Multiple Input/Output Process Trainer TEMPERATURE PROCESS

CONTROLLER

Panel Features:

 Power ON/OFF switch

 Heater selection switch

 Heater and pump indicators
 High current fuse carrier for
 Heater protection
 Provision to run the stirrer
 Digital panel meters
 Two numbers of industrial PID Controller
 Electrical test points are provided to measure the current signal
 Mimic Diagram

Features:

 Two numbers of flow Transmitter (DPT) are provided to sense the flow of
the liquid.
 Three numbers of temperature transmitter (RTD) are provided at various
stages to measure the temperature.
 Five numbers of level sensor (RF capacitance) are provided to sense the level
of each tank.
 Industrial type Conductivity sensor is provided to analyze the conductivity of
given Solution.
 RTD sensor (or) Thermocouple acts as a temperature sensor.
 Digital panel meters are provided to indicate the output of each sensor.
 Provision to measure the conductivity.
 Two numbers of motorized control valve or pneumatic control valve are
provided to control the flow of the pipe line.
 A powerful thyristor based power driver is provided to drive the heater
power.
 An industrial type water heater is used as a heat Source.
 Storage tank of 50 litre capacity (SS).
 Process tank of 15 litre capacity (SS).
 Four numbers of acrylic tank are provided to study the response of four tank
systems.
 In necessary location Ball valve, globe valve and needle valves are provided.
 Two numbers of stirrer are provided in the temperature process and alkaline
process.
 Three numbers of centrifugal pump (FHP) is used to circulate the water from
storage tank.
 Six numbers of rotameter are provided in the process inlet to visualize the
real flow.
 Regulated power supply is mounted in the panel.
 All the flow lines are fitted by (SS) pipe fitting.
 An over head tank is provided to give constant flow.
 All the equipments are mounted in a rugged and mobile type metallic work
station.
Analog PID Controller

The analog PID controller is a special purpose analog controller with operational
amplifiers The controller permits a detailed analysis of the application of
proportional, integral and derivative control to the improvement of their
performance. The controller may be used at high speed for oscilloscope observation
or at a low speed for meter observation.

FEATURES:

 Two analog meters (centre zero meters) to display the set variable and
process variable.

 In built regulated power supply.

 Provision to vary and measure the setpoint (0-5)V
 Provision to vary the proportional gain, Integral time and derivative gain.
 Provision to give either (4-20)mA or (0-5)V externally as a process variable.
 Provision to select the controller output as (4-20)mA or (0-5)V internally.
 All the components are mounted in an attractive cabinet.
 Interface with any realtime process (Level, Flow, Temperature, Pressure, DC
motor speed control etc.,)
IPM Based Power Module

Power Module is designed for Motor control Applications upto 3 HP by using IGBT
& DIODE Technology Based IPM. Input:1 Phase / 3 phase 50 Hz AC. Output :
400V/10A (MAX), AC/DC on each Leg of 3 phase Bridge

FEATURES:

 1200V, 25A, 3 Phase IGBT Inverter Bridge

 1200V, 10A IGBT for Over Voltage breaking

 Built - in Over Voltage, Under Voltage, Over Current & Over Temperature
Protection

ADDITIONAL FEATURES:

 1200V, 25A Converter Bridge for AC-DC power conversion

 4 Nos of Hall Effect current sensors are provided to sense the DC Link
current & 3 output current of the Inverter Bridge
 1 No of Hall Effect Voltage sensor is provided to sense DC Link voltage
 All the PWM signals are isolated using Opto Isolator
 Protection circuit for over current with LED indication
 Optically Isolated Fault signal from the IPM is given to the Embedded/DSP
controllers for protection.
 Independent Power supplies for all Isolated circuits.
 0-900V Voltmeter is provided to Indicate the DC Link Voltage
 All current, PWMS & Feedbacks are terminated at Front panel
 FRC Connectors are provided to Interface with the Embedded/DSP
controllers
 All the Input/output Lines are terminated at Banana sockets.
Level Process Controller

Features:

 It is a miniature version and occupies less space.

 A RF capacitance Level Transmitter is used to sense the tank level.

 An Industrial standard electro pneumatic converter is used to control the
control valve.
 A Pneumatic control valve is used to control the Level of the tank.
 A Process tank of 3 liter capacity with graduated level scale.
 A Rust proof reservoir tank (SS) capacity of 8 liters.
 A centrifugal pump is provided for water circulation.
 An air Regulator cum filter of capacity (0-2.1) Bar is provided to regulate the
Air pressure.
 Bypass line provision is provided to avoid pump over loading.
 Hand valve provision is provided to make the disturbance study.
  All the water flow lines are fitted by SS pipes.
 USB/Serial port data acquisition is provided.

Level Process Station

Panel Features:

 Digital Panel Meters.

 Mimic diagrams.
 Pressure gauges are provided, wherever necessary.
 Level switches are provided for overflow indication.

Features:

 The Level Process Station is an attractive module.

 All are the industrial (4-20) mA standard interfacing signals.
 It provides a real industrial feeling of the processes to the students.
  A RF Capacitance level transmitter is used to sense the level (700mm) of tank.
 An Electronic Regulated Power supply is fixed for voltage regulation.
 An Air regulator cum filter is provided to regulate the air pressure.
 An Industrial standard electro pneumatic converter is mounted to control the
control valve.
 A Globe pneumatic control valve is used to control the flow rate
 All the air flow lines are fitted by flexible hoses/fittings for better reliability.
 A Rotameter (1000 LPH) is provided for Visual Indication of flow rate.
 A Transparent Process Fiber tank (800mm) with graduated level scale.
 A Solenoid Valve is provided for Load Disturbance study.
 A Rust proof Reservoir Tank (SS) capacity of 45 Liter.
 By pass line is provided to avoid pump over loading.
 A Centrifugal Pump is used for water circulation.
 All components are fixed in a mobile rack.
 All water flow lines are fitted by SS pipes.
 USB/Serial port data acquisition is provided.

Pressure Process Station

Panel Features:

 Digital Panel Meters.

  Mimic diagrams.
 Pressure gauges are provided, wherever necessary.

Softwares

 MATLAB
 LabVIEW
 PLC
 C/VB Compatibility

Features:

 The Pressure process station is an attractive module comparing to the

Analyzer and Laboratory trainer.
 All are the industrial standard (4-20)mA interfacing signals.
 It provides a real industrial feeling of the process to the students.
 A Piezo Resistive Pressure Transmitter (0-7)Bar is used to sense the pressure.
  An Electronic Regulated Power supply is fixed for voltage Regulation.
 An electro pneumatic converter is mounted to control the pneumatic control
valve.
 A globe Pneumatic Control Valve for controlling flow of air.
 An air regulator cum filter is provided for Air regulation.
 A two separate pressure tank is provided as process tank with pressure
gauges and relief valves.
 All the air flow lines are fitted by flexible hoses/fittings for better reliability.
 Hand valve provisions are given for series, parallel connection of pressure
tanks.
 USB/Serial port data acquisition is provided.

PROCESS CONTROL THERMOCOUPLE

Process control thermocouples have applications in any manufacturing or fabrication processes requiring some type of
temperature control. One of several industries that require tight temperature control is the semiconductor wafer
fabrication. The gases used in the wafer process demand uniform heating of those supply lines. When lines are heated
unevenly, cold spots emerge and condensation is produced which contaminate the process. This requires expensive tool
downtime. If hot spots occur in the lines, the gas composition breaks down which results in production yields being
diminished. The tools that manufacture of the actual wafers require uniform temperature controls. The same controls
are necessary for the manufacturing of solar and display panels. Applying precision heater circuits utilizing process
control thermocouple for thick film fabrication applications is beneficial in reducing the overall weight of the
thermocouple assembly.

Like the semiconductor fabrication industry, chemical manufacturing requires precise temperature control and optimum
chemical mixture. A new and emerging specialty category of the chemical industry is fuel cells. Each aspect of research,
development or manufacturing requires precision measurements for temperature control and accurate fluid handling to
maximize the fuel cell operation. The most important and complex task is the control of gases. This can be handled by a
Thermal Mass Flow Controller (TMFC). The thermal mass flow controller offers the best response time, turndown
capacity and accuracy. The TMFC is connected to upstream and downstream temperature sensors. The temperature
sensor may be a thermocouple or RTD for external contact applications or thermowell type for internal, direct gas
contact.

PROCESS CONTROL RTDs

Process control RTDs (“Resistance Temperature Detectors”) are a good temperature sensor type for manufacturing or
fabrication applications. RTDs are very suitable for semiconductor wafer processing fabrication because they offer
accuracy and stability. The gases used in semiconductor wafer fabrication require the gas supply lines to be uniformly
heated to optimize gas flow. If the supply lines are heated unevenly, cold areas occur which produce condensation which
can contaminate the integrity of the gas. If hot spots occur in the lines, the gas composition can break down which
results in diminished production yields. The importance of uniform temperature control by using RTDs as the primary
temperature sensor can be critical. The same issues of temperature control exist for the manufacturing of solar and
display panels. Applying precision heater circuits utilizing RTDs as the primary temp sensor for thick film fabrication
applications is will help reduce the overall weight while keeping the cost of the process control RTD assembly down.

Chemical manufacturing, like the semiconductor fabrication industry, requires precise temperature control and optimum
chemical mixture. An upcoming and growing specialty category, new to the chemical industry is fuel cells. The fuel cell
industry is very similar to semiconductor wafer fabrication because it requires precision measurements for temperature
control and accurate fluid handling to maximize the fuel cell operation. As with wafer fabrication, the control of gases is
one of the most important and complex task in the development or the manufacturing of a fuel cell. In general, most
engineers prefer using a Thermal Mass Flow Controller (TMFC). The thermal mass flow controller provides the best
accuracy, response time and flow capacity. The TMFC works by connecting to an upstream and downstream
temperature sensor. Depending on the application, the temperature sensor for external contact type may be a
thermocouple or RTD, any internal, direct gas contact would use a thermowell.

PROCESS CONTROL TEMPERATURE SENSOR

C-Temp International has been designing and manufacturing process control temperature sensor since 1981. For over 31
years, the company has been building temperature sensors for a variety of process control industries and varying
applications from component level units to multi-functional, custom assemblies. Our specialization is custom
temperature sensor assemblies that include the use of thermocouples, RTDs (“Resistance Temperature Detectors”),
thermistors, and thermowells. We manufacturer customer’s designs by building from print or we design and build from
spec. We build our process control temperature sensor in an ISO9001 facility to meet the highest quality standards. We
primarily manufacture in the United States, however, we have contract manufacturing in China to support high volume
requirments.