MPS PA Flow Fluid Lab PA GB
MPS PA Flow Fluid Lab PA GB
description
MPS PA Compact
Workstation Flow
Control
Fluid Lab PA
Order no.:
Status: 06/2008
e-mail: info@adiro.com
All rights reserved, including translation rights. No part of this publication may be reproduced or
transmitted in any form or by any means, electronic, mechanical, photocopying, or otherwise, without
the prior written permission of Festo.
Table of Contents
Introduction____________________________________________________________ 5
Introduction _________________________________________________________ 5
Important notes______________________________________________________ 7
2.4 Start Fluid Lab®–PA and definition of the serial port ______________ 18
3.2 Test the flow control process via the proportional valve ___________ 26
4. Test the control process with the Measuring and Control window ___ 27
4.2 Test the flow control process via the proportional valve ___________ 33
5.2 Definition of the maximum flow rate using the proportional valve ___ 44
Simulation ____________________________________________________________ 63
7. Simulation ________________________________________________ 63
Introduction The Festo Didactic learning system for process automation is designed to meet a
number of different training and vocational requirements. The systems and stations
of the learning system for process automation facilitate industry-orientated
vocational and further training and the hardware consists of didactically suitable
industrial components.
The Compact Workstation Flow Control of the learning system for process
automation provides you with an appropriate system for practice-orientated tuition
of the following key qualifications
Social competence,
Technical competence and
Methodological competence
Actual project phases can be taught by means of training projects, such as:
Planning,
Assembly,
Programming,
Commissioning,
Operation,
Maintenance and
Trouble Shooting
Training contents Training contents covering the following subjects can be:
Process Engineering
– Reading and drawing of flow charts and technical documentation
Electrical technology
– Correct wiring of electrical components
Sensors
– Correct use of sensors
– Measuring of non-electrical, process and control variables
Closed-loop controller
– Configuration, assigning operation parameters and optimization of a
Closed-loop controller
Commissioning
– Commissioning of a closed-loop system
– Commissioning of a process engineering system
Trouble Shooting
– Systematic trouble shooting on a process engineering system
– Maintenance of a process engineering system
– Operation and observation of a process
Important notes The basic requirement for safe use and trouble-free operation of
Fluid Lab®–PA is to observe the fundamental safety recommendations and
regulations.
These operating instructions contain important notes concerning the safe operation
of Fluid Lab®–PA.
Furthermore, the rules and regulations for the prevention of accidents applicable to
the place of use must be observed.
Participants must only work on the station under the supervision of an instructor.
Observe the data in the data sheets for the individual components, in particular all
notes on safety!
Electrics
Electrical connections and dis-connections are only allowed when when the power is
disconnected! Use only low voltage of up to 24 V DC.
Pneumatics
If you use pneumatic components within your system, please do not exceed the
permissible pressure of 8 bar (800 kPA). Do not switch on compressed air until you
have established and secured all tubing connections. Do not disconnect air lines
under pressure. Particular care is to be taken when switching on the compressed air.
Cylinders may advance or retract as soon as the compressed air is switched on.
Mechanics
Securely mount all components on the plate. No manual intervention unless the
system is in Stop mode. The pump can be mounted horizontally or vertically. If
mounted, the output of the pump must point upwards. For further information
please refer to the corresponding data sheet of the pump.
Process engineering
• Before filling the tanks with water, switch of the 24 VDC power supply and
disconnect the 220 (230) VAC power from the socket
• The use of tap water in quality of drinking water (recommended), ensures a
prolonged maintenance-free operation of the system (proportional valve and
pump).
• The maximum operating temperature of the tanks must not exceed +50 °C.
• Do not operate the heating unit unless the heating element is fully immersed in
fluid.
• Do not operate the piping system with a system pressure higher than 0,5 bar.
• Do not operate the pump without fluid, running dry or used for sea water or
contaminated fluids.
• Please empty fluids from the system (tanks, piping, close valves) before you
make changes at the piping system.
• It is possible to drain the fluids inside the Fluid Lab®–PA by opening the manual
hand valve V205
Fluid Lab®–PA general The Fluid Lab®–PA software in combination with the EasyPort digital/analog offers
information you the possibility to measure and analyze the signals of 8 digital and 4 analog
inputs.
The electrical control interface (E/A Syslink and analog terminal) is the same like for
MPS.
With the Compact Workstation of the learning system for process automation you
have the possibility to work with the following closed loop process:
By using the simulation environment with the continuous loop control you can
simulate the following functions:
1. Installation of Please insert the Fluid Lab®–PA CD in the drive and start the setup. Please follow the
Fluid Lab®–PA instructions on the screen to install the following software packages in different
languages:
The EcOCX driver is needed for the communication between Fluid Lab®–PA software
and EasyPort digital/analog via the serial interface RS 232.
During the installation process you are prompted whether to install EzOCX or not. If
you choose “no”, you are able to run the installation process of EzOCX manually by
opening the Setup.exe in EzOCX sub-folder.
© ©
Because Fluid Lab®–PA is developed with LabVIEW of National Instruments the
software uses a runtime environment to be executed on your system.
©
During the installation process you are prompted whether to install the LabVIEW
Runtime Environment or not. If you choose “no”, you are able to run the installation
©
process of LabVIEW runtime environment manually by clicking the
“LVRunTimeEng.exe” in “Runtime-Engine 71” sub-folder.
1.1 User name and On the back side of the CD there is a sticker which mentiones the exact user name
license key and license key which have to be inserted into the corresponding installation
window.
Please make sure, that you put the exact phrase of the user name. For example the
sticker looks like:
you must put the entire phrase of License 2#4 for GUC, Cairo, Egypt as the user
name.
You are able to change the license status by editing the “FGB.ini” file manually with
Notepad.exe e.g. after the successful installation of Fluid Lab®–PA. This file can be
found in the main installation folder.
1.2 Change the text Fluid Lab®–PA is designed with multi language support. The displayed window and
appearance popup text are available in the languages mentioned below.
The text in the different Fluid Lab®–PA windows can be changed. Use an editor like
©
Microsoft Editor e.g. The relevant files are located in subdirectories of the
Fluid Lab®–PA directory and differ by their suffix (file name extension):
Every line starts with a number and a following text. It is recommended not to
change the layout. only edit the text behind the colon. Please use short text only.
Please note that the length of the text must not exceed about 54 signs. If the text is
longer it will be cut off.
Fluid Lab®–PA provides a “Pop up” function, which helps you to orientate with every
single component on the window. If you move the mouse over a component and
leave it there a text will come up to give you information about the component. The
©
pop up’s are collected in a text file which can be opened with Microsoft Editor for
example. The relevant files are located in the same subdirectories than the windows
text mentioned one page before but have a different suffix (file name extension) -
popup.eng for English language for example.
To change the text, please proceed like mentioned one page before for the windows
text.
To change the text for the proportional valve for example please (see picture below)
edit the line “21A4” in the popup text file.
2. Preparation of the After unpacking the Compact workstation, please proceed to set-up the system as
workstation follows:
1 EasyPort DA (interface)
2 I/O terminal SysLink (XMA2 is part of the workstation)
3 Analog terminal (X2 is part of the workstation)
4 PC data cable RS 232
5 SysLink cable
6 Analog cable, 15-pin parallel
The power supply 24 VDC has to be connected to the interface – 24V + at the
+
EasyPort where the brown cable must be connected to and the blue to -
2.2 Fill up the tank 201 After all cable connections have deen done, please fill the tank 201 with 10 liter of
water. Please switch off the 24 VDC power supply and disconnect the 220 (230 VAC)
power line from the socket during the filling process.
2.3 Close of the manual Please close all manual hand valves within the system as shown within the picture
hand valves as an example for V101.
2.4 Start Fluid Lab®–PA Please connect the 24 VDC power supply and switch it on and start the
and definition of Fluid Lab®–PA software. The following window will appear (of course with a different
the serial port user name).
(If the message EASYPORT – no communication appears, please enter the Setup
menu) Setup
(Check your COM port you are using at your computer – must corresponding to the
COM port in the left upper corner. If you use another serial port than COM 1, please
open the serial port menu, otherwise please proceed with the next screen shot on
the next page) COM ? (click on COM 1 to get the list of available serial ports)
COM 1 (choose the correct COM port – for example COM 2)
(Click onto the symbol to save the setup) (choose the name default) OK
Close the Fluid Lab®–PA program window) X
(Restart Fluid Lab®–PA) (if your COM port is correct, there will be a connection
between the computer and the EasyPort and the message
EASYPORT – no communication
disappears and the Status LED on the EasyPort is blinking short time off and long
time on).
3. Test the process Test the process means to activate the different actuators and check the reaction on
with the Setup the analog sensor (Channel 1). The following digital and analog in- and outputs will
menu be used for this projects:
(If the connection between the computer and the EasyPort is ok, please enter the
menu Setup again) Setup
3.1 Test the flow We are going to activate the pump analog and pump water from tank 201 to
control process tank 201 (circulation) and watch if the analog sensor value changes (flow sensor
Channel 1). Please open the manual valves V201 and V203 to proceed.
(Pre-select the output 2 = 1 to be able to activate the pump analog and set the
analog value to the pump to 6,0 V - Analog Output 1. Watch the Channel 1 signal,
which should increase as the output voltage to the pump increases.
(After finish the test, please switch the analog output voltage to the pump to 0 Volt,
deactivate the pump analog Output 2 = 0 and close all manual valves)
3.2 Test the flow We are going to activate the pump digitally and the proportional valve analog and
control process via watch if the analog sensor value changes (flow sensor Channel 1). Please open the
the proportional manual valves V201 to proceed.
valve
(Pre-select the output 4 = 1 to be able to activate the proportional valve analog, set
the analog signal to the proportional valve to 5,0 V - Analog Output 0 and activate
the Output 3 = 1 to switch the pump on digitally and watch the Channel 1 signal,
which should increase as the output voltage to the proportional valve increase. After
the test is finished, please set analog signal to the proportional valve to 0 V, the
Outputs 3 = 0 and Output 4 = 0 and close the manual valve).
4. Test the control Instead of using the Setup window to test the different control process, we are going
process with the to use the window of Measuring and Control to proceed according to the exercises of
Measuring and 3.1 to 3.2
Control window
Please activate the window Measuring and Control
4.1 Test the flow We are going to activate the pump analog and pump water from tank 201 to
control process tank 201 (circulation) and watch if the analog sensor value changes (flow sensor
Channel 1). Please open the manual valve 201 and V203 to proceed.
(Start the process) Start (activate the manipulated value of the analog pump)
Contr.val.ON (watch the flow sensor signal) (stop the process) Contr.val.OFF
Stop (delete the actual screen) Delete (close the valve 104)
4.2 Test the flow We are going to activate the pump digitally and the proportional valve analog and
control process via watch if the analog sensor value changes (flow sensor Channel 1). Please open the
the proportional manual valve accordingly to proceed.
valve
(Pre-set the value to the proportional valve to 5,0 V at the Analog Output 0)
(Start the process) Start (activate the manipulated value of the analog
proportional valve) Contr.val.ON (watch the flow sensor signal) (stop the
process) Contr.val.OFF Stop (delete the actual screen) Delete (close the
valve 109)
5. Definition of the So far we have been working only with analog voltage signals of 0 – 10 V without
factors for the focussing on the real process value of l/min for the flow process.
process variables
To do so, we have to calculate the relation between the analog voltage signals and
the real process variable. We are going to do that using the Setup menu.
Umax Process represents the maximum analog sensor signal we can reach with the
workstation
Xmax Process represents the maximum process variable we can reach with the
workstation (later we need that information by using the industrial
controller DR 19)
Umax 10 V
f factor - represents the relation between the voltage signal and the
process variable
5.1 Definition of the Using the flow control, the relation of the voltage signal of the flow sensor and the
flow rate factor process variable has to be defined by an experiment and calculated.
Umax Process in [V] represents the flow sensor signal at Channel 1 using the
maximum power of the pump (digital Output 3 = 1)
Xmax Process in [l / min] represents the maximum flow rate with the workstation
which has to be defined by an experiment and calculated
Xmax in [l / min] represents the maximum flow rate if the flow rate sensor
would have a 10 V signal
Xmax = f * Umax
Remark:
To do this experiment, we have to have another MPS PA station connected
because we have to measure the amount of water per 1 minute. In the tank of the
other station must be an exactly defined level of water in the tank for example
3 liter as a defined starting point!!!
To do the experiment, we will pump water from tank 201 to a tank 102 of the Level
control station for example exactly one minute. We are going to check the maximum
voltage signal of the flow rate sensor and check the height of the water reached
within this minute.
To proceed, please set the output 0 to 1 to open the valve M202 (not shown within
the picture) and start the pump digitally by switching the output 3 to 1 for exactly 1
minute. After 1 minute is over, please set the outputs 0 and 3 to 0.
Xmax = f * Umax
By the experiment we found out, that the level of water in the tank raises by
4,95 liter, by means of:
The value for Umax Process we found by the experiment (signal at Channel 1):
Umax = 10 V
f = 0,77 l / min / V
Flow control with pump 6,42 V 4,95 l / min 7,7 l / min 0,77 l / min / V
5.2 Definition of the This exercise is only important to find out the maximum flow rate by using the
maximum flow rate proportional valve activated with the maximum voltage of 10 V. The factor will be the
using the same as for the flow rate done before of course, but if we are going to use the
proportional valve industrial controller DR 19, we need to know the maximum scale level we can reach.
Please open the manual valves accordingly.
Please do the following exercise and check the voltage level at the flow sensor. We
are going to use the pump digitally, activate the valve M202 (output 0) and activate
the proportional valve with 10 V.
Please switch the output 0, 3, and 4 to 1. After the test is finished, please set the
outputs 0, 3 and 4 to 0 again.
As we can see, the maximum voltage level at the flow sensor is lower using the
proportional valve. The reason for that is, that the diameter of the valve is smaller
than the tubes.
The maximum value of 3,24 V is corresponding to the maximum flow rate of:
Flow control with pump 6,42 V 4,95 l / min 7,7 l / min 0,77 l / min / V
6. Continuous control In the following projects we are going to reaIise continuous control for the flow
process using different controller types. Please open the window of Closed loop
Control – continuous in the main menu.
We are also going to change the values of the parameters during each process,
mentioned by 1 – Start – Stop a.s.o. It is possible to start and stop the process at any
time, change the parameters and start the process again.
These steps are marked with 1 a.s.o. within the chart and with 1 – Start – Stop
a.s.o. within the table
1 - Start – Stop 2 - Start – Stop 3 - Start – Stop 4 - Start – Stop 5 - Start – Stop
P x x x x x x x x x x
I x x x x x x x x x x
PI x x x x x
PD x x x x x
PID
For the flow control, we will open and close the manual valve V201 to realise a
disturbance value.
We will not evaluate the results of the different continuous control results with the
different controllers and parameters. It is part of this project, that you find the best
control and parameters by yourself.
6.1 Continuous flow Please proceed to prepare the continuous flow control with different parameters as
control follows:
(Select manipu. (manipulated value) to A_OUT1 like it was before and change the
Actual value to 1 which represents the flow sensor signal of Channel 1)
1 - Start – Stop 2 - Start – Stop 3 - Start – Stop 4 - Start – Stop 5 - Start – Stop
1 - Start – Stop 2 - Start – Stop 3 - Start – Stop 4 - Start – Stop 5 - Start – Stop
P x x x x x x x x x x
I x 1,0 x x 2,0 x x 4,0 x x 8,0 x x n.u. x
PI x x x x x
PD x x x x x
PID
1 - Start – Stop 2 - Start – Stop 3 - Start – Stop 4 - Start – Stop 5 - Start – Stop
P x x x x x x x x x x
I x x x x x x x x x x
PI 1,0 1,0 x 2,0 2,0 x 2,0 1,0 x 3,0 0,7 x 1,0 2,0 x
PD x x x x x
PID
From step 3 onwards, we also changed the setpoint down and up to see the reaction
of the controller.
1 - Start – Stop 2 - Start – Stop 3 - Start – Stop 4 - Start – Stop 5 - Start – Stop
P x x x x x x x x x x
I x x x x x x x x x x
PI x x x x x
PD 1,0 x 1,0 2,0 x 2,0 n.u. x n.u. n.u. x n.u. n.u. x n.u.
PID
1 - Start – Stop 2 - Start – Stop 3 - Start – Stop 4 - Start – Stop 5 - Start – Stop
P x x x x x x x x x x
I x x x x x x x x x x
PI x x x x x
PD x x x x x
PID 1,0 1,0 0,1 2,0 2,0 0,1 2,0 1,0 0,1 2,0 2,0 0,05 3,0 2,0 0,1
From step 3 onwards, we also changed the setpoint down and up to see the reaction
of the controller.
The last parameter settings, which is not mentioned within the table have been:
kpr = 1,0
Ti = 2,0
Tv = 0,1
6.2 Continuous control After the optimisation of the process, please fill-in the best results you got for the
evaluation flow control process within the following table:
The process evaluation defined the following optimised parameters and controllers:
Flow
After finishing the continuous control, please disconnect the Easyport from the
computer and close the continuous control window to prepare for the simulation.
7. Simulation Besides the close loop control of the workstation process, you are also able to
simulate several 2-step- and continuous controls. Please refer to the following page
of how to proceed.
(Disconnecting the Easyport from the computer, please open the Setup menu) Setup
(Change from EASYPORT to Simulation and close the Setup window again)
7.1 Simulation of the We are going to show you the following examples of how to proceed to simulate a
continuous control continuous control process:
with the same parameters than for the real continuous control with the workstation.
Please continue this exercise with the other controllers and parameters by yourself
as you did it for the process control of the workstation and compare the results.
(Please open the window of the continuous control to proceed) Closed loop Control
– continuous
7.1.1 Simulation of the We are going to simulate the continuous flow control process with the same
continuous flow parameters than for the real process. We will only show you how the I-control
control process has to be done. Please continue with the other controllers and parameters
by yourself and compare each result with the real process.
Remark:
the designations of the manual valves and tank numbers may vary from the real
hardware!!!
(Select the closed-loop process) Select Closed Loop (select the flow control) Flow
(Activate the simulation process by switching the Output 0= 1 and Output 2 = 1))
(Set the first parameter to 1,0 and start the process) Start
1 - Start – Stop 2 - Start – Stop 3 - Start – Stop 4 - Start – Stop 5 - Start – Stop
Please proceed with the other controls and parameters according to the following
table:
1 - Start – Stop 2 - Start – Stop 3 - Start – Stop 4 - Start – Stop 5 - Start – Stop
PID 1,0 1,0 0,1 2,0 2,0 0,1 2,0 1,0 0,1 2,0 2,0 0,05 3,0 2,0 0,1
After finishing the entire project of level control, please switch off the level control
simulation) OFF