Universal Process Control Trainer | Prozessi PX 29
The Universal Process Control Trainer Prozessi PX 29 teaches advanced process control using DCS architecture with over 25 configurable experiments. Features Honeywell HC900 controller with 8 control loops, four transmitter types, dual control valves, patch board configuration and 1 HP compressor with diaphragm pump. Supports single-loop, cascade, feedforward, ratio and MIMO control. Includes Hybrid Control Designer and SCADA software. Frame assembly 1150L x 800W x 1900H mm.
The Universal Process Control Trainer Prozessi PX 29 demonstrates industry-standard process control using DCS, SCADA and advanced control techniques. This Universal Process Control Trainer integrates temperature, flow, level and pressure control with pneumatic and electric actuation on a single configurable platform.
Product Overview
The Universal Process Control Trainer Prozessi PX 29 resembles a small industrial process plant with modular subassemblies for comprehensive control study. It uses a Honeywell HC900 hybrid controller with 8 control loops, RS232/RS485/Ethernet communication and Hybrid Control Designer software. A patch board allows configuration of over 25 different experimental setups. Components include a heating tank with RTD sensors, process tanks with transmitters, pneumatic control valves with positioners, flow sensors (rotameter, orifice, venturimeter), a 1 HP compressor with 45L receiver, a diaphragm pump with VFD, solenoid valves and I/P converters. Separate modules for heating, control, I/P conversion, water supply and flow sensing provide direct access to transmitters and control elements for external controller integration.
Universal Process Control Trainer Prozessi PX 29 — Technical Specifications
| Specification | Value |
|---|---|
| Product Code | Prozessi PX 29 |
| Control Unit | Honeywell HC900, AI 8, AO 4, DI 16, DO 16, 8 control loops |
| Communication | RS232, RS485, Ethernet |
| Software | Hybrid Control Designer, SCADA supervisory software |
| Temperature Sensors | PT100 RTD, Range 0-100°C (2 units) |
| Temperature Transmitter | PT100 2-wire, 0-100°C, 4-20 mA (2 units) |
| Flow Transmitter | DP transmitter, 0-200 mmH₂O, 4-20 mA, Square root |
| Level Transmitters | DP transmitter (0-500 mmH₂O), GPT (0-600 mmH₂O), 4-20 mA |
| Pressure Transmitter | GPT, 0-2.5 bar, 4-20 mA |
| Position Transmitter | Electronic, 4-20 mA output |
| I/P Converters | Input 4-20 mA, Output 3-15 psig (2 units) |
| Control Valves | Pneumatic, 1/2″ size, 3-15 psig, Linear and Equal % (2 units) |
| Rotameter | 40-400 LPH |
| Compressor | 1 HP, 3.8 CFM, 10 kg/cm² with 45L tank |
| Diaphragm Pump | Positive displacement, 200 LPH capacity |
| Heater | Electrical, 2 coil, 3 KW capacity |
| Overall Dimensions | 1150L x 800W x 1900H mm |
Technical Data
Transmitter and Sensing Components
| Component | Specification |
|---|---|
| RTD Sensor PT100 | Range 0-100°C, Direct immersion |
| Temperature Transmitter | 2-wire, 4-20 mA output, Range 0-100°C |
| Flow DP Transmitter | Range 0-200 mmH₂O, Square root extraction |
| Level DP Transmitter | Range 0-500 mmH₂O, Linear output |
| Level GPT Transmitter | Range 0-600 mmH₂O, 4-20 mA |
| Pressure Transmitter | Range 0-2.5 bar, 4-20 mA |
| Position Transmitter | Electronic, 4-20 mA feedback |
Actuation and Control Components
| Component | Specification |
|---|---|
| I/P Converter (2 units) | Input 4-20 mA, Output 3-15 psig |
| Control Valve (2 units) | Pneumatic, 1/2″ size, 3-15 psig, Linear and Equal % characteristics |
| Valve Positioner | Electronic feedback, 4-20 mA |
| Solenoid Valve (2 units) | 2/2-way normally closed, 1/4″ BSP |
| Heating Controller | Proportional power controller (SSR), 4-20 mA input |
| Heater Element | Electrical, 2 coil, 3 KW capacity |
Pumping and Pneumatic System
| Component | Specification |
|---|---|
| Centrifugal Pump | Fractional horsepower |
| Diaphragm Pump | Positive displacement, 200 LPH, VFD driven |
| Air Compressor | 1 HP, 3.8 CFM, 10 kg/cm², 45L receiver tank |
| VFD Drive | Single phase 200 VAC input, 1.1 A, 3-phase AC output |
Flow Measurement Devices
| Device | Range/Specification |
|---|---|
| Rotameter | 40-400 LPH direct reading |
| Orifice Meter | Differential pressure measurement |
| Venturi Meter | Differential pressure measurement |
Key Features
- Universal Process Control Trainer: over 25 configurable experimental setups
- Honeywell HC900 DCS controller with 8 control loops and 36 configurable I/O
- Patch board allows rapid experiment reconfiguration
- Four transmitter types for temperature, flow, level and pressure measurement
- Dual I/P converters and dual control valves for multi-loop control
- 1 HP compressor with 45L receiver and diaphragm pump with VFD
- Direct access to transmitters and control elements via patch board
- Single-loop, multi-loop, cascade, feedforward, ratio and MIMO control capability
- Hybrid Control Designer software with supervisory SCADA package
Experiments
- Study of I/P converter calibration and characteristics
- Study of differential pressure transmitter response
- Study of control valve characteristics and valve coefficient
- Study of valve positioner operation and tuning
- Rotameter calibration
- Orifice meter coefficient of discharge
- Venturi meter coefficient of discharge
- Interacting and non-interacting system step response
- Temperature control of direct heating process
- Flow control of pump and process outlet
- Level control by inlet and outlet flow manipulation
- Pressure control of closed tanks (air and water)
- Cascade control configurations (Level+Flow, Temperature+Flow, Level+Pressure)
- Feedforward control and feedforward plus feedback control
- Ratio control of flows
- Three-element and interactive control
- MIMO pressure and level control of interactive loops
- PLC study and control via DCS
Construction and Design
The Universal Process Control Trainer Prozessi PX 29 is assembled as modular subassemblies on a frame (1150L x 800W x 1900H mm). A heating tank module contains a 3 KW heater and two PT100 RTD sensors. A control panel module houses the Honeywell HC900 controller, power supplies and a jack plug patch board for experiment configuration. An I/P converter module contains two I/P converters and pressure gauges. A water supply module includes a centrifugal pump, 200 LPH diaphragm pump with VFD, supply tank, rotameter and solenoid valves. A control valve module holds two pneumatic valves with positioners and position transmitters. Process tanks include an SS pressure tank with pressure transmitter and a level tank with both DP and GPT level transmitters. Separate flow sensing elements (orifice, venturi, DP transmitter) and a 1 HP compressor with 45L receiver complete the assembly. The patch board provides direct access to all transmitters and control points for external controller integration.
Software
Hybrid Control Designer allows FBD (function block diagram) development and download to the HC900 controller. Supervisory SCADA software provides data access, trend plots, data logging, printing and data export. Pre-configured templates support manual and auto tuning, Ziegler-Nichols tuning, Bode plot stability analysis and multiple control strategies.
Scope of Delivery
- Universal Process Control Trainer Prozessi PX 29 complete assembly with all modules
- Honeywell HC900 hybrid controller with 8 control loops
- Heating tank with 3 KW heater and RTD sensors (2 units)
- Process tanks (pressure and level) with transmitters
- Two pneumatic control valves with positioners
- Two I/P converters with regulators and gauges
- Rotameter, orifice meter and venturi meter
- 1 HP air compressor with 45L receiver tank
- Diaphragm pump with VFD drive
- Centrifugal pump and solenoid valves
- Patch board with jack plugs and sockets
- Hybrid Control Designer software
- SCADA supervisory control software
- Temperature, flow, level and pressure transmitters
- Position transmitter and electronic feedback
- Proportional heating controller
- Power supplies and distribution panel
- Interconnecting piping and electrical cabling
- User documentation and 27 experiment procedures
Optional Accessories
- Extended patch board configuration kit
- Additional I/P converter modules
- Data logging and trending software upgrade
- PLC interface module for external controller study
Q1: How many experiments can be configured on the Universal Process Control Trainer?
A: Over 25 different experimental setups are possible using the patch board, covering single-loop, multi-loop, cascade, feedforward, ratio and MIMO control strategies.
Q2: Can external controllers be connected to the Universal Process Control Trainer?
A: Yes, the patch board provides direct access to all transmitters and control elements, allowing connection of external PLCs, DCS systems or laboratory controllers.
Q3: What control methods are supported?
A: The Universal Process Control Trainer supports on/off, proportional, PI, PID and PLC control with manual or auto tuning, open and closed loop tuning, and Bode plot stability analysis.
Q4: What types of processes can be studied?
A: Temperature, flow, level and pressure control in single and multi-loop configurations including cascade, feedforward, ratio and three-element control topologies.
Q5: Is software included?
A: Yes, Hybrid Control Designer software and SCADA supervisory control software are included with data logging, trend plotting, printing and data export features.
Need Assistance? We're Here to Help!
Connect with our team for product specifications, pricing, and customized solutions for your institution or project.
