical, as well as a block, or
circuit, diagram showing the circuit parts of the hardware board involved in the practical.
On the diagram are the monitoring points that you use to explore how the system works
and to make measurements. The horizontal divider bar between the instructions and the
diagram can be moved up and down if you want the relative size of the practical
instruction window to diagram to be different. Note that the aspect ratio of the diagram is
fixed.
Information Buttons on Practical Diagrams

On many of the symbols on the diagram you will find a button that gives access to new
windows that provide more information on the circuit that the symbol represents. Note that
38-004
Appendices
these windows are modal, which means that you can have only one open at a time and
you must close it before continuing with anything else.
A Further Information point looks like this
Probes
The practical diagram has probes on it, which start in default positions. These determine
where on the hardware the signals are being monitored.
Selecting and Moving the Probes

Probes are indicated by the coloured icons like this
If this probe is the selected probe it then looks like this
probe). You select a probe by left clicking on it.
.
(notice the black top to the
Monitor points look like this

If you place the mouse over a monitor point a tool-tip will show a description of what signal
it is.
You can move the selected probe by simply clicking on the required monitor point. If you
want to move the probe again you do not have to re-select it. To change which probe is
selected click on the probe you want to select.
You can also move a probe by the normal drag-and-drop method, common to Windows
programs.
Probes and Test Equipment Traces

The association between probes and traces displayed on the test equipment is by colour.
Data from the blue probe is displayed as a blue trace. Yellow, orange and green probes
and traces operate in a similar way. Which piece of test equipment is allocated to which
probe is defined by the practical.
Note that the phasescope shows the relative phase and magnitude of the signal on its
input probe using another probe as the reference. The reference probe colour is indicated
by the coloured square to the top left corner of the phasescope display.
Practical Buttons
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Appendices
On some practicals there are buttons at the bottom of the diagram that select some
parameter in the practical. These can be single buttons or in groups. Only one of each
button in a group may be selected at one time.
Slider Controls
Where slider controls are used you may find you can get finer control by clicking on it and
then using the up and down arrow keys on your keyboard.
38-004
Appendices
38-004
Appendices
As discussed in the previous assignment, the ABB Commander 350 Process Controller
used within the 38-300 is a universal digital microprocessor-based single loop
programmable controller, which can measure, display and control temperature, pressure,
The 38-300 accepts a large variety of input signal types:
Thermocouple (THC)
Resistance
In your case, since the 38-300 communicates with the PI, its process inputs and control
outputs are of the 4-20mA loop current type.
The 38-300 features local, remote or dual set-point, and retransmission of the set-point or
process variable.
In addition, according to user requirements, there are logic inputs and time proportioned,
voltage activated relays, labelled n.o (normally open) and n.c (normally closed).
The ABB Commander controller is equipped with control algorithms for various types of
control which were mentioned earlier. These will be illustrated in later assignments so that
you become familiar with the full capabilities of the 38-300.
The 38-300 contains analogue to digital and digital to analogue converters. The
sample time of these devices must be faster than the dynamics of the process for the
controller to operate the system reliably.
The sample time of the 38-300 for both converters is 125ms, which is much faster than
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Appendices
This assignment introduces you to further elements of the 38-300 controller including
calibration.
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