INTRODUCTION

To Electric Motor Control

Group 3 Mapua University

 RULES AND STANDARDS
• National Electrical Code (NEC)
• National Electrical Manufacturer’s Association (NEMA)
• International Electrotechnical Commission (IEC)
• Underwriter’s Laboratories (UL)
• Occupational Safety and Health Administration (OSHA)
 ELECTRICAL SAFETY
• Remove all metal jewelry
• Inspect equipment before use
• Never remove the grounding prongs on AC plugs
• Keep a clean and organized workplace
• Do not work while the floor is slippery
• Move carefully
• Never work alone
• Keep focused
• Work with one hand
• Wear Personal Protective Equipment
 LOCKOUT/TAGOUT

• Lockout stops electrical systems and machines (usually for

maintenance)
• Tagout informs other employees
 GROUNDING
• The act of connecting metal parts of an electrical system to the
earth ground
• Limits the voltage of all metal parts in a system
• Reduces risk of shock
SHOCK HAZARD
 THREE-PHASE POWER

• Electrical power transmitted in three phases

• Has three windings at a 120° angle from each other
COMPARISON
 DELTA AND WYE
• Three-phase power configurations
• Both have conductors called neutrals
 GROUNDED SYSTEMS
• Grounded systems are electrical systems with:
⚬ Three Phase Feed
⚬ Neutral Conductor
• Ungrounded systems do not have a neutral conductor
• Grounded and ungrounded systems have different behaviors
 THREE-PHASE MOTOR

• Has stator with three separate sets of windings

• Follows three-phase configurations of circuits
• The power is fed to the stator windings 120 degrees apart
 SQUIRREL CAGE MOTOR

• Consists of an induction motor and a squirrel-cage casing

• Induction motor is made of heavy copper bars
MOTOR SLIP FORMULA
 NAMEPLATE

• All motors are required by the NEC to show its data such as:
⚬ Manufacturer ⚬ Phases
⚬ Frame ⚬ Ambient Temperature
⚬ Horsepower ⚬ Insulation Class
⚬ Voltage ⚬ NEMA Code
⚬ Amps ⚬ Electrical Efficiency Rating (EEF)
⚬ Speed ⚬ Motor Service Factor
⚬ Frequency
⚬ Service Factor
NAMEPLATE
 MOTOR STARTUP
• Motors begin with a surge of electricity called in-rush current
• May become a problem when using normal fuses
 TIME-DELAY FUSE
• Has two parts:
⚬ Instantaneous element
⚬ Time-delay element/Overload element
• Time-delay element is designed for in-rush current
 DISCONNECT DEVICES
• Used to provide overcurrent protection
• Happens in short circuits and overloads
• Common types of Disconnect devices:
⚬ Fusible Disconnect
⚬ Circuit Breaker
• Must be at max 50 feet from motor
controller
 OVERCURRENT PROTECTION
• There are three factors in selecting overcurrent protection:
⚬ Rated Full-Load Current
⚬ Conductor Ampacity
⚬ Locked-Rotor Current
• These factors are helpful in case of a short circuit
 PLC MOTOR
Control

Group 3 Mapua University

 PLC MOTOR CONTROL
• PLC stands for ‘Programmable Logic Controller’
• Most common motor control uses magnetic motor starter
 MOTOR STARTER
• Motor starters contains a solenoid/coil and supply power to the
motor
 FLUID POWER MOTOR CONTROL
• Has pneumatic and hydraulic motors
• Often uses Solenoid-Operated Directional Control Valve (DCV)
• DCV acts as a motor starter
 SEAL-IN PROGRAM LOGIC
• Keeps the motor running after the start button is pushed
• After input is gone, output is continuous
INTERNAL OUTPUT INSTRUCTIONS
• Used to perform logic controls in hardwired circuits
OUTPUT INSTRUCTION OPERATIONS

• Internal output addresses control NO and NC input

instructions
• At activation by program logic, NO and NC instructions turn
true and false
 SEAL-IN LOGIC WITH
INTERNAL OUTPUTS
• Internal output instructions are used for seal-in logic
 START RUNG APPLICATION
• Uses Seal-in Logic to activate all parts of the program or the
start
• Used when a cycle repeats
Introduction
to Variable
Frequency
Drive (VFD)
AC Drives
CRISOSTOMO, ARLYQUIN DC
FUNCTION AND OPERATION
OF TWO COMMON TYPES OF VARIABLE
SPEED AC DRIVES
• AC power operates motors by generating a magnetic field that

moves the rotor. The speed of this field is determined by the

frequency of the power source, with higher frequencies resulting in

faster motor rotation. Utility power typically cycles at 60 Hz,

maintaining a constant motor speed. Variable speed drives alter the

frequency of the power source to adjust motor speeds accordingly.

• Variable speed AC drives modify both frequency and voltage for AC

motors. Altering frequency adjusts the rotation of the magnetic field,

affecting motor speed. However, increased motor speed requires

higher voltage to maintain torque output.

FUNCTION AND OPERATION
OF TWO COMMON TYPES OF VARIABLE SPEED AC
DRIVES
• A common variable speed AC drive is the general-purpose drive, which

consists of three stages: converting AC to DC, boosting and filtering it, and

then converting it back to AC at various frequencies and voltages.

• RECTRIFIER -The rectifier section converts AC power to DC using SCRs o

diodes, resulting in a DC output with ripple voltage smoothed out in

subsequent stages.

• DC-LINK - it flattens ripple from the rectified DC signal and adjusts voltage

to match the desired output frequency.

• INVERTER - it The inverter section converts the DC back into an AC signal

that feeds a 3-phase motor. Simple inverters consist of six high-powered

 ADVANTAGES AND
OF USINGDISADVANTAGES
AN AC DRIVE INSTEAD OF A DC
DRIVE
INVERTER DRIVE
• A microprocessor, housed in the control section
SWITCHING
of the drive, typically governs the switching of

these devices. Programmed to sequence the

transistors' activation, the microprocessor

generates the AC signal driving the motor. The

frequency of the AC output, and consequently

the motor speed, is determined by the rate of

switching.
 ADVANTAGES AND
OF USINGDISADVANTAGES
AN AC DRIVE INSTEAD OF A DC
DRIVE
• AC drive shift the AC power’s frequency to

affect an AC motor’s speed. It is also lighter and

do not run by friction so its design is very

efficient in converting input power to Torque.

• DC drives vary DC current to adjust the speed

of a DC motor. DC motors also have much

higher starting torque.

 ADVANTAGES OF AC DRIVE
MOTOR STARTING

The simplest way to start a motor is using a direct on line, or

DOL, starter. This method applies full line voltage directly to the
motor terminals to power up the motor.

However, using an AC drive to start a 3- phase motor offers

several advantages over using a DOL starter:
-Better Control of Acceleration Control of Inrush Current
-Smaller Drive Motors
-Reduced Mechanical Stress
-Motor Operation
-Multiple Motor Control
 SOFT-START DRIVES

-In various applications, smaller AC drives are

employed instead of conventional magnetic motor
starters. These drives are commonly known as
soft-start drives. Soft-start applications encompass
pumps, conveyors, grinders, and fans.
 USE OF A SINGLE-PHASE
POWER
• Another significant capability of certain AC drives is
their ability to operate a 3-phase motor without
requiring 3-phase power input. These drives can
utilize single-phase power and generate the
necessary 3-phase signal to drive the motor,
enabling locations without readily available 3-phase
power to utilize 3-phase motors.
 DISADVANTAGES OF AC
DRIVE MOTOR STARTING
• Direct-On-Line (DOL) starters offer certain benefits
compared to AC drives concerning startup torque
and cost.
• Conventional line-started motors typically generate
around 200% of rated full-load torque during
startup, whereas AC drives typically yield only about
150%.
• The intricate electronics and elevated operational
expenses contribute to the higher cost of AC drives.
Additionally, maintaining and diagnosing issues with
AC drive setups is more challenging compared to
 VARIABLE SPEED AC DRIVE
CONTROL

While programmable AC drives typically offer motor operation

via a built-in keypad, numerous applications require external
control.

The most straightforward control method is the 2-wire circuit,

which activates the motor for on/off functionality.

Three-wire control schemes operate similarly but incorporate a

parallel circuit that maintains the starter circuit, ensuring
automatic motor operation.
VFD INPUTS AND OUTPUTS

• Inputs for 2-wire and 3-wire controls encompass

pushbuttons, switches, potentiometers, sensors, and

PLCs, with many AC drives supporting combinations of

these devices.

• Additionally, AC drives feature terminals for line power

inputs and motor power outputs. Certain drives are

equipped with output relays capable of activating indicator

lights to indicate fault conditions.

 CONTROL SETTINGS

• Programmable AC drives frequently offer users the option to switch between manual and

automatic input modes.

• Additionally, users can choose the signal that dictates the speed command, which may

include an internal frequency (derived from the maximum frequency output), an external

0-10 V signal, an external 4-20 mA signal, or input from the built-in potentiometer.
JOGGING A MOTOR WITH A
VFD
• Jogging a motor involves momentarily activating

the contacts to operate at a slower pace than its

regular running speed. This facilitates tasks such

as aligning parts or running a machine through its

maintenance or repair operations.

JOG SETTINGS

-Digital Input 1 (A051)/Digital Input 2 (A052) - This parameter activates the I/O terminals on

the VFD for a range of preset functions.

-Jog Frequency (A078) - This parameter sets the maximum frequency of the drive output

while jogging.

- Jog Acceleration/Deceleration (A079) - This parameter sets the rate the motor

speeds up when triggered, and the rate the motor stops when released
BASIC FLOW
MEASUREMENT
AND CONTROL
by ARLYQUIN DC. CRISOSTOMO
 SEGMENT 1: FLOW MEASUREMENT UNITS
OBJECTIVE 1: DESCRIBE THE BASIC
FUNCTION OF FLOW MEASUREMENT AND
GIVE AN APPLICATION (FLOW
MEASUREMENT)
Flow measurement is the measurement
of the volume or mass of material that
passes a given point during a specified
time period. This is frequently the
manipulated variable in a control loop,
regardless of the controlled variable.

EX: maintaining the level in a tank often requires controlling

the flow into or out of the tank, or sometimes both.
 SEGMENT 1: FLOW MEASUREMENT UNITS
OBJECTIVE 1: DESCRIBE THE BASIC FUNCTION
OF FLOW MEASUREMENT AND GIVE AN
APPLICATION (FLOW AS BOTH CONTROLLED
AND possible
It is also MANIPULATED VARIABLES)
for flow to be both the
controlled and the manipulated variable.
The example shows a flow sensor
measuring the flow of liquid in a process
system. The flow sensor sends a signal to
a transmitter.

,The transmitter sends its output to a controller. Then, a signal is sent

to the valve via an I/P converter to control the flow at the desired rate.
 SEGMENT 1: FLOW MEASUREMENT UNITS
OBJECTIVE 1: DESCRIBE THE BASIC FUNCTION
OF FLOW MEASUREMENT AND GIVE AN
APPLICATION (FLOW AS BOTH CONTROLLED
AND MANIPULATED
Control Systems: A VARIABLES)
controller is a
hardware device or a software program
that manages or directs the flow of data
between two entities. In general, a
controller can be thought of as
something or someone that interfaces

between two systems and manages communications between

them.
 SEGMENT 1: FLOW MEASUREMENT UNITS
OBJECTIVE 2: DEFINE THE THREE FLOW
MEASUREMENT UNITS (VELOCITY FLOW
MANAGEMENT)
Velocity refers to the time it takes a fluid to
travel a given distance. The velocity of a fluid
is typically specified in feet per second or
meters per second.
Velocity measurement is common in
applications where fluid velocity is directly
related to the process performance.

EX: In a heat exchanger where fluid velocity affects the heat

transfer rate.
 SEGMENT 1: FLOW MEASUREMENT UNITS
OBJECTIVE 2: DEFINE THE THREE FLOW
MEASUREMENT UNITS (VOLUME FLOW
MANAGEMENT)
Volume flow rate describes the volume of
fluid that flows past a given point in a period
of time. The volumetric flow rate combines
the velocity of the fluid and the area of the
pipe or container.
Volumetric flow is typically expressed in
cubic feet per minute, gallons per minute, or

liters per minute, as shown in the illustration provided.

VOLUMETRIC FLOW MANAGEMENT EXAMPLES
 SEGMENT 1: FLOW MEASUREMENT UNITS
OBJECTIVE 2: DEFINE THE THREE FLOW
MEASUREMENT UNITS (MASS FLOW
MANAGEMENT)
Mass flow rate describes the mass of fluid
that flows past a given point in a period of
time. It combines the density of the fluid and
the volumetric flow rate. The mass flow rate
is often expressed in pounds per minute, or
kilograms per minute. Mass flow
measurement is the most accurate method

of measurement of the quantities of material flowing through the

system because density variations do not cause a reading error.
MASS FLOW MANAGEMENT EXAMPLES
VELOCITY VS VOLUMETRIC RATE

This example
compares the
flow rates in 25
mm and 50 mm
diameter pipes.
VELOCITY VS MASS RATE
This example compares the
volumetric (Qv) and mass
(Qm) flow rates for three
fluids with different
densities.
OBJECTIVE 3: DESCRIBE HOW TO CONVERT BETWEEN VELOCITY AND
VOLUMETRIC FLOW RATE UNITS

These formulas show the conversion from velocity units to volumetric

flow rate units given the inside diameters (ID) of the pipe. The constants
given are based on the relationship between the ID of the pipe and its
cross-sectional area where r is the radius.
 STANDARD PIPE SIZES

Pipes come in standard sizes of both US

customary and metric units. To determine
the inside diameter (ID) of a pipe, it is looked
up in a table like the one at the right.

The nominal pipe size (NPS) is an

approximation of the actual ID and is used
for convenience in naming the pipe size.

EX: Schedule 40 pipe with a nominal size of 1 ince has an ID of 1.049

in. Diameter Nominal (DN) is the metric equivalent of the NPS.
 SEGMENT 1: FLOW MEASUREMENT UNITS
OBJECTIVE 4: DESCRIBE HOW TO CONVERT
BETWEEN VOLUMETRIC AND MASS FLOW RATE
UNITS (MASS FLOW RATE)
Mass flow rate can be measured by a mass
flow meter or it can be calculated from
volumetric flow.
The calculation is useful because the mass
flow rate does not change as the
temperature or pressure changes.

Therefore, sensors that measure mass flow are more accurate

than sensors that measure volumetric flow.
OBJECTIVE 4: DESCRIBE HOW TO CONVERT BETWEEN VOLUMETRIC AND
MASS FLOW RATE UNITS

These formulas show the conversion from volumetric flow rate units
to mass flow rate units. The constants given are required for
conversion from Lpm to m^3/min or gpm to ft^3/min.
 DENSITY OF COMMON FLUIDS

This table lists the density of some

common fluids.

Gasoline comes in 3 different grades, each

of which has a different density. Also, the
density of milk differs based on the
percentage of milk fat.

EX: 2% milk has less density than whole milk.

 SEGMENT 2: FLOW SENSORS
OBJECTIVE 5: DESCRIBE FOUR CATEGORIES OF
FLOW SENSORS AND GIVE AN APPLICATION OF
EACH (DIFFERENTIAL PRESSURE)
Differential pressure flow sensors measure
flow by measuring the pressure difference
across a restriction. They require a
differential pressure transmitter to convert
the pressure reading to a flow rate.

Differential pressure flow sensors include orifice plates, pitot tubes,

Venturi tubes, and flow nozzles.
OBJECTIVE 5: DESCRIBE FOUR CATEGORIES OF FLOW SENSORS AND GIVE AN
APPLICATION OF EACH (DIFFERENTIAL PRESSURE)
OBJECTIVE 5: DESCRIBE FOUR CATEGORIES OF FLOW SENSORS AND GIVE AN
APPLICATION OF EACH (DIFFERENTIAL PRESSURE)
Differential pressure
transmitter has internal
circuitry and a
microprocessor that
uses the differential
pressure and flow rate
to calculate the flow
rate.
 SEGMENT 2: FLOW SENSORS
OBJECTIVE 5: DESCRIBE FOUR CATEGORIES OF
FLOW SENSORS AND GIVE AN APPLICATION OF
EACH (VELOCITY)
Velocity flow sensors determine volumetric
flow rate based on the velocity of the
process fluid. Velocity flow sensors include
magnetic, turbine, ultrasonic, and vortex
shedding flow sensors.
 SEGMENT 2: FLOW SENSORS
OBJECTIVE 5: DESCRIBE FOUR CATEGORIES OF
FLOW SENSORS AND GIVE AN APPLICATION OF
EACH (VELOCITY)
A turbine flow sensor measures flow by
measuring the speed of its rotor blades as
they rotate. Each time a blade rotates past
the magnetic pick up, the sensor creates a
pulse. The frequency of the pulses, which is
proportional to the flow rate, is read by

another instrument (transmitter) that converts the frequency rate into

a flow rate measurement.
 SEGMENT 2: FLOW SENSORS
OBJECTIVE 5: DESCRIBE FOUR CATEGORIES OF
FLOW SENSORS AND GIVE AN APPLICATION OF
EACH (VOLUMETRIC)
Volumetric flow sensors, also called positive
displacement (PD) sensors, typically contain
one or more rotating gears or rotor that
measure flow by trapping a known amount
of process fluid in the sensor.

Therefore, the volume of the fluid that passes through the sensor is
proportional to flow rate.
 SEGMENT 2: FLOW SENSORS
OBJECTIVE 5: DESCRIBE FOUR CATEGORIES OF
FLOW SENSORS AND GIVE AN APPLICATION OF
EACH (MASS)
Mass flow sensors measure the mass flow
rate of both liquids and gases. Mass flow
sensors include Coriolis and thermal flow
sensors. Some sensors are able to measure
the mass flow directly, independent of any
physical properties of the fluid.

A coriolis mass is able of measuring the vibration of

the tubes as fluid flows through them.
 SEGMENT 2: FLOW SENSORS
OBJECTIVE 6: DESCRIBE THE OPERATION OF A
TURBINE FLOW SENSOR
A turbine flow sensor uses a rotor and a
magnetic pick up to create a pulse
frequency that is proportional to flow. The
rotor is located inside the sensor body,
while a magnetic pickup, which detects the
rotation of the rotor blades, extends
outside the sensor body.

The flow of liquid past the blades causes the rotor to rotate. The
magnetic pickup creates a pulse each time a blade passes by.
 SEGMENT 2: FLOW SENSORS
OBJECTIVE 7: DESCRIBE THE OPERATION OF A
PADDLEWHEEL FLOW SENSOR
A paddlewheel flow sensor, or tangential
turbine sensor, is a type of flow sensor that
uses a rotating paddlewheel to determine
the volumetric flow rate. The paddlewheel
flow sensor generates electrical pulses
based on the rotation of the rotor just like a
standard turbine flow sensor.

However, the paddlewheel blades are perpendicular to the flow

which is shown above.
 SEGMENT 3: FLOW MEASUREMENT
OBJECTIVE 8: DESCRIBE THE OPERATION OF THE
GF SIGNET 9900 DIGITAL TRANSMITTER (DIGITAL
TRANSMITTER OPERATOR INTERFRACE)
Most digital transmitters have a display and
programming keys that allow the user to
navigate menus and set the parameters to
make the transmitter correctly interpret the
signal produced by the sensor. The display
also allows monitoring of the measured
quantity.

The flow unit parameter sets the measurement units for the flow
rate (GPM, LPM, or FPS).
 SEGMENT 3: FLOW MEASUREMENT
OBJECTIVE 9: DESCRIBE THE CALIBRATION
PARAMETERS OF THE GF SIGNET 9900 DIGITAL
TRANSMITTER (STANDARD PARAMETERS)
Digital transmitters must be calibrated to
properly display the flow rate. This involves
setting parameters in the transmitter,
usually with a keypad.
Flow K - factor respresents the number of
pulss per volumetric unit (gallons, liters,

that the flow sensor generates. It provides the processor with the
conversion factor needed to convert the pulse frequency to the
desired flow rate.
OBJECTIVE 9: DESCRIBE THE CALIBRATION PARAMETERS OF THE GF SIGNET
9900 DIGITAL TRANSMITTER (ADDITIONAL PROGRAMMABLE PARAMETERS
FOR THE GF SIGNET 9900)
 SEGMENT 3: FLOW MEASUREMENT
OBJECTIVE 10: DESCRIBE HOW TO CONFIGURE
A GF SIGNET 9900 DIGITAL TRANSMITTER TO
FLOW (VIEW MODE)
A GF Signet 9900 digital transmitter has two
motors: View and Menu. The transmitter
normally operates in the View mode. An
example of this mode is shown. The user
enters the Menu mode whenever the
transmitter needs to be configured.
 SEGMENT 4: BASIC FLOW CONTROL
OBJECTIVE 11: DESCRIBE THE OPERATION OF A
CLOSED LOOP FLOW CONTROL SYSTEM (FLOW
CONTROL LOOP)
Flow control loop contains the same
elements as a level control loop except the
sensor measures flow instead of level. An
example of a flow control loop is shown at
the right.

It provides a feedback signal to a controller which determines the

necessary output to send to a final control element such as a valve.
Skill 3: Configure A GF signet
9900 Digital Transmitter for
Flow
Procedure
1. Perform a lockout/tagout (is a safety procedure used to
control hazardous energy during maintenance or servicing of
equipment and machinery. It aims to prevent unintentional
energization of the equipment)

2. Setup the T5552

T5552 Setup
1. Check the air supply: See if the air hose is already connected to the device. If it is, adjust
the air pressure to zero pounds per square inch (psi). If it's not connected, you don't need to
connect it for this procedure.
2. Connect the power: Plug the power cord of the device into an electrical outlet.
3. Fill the reservoir tank: Fill the tank of the device with water.
4. Open the drain valves: Fully open the drain valves labeled HV 300 (HV3) and HV 100C
(HV4) by turning them counter-clockwise.
5. Open the flow control valves: Fully open the flow control valves labeled HV 100B (HV1)
and HV 100A (HV2) by turning them counter-clockwise.
6. Open another flow control valve: Fully open the flow control valve labeled HV 100D by
turning it counter-clockwise.
7. Close the manual flow control valve: Fully close the manual flow control valve labeled FV
100 (HFV) by turning it clockwise.
8. Verify the paddlewheel flow sensor: Check if the paddlewheel flow sensor is installed as
shown in figure 3-1 of the manual. If it's not installed, ask your instructor to install it.
 Procedure
3. Connect the circuit as shown
4. Make sure the instructor has used the
factory reset option to reset the sensor type.
This will allow the transmitter to
automatically detect the type of sensor that
is connected.
5. If the sensor type cannot be automatically
detected, you will need to manually select
the correct sensor type later in the
configuration process.
6. Turn on the main circuit breaker.
7. The transmitter display should show
"SELECT SENSOR and PUSH Enter, with
"Enter" flashing".
Procedure
8. Press the ENTER key: Briefly press the ENTER key to allow
the transmitter to determine the type of sensor that is connected.
9. Verify the sensor type: After a few seconds, "FLOW" should
appear on the display to indicate that a flow sensor has been
detected. If "FLOW" is not displayed, use the up and down arrow
keys to scroll through the sensor types until "FLOW" appears.
10. Set the sensor type: While "TYPE FLOW" is displayed on
the screen, press the ENTER key again to confirm that a flow
sensor is connected.
11. Enter the menu mode: Press and hold the ENTER key for 3
seconds to enter the menu mode of the transmitter. The main
menu screen should then appear on the display.
Entering Calibration Menu (CAL)
1. Check the menu: Look at the current menu item. If it doesn't say
"CAL" (with "CAL" blinking), then:
1. Use the up and down arrows to scroll until "CAL" is highlighted.
2. Press the ENTER key to enter the calibration menu.
2. Initial setting check: Once in the calibration menu, the first option
displayed will likely be "HOLD OUTPUTS."
1. If it says "NO," you can skip to the next step (C).
3. Change the setting: If "HOLD OUTPUTS" doesn't say "NO," use the
right arrow to select it.
4. Choose "NO": Use the up or down arrow to change the value to
"NO."
5. Confirm the change: Press the ENTER key to save the new setting.
Changing the Values to set the
Parameters
1. Press the right arrow key to select the parameter.
2. Use the up and down arrow keys to change the value.
3. Press the right arrow key to move to the next digit.
4. Repeat steps 2 and 3 to change all the digits.
5. Press the Enter key to save the new setting.
6. When finished press the up and down arrow keys together to
exit the calibration menu
Entering the Input Menu
1. Check the display: See if "INPUT MENU" is currently
selected. If it's not, use the up and down arrows to highlight
"INPUT MENU" and then press Enter. This will take you to the
input menu.
2. Skip or adjust parameter (if needed): * The first parameter
you'll see might be "HOLD OUTPUTS." If it already says "NO,"
you can move on to step 3. * If it doesn't say "NO," use the right
arrow to choose it, then use the up or down arrows to change the
value to "NO." Finally, press Enter to save the change.
Entering Loop Menu
1. Check the LOOP menu:
Look at the current menu selection on the display.
If "LOOP" is not highlighted, use the up and down arrow keys to
select it.
2. Enter the LOOP menu:
Once "LOOP" is highlighted, press the ENTER key to enter the
LOOP menu.
Entering Relay Menu
1. Check the display: Look at the current menu selection.
2. Select "RELAY" (if not already selected):
If "RELAY" is highlighted, skip to step 3.
If "RELAY" is not highlighted, use the up and down arrow keys to
select it.
3. Press Enter: Press the ENTER key to enter the RELAY menu.
Entering Option Menu
1. Check the OPTION menu:
Look at the current menu selection on the display.
If "OPTION" is not currently highlighted (flashing), use the up and
down arrow keys to select it.
2. Press Enter: Press the ENTER key to enter the OPTION
menu.
3. Return to Main Menu
4. Leave the system set up and proceed to Skill 4.
 Skill 4: Measure Flow
Using a Paddlewheel Flow
Sensor
Procedure
1. Ensure that the circuit is still connect from the previous skill as
shown
Procedure
2. Make sure the paddlewheel flow sensor is installed
correctly:
• Check if the sensor is mounted on the trainer and sitting
flat (horizontally), as shown in figure 4-2 of the manual.
• Ensure its electrical connector is properly plugged into the
trainer, as shown in the figure.
• If anything is incorrect, ask your instructor for help with
installation and configuration.
 Manual control of flow into the process
tank
and measure the flow
1. Turn on SS1
2. Open manual flow control valve FV 100 until it indicates a flow rate
of 0.5 gpm
3. Observe and record the flowrate through the rotameter
4. Record the reading on the loop calibrator or multimeter
5. Repeat steps 2 3 and 4 but with a flowrate of 1.0 gpm
6. Repeat step 5 but with a flowrate of 1.3 gpm
7. If the readings do not match within a tolerance of +/- 0.2mA then
repeat skill 3 to reconfigure the digital transmitter.
8. Turn off SS1
9. Close the manual flow control valve
Changing the flow units to Liters per
Minute
Changing the flow units to Liters per
Minute
1. Turn on SS1
2. Open Manual flow control valve FV 100 until the transmitter
reads 2.51 lpm
3. Observe the reading on the transmitter if it equals to the
reading on the rotameter
4. Increase or decrease the flow rate using the control valve and
the displayed flowrate and the rotameter flowrate
Shutting Down the T5552
1. Turn off switch SS1 this will turn off the circulation pump

2. Close the manual flow control valve FV 100

3. Open both process tank manual drain valves HV300 (HV3)

and HV 100C (HV4). This will drain the process tank
4. Close the valves when tank is completely drained
5. Turn off main circuit breaker
6. Disconnect the circuit
 Operate a Flow Control
Loop Using a Paddlewheel
Sensor
Procedure
1. Perform a lockout/tagout

2. Set up the T5552

Setting up the T5552
1. Connect the air supply line to the T5552 and set the pressure
to 20psi
2. Fill the tank with water
3. Open HV300 and HV100C
4. Open the control hand valves HV 100B and HV100A
5. Open valve HV 100D
6. Open the flow control valve FV 100
7. If not yet installed, Have the paddlewheel flow sensor mounted
on the trainer oriented horizontally and that the electrical
connector is plugged into the trainer.
8. Connect the circuit as shown
Procedure
3. Remove the lockout/tagout

4. Turn on the main circuit breaker

5. Turn on switch SS1 and adjust flow control valve FV 100 until
1.2gpm is indicated, and then turn off SS1
6. Set the GF Signet 9900 transmitter in Menu mode and set the
indicated parameters
7. Exit the menu mode after setting up the parameters
8. Using the Honeywell UDC 3500, program it to the parameters
listed below.
9. Adjust the controllers set point to 0.8 gpm
10. Procedure to Automatically control the flow through the circuit:
• Turn on switch SS1 to engage circulation pump
• Press the Man/Auto Key to activate automatic mode
• Display controller output (OUT) using the Lower Display key.
• Record the value as PV reaches a steady state and the controller
output and the error at steady state.
11. Procedure to test the effect of changing the integral setting:
• Turn off SS1
• Place the controller in Manual mode after the output goes to 0.0
• Go to SETUP using Setup key and select TUNING option
• Use Func Loop ½ ket to select integral control option and adjust to
0.1min
• Exit SETUP menu
• Repeat Step 10
• Repeat Step 11 but set the integral control option (RSET MIN)
value to 0.05 minute.
• Then Repeat step 10 again.
12. Causing a disturbance and observe the response of the
system:
• Place controller to manual mode
• Change output to 0.0
• Adjust flow control valve FV 100 until both the PID controller and
transmitter reads 1.0gpm
• Place controller to automatic mode
• and repeat step 10
• Test how the controller responds to the decreased maximum flow
• Place controller to manual mode and change output to 0.0
• Adjust flow control valve FV 100 until it reads 1.2 gpm
13. Observe the system response to changing the SP to a higher
value:
• As the controller is in manual mode and still indicates 1.2 gpm repeat
step 10
14. Observe the system response to changing the SP to a lower
value:
• Place controller in manual mode and change output to 0.0
• Change setpoint to 0.5 gpm
• Revert the controller back to automatic mode and determine if controller
output increases or decreases
15. Controlling the flow using only proportional control:
• Turn off SS1

• Place controller on manual mode after output goes to 0.0

• Enter SETUP menu and adjust CONT ALG parameter to PD+MR in the
ALGORITHM function

• Adjust MIN RSET value to 0 in TUNING function group

• Exit SETUP menu

• Set controller setpoint to 0.8 gpm

• Turn on SS1 and repeat step 10

16. Observing a proportional response of the system at a new SP:
• Place controller on manual mode

• Adjust controller setpoint to 1.0gpm

• Press the Man/Auto Key to activate automatic mode

• Display controller output (OUT) using the Lower Display key

• Record the value as PV reaches a steady state and the controller

output and the error at steady state.

• Turn off SS1 and revert controller back to manual mode after output
goes to 0.0
17. Observing how changes in gain affect a proportional flow
control system.
1. Adjust controllers setpoint to 0.8gpm and repeat step 10
2. Turn off SS1 and revert controller back to manual mode after output
goes to 0.0
3. Enter TUNING option and use Func Loop ½ to select the GAIN and
adjust setting to 3.2 after which exit the SETUP menu
4. Repeat step 10
5. Repeat substep 2 and 3 but adjust the GAIN setting to 15.0 and then
exit SETUP menu
6. Repeat step 10
18. Shut down T5552
• Turn off switch SS1

• Close the flow control valve FV100

• Close both tank drain valves HV 300 (HV3) and HV 100C (HV4)

• Turn off main circuit breaker

• Disconnect the circuit

Pressure
Control System

Presented by: Jericho Karlo D.

Dela Cruz
 On/off control
Overview
• The on/off and continuous control techniques are two
different types of control methods that are frequently
employed in pressure control systems.
• Control methods that are the most fundamental include
on/off control, often known as two-position control. By
sending a signal that controls a device as either completely on
(100%) or entirely off (0%), the controller is able to respond to
any process variable input.
• According to the on/off control approach, for instance, a valve
can only function in one of two potential states at any one
time.
 On/off control Sample

• In the picture provided, a pressure control

system regulates the outlet valve operated by a
solenoid.
• If the pressure goes above the specified limit of
150 kPa, the valve will open completely.
Enabling fluid to flow through the valve reduces
the fluid pressure in the pipe.
• If the pressure drops below 130 kPa, the valve
will automatically close. By implementing this
measure, it will block the flow of fluid when
there is a rise in fluid pressure within the pipe.
Advantages and Disadvantages
of On/Off Control

• One of the key benefits of utilizing on/off

control is its straightforward and
cost-effective operation.
• One significant drawback is that the
on/off control is not suitable for control
applications that need precise
adjustments close to the set point.
 • While an on/off control method is restricted
Continuous to two potential outputs, the continuous
control method provides a range of outputs.
Control The value can fluctuate from fully on (100%)
Overview to fully off (0%).
For optimal performance, it is important to
supply the controller with tuning parameters
to generate the desired controller output.
 Continuous Control Sample

• Here is an illustration of a continuous control

application.
• The solenoid-operated valve can function at any
position between fully open and fully closed.
• The controller responds to the discrepancy
between the current pressure and the desired
set point (140 kPa) by sending a signal that
modifies the valve's position.
 Advantages and Disadvantages of Continuous Control

• One of the key benefits of utilizing

continuous control is the ability to
maintain a stable control process with
minimal deviation from the setpoint.
• One significant drawback is that
continuous control systems are usually
pricier and more intricate than on/off
control systems.
On/off Pressure
Control System
Diagram
Valve Position Oscillation in an
On/Off Pressure Control System

• A control system that compares the

desired pressure with the actual pressure
can lead to the valve rapidly transitioning
between fully open and fully closed
positions.
• The diagram illustrates the quick change
in the valve's position in response to
fluctuations in pressure. The quick
changes in direction can lead to harm to a
control valve.
Controller Input/Output
Connections
• The diagram illustrates the connections
that are necessary for an
• application of pressure control controlled
by on/off.
A connection is made between the signal
conditioner of the proportional solenoid
valve and the analog output terminal on
the controller.
• An analog input is connected to a
pressure sensor, which is responsible for
monitoring the pressure that is present
within the tank.
 Closed-Loop Pressure Control System

• Maintaining pressure at a
predetermined setpoint is the
responsibility of a closed-loop pressure
control system.
• When compared to an on/off pressure
control system, which can only keep the
tank pressure between the high and low
limits, this method offers a measure of
control that is more exact.
 Closed-Loop Pressure
Control System Diagram
• An illustration of the signal flow of a
closed-loop pressure control system is
provided by the block diagram that is
displayed.
Following the reception of the process
variable (PV) signal generated by the
pressure sensor, the controller performs a
comparison between the signal and a
setpoint (SP) that is stored in the memory of
the controller.
• The position of the control valve is altered as
a result of the controller's output, which is
determined by the difference (error)
between the SP and PV values.
Closed-Loop Pressure Control Operation

• In the diagram provided, the pressure is

directed to the pressure tank inlet. The
system is designed to keep the tank
pressure at 200 kPa through closed-loop
control.
Presented by: Jericho Karlo D. Dela Cruz

Ultrasonic Level Measurement and

Control
 Ultrasonic Level
Sensor

• An ultrasonic level sensor is a device used

for measuring levels by transmitting and
reflecting ultrasonic waves to determine
the material level in a container.
 Internal Construction

• There are two main internal components of an

ultrasonic level sensor.
1. Transmitter
2. Transducer
 Tramsductor
Contruction

• An ultrasonic level sensor's transducer has three

main components.
1. Backing Material
2. Piezoelectric Crystals
3. Electrodes
 Sensor Diameter and Frequency Relationship

• Ultrasonic sensors with a larger

diameter can typically cover longer
distances by emitting waves at a
lower frequency (within the 20 to 45
kHz range).
• Lower frequency waves have a
greater range of travel compared to
higher frequency waves in level
measurement due to reduced
chances of absorption by foreign
materials.
Installing and Operating an
Ultrasonic Level Sensor
• There are four important factors to consider
when installing and operating an ultrasonic
level sensor.
✔ Temperature
✔ Type of Material
✔ Size of Container
✔ Wave Obstructions
 Manufacturer
Specifications

• The manufacturer's specifications detail

the operating temperatures for the sensor
and the ultrasonic beam width to avoid
errors caused by these factors.
• Usually, containers need to be a minimum
of 0.3 meter wider than the beam width.
 - Some ultrasonic level sensors have two wiring configurations:
– Inverted
Wiring Configuration – Non-Inverted
 Advantage of
Non-Inverted
Measurement

• When it comes to non-inverted

measurements, determining the
distance between the sensor and the
liquid's top is easier than calculating the
actual level. This is due to the
straightforward connection between the
output and the distance.
As the distance varies, the output also
changes accordingly.
 Wiring for Non-Inverted
Measurement

Shown is an ultrasonic level sensor wired

to a process meter or controller for
non-inverted measurement:
• Positive and Negative Wires
• Third Wire
• Fourth Wire
 Inverted Measurement
• When the measurement is inverted, the
sensor's analog output decreases as the
ultrasonic waves move further away.
Wiring for Inverted
Measurement
• Setting up an ultrasonic sensor for inverted
measurement is done in a similar way to
setting it up for non-inverted measurement.
• Nevertheless, the fourth wire is connected
to the positive power supply wire rather
than being excluded from the circuit.
• Connecting the fourth wire to the power
supply reverses the output signal from 4-20
mA (0-10 V) to 20-4 mA (10-0 V).
Calibrating an Ultrasonic Sensor for Non-Inverted
Measurement

Calibrating an ultrasonic sensor for

non- inverted measurement
requires three basic steps:
• Position Sensor at Top of Tank
• Adjust Sensor Zero
• Adjust Sensor Span
 Adjust Sensor Zero and Span

• Several ultrasonic level sensors come with

potentiometers for adjusting the zero and
span of the output.
• Adjusting the zero and span requires
connecting a loop calibrator or digital
multimeter (DMM) in series with the sensor's
output if using current output.
• Displayed here is the current output of an
ultrasonic sensor connected to a loop
calibrator.
 Important insights
• Understand the Sensor and Container Setup: Know your ultrasonic level sensor's specs and limits. Know the
container's size, material, and the substance being measured.

• Mount the Sensor: Place the ultrasonic sensor above the container so it can see the liquid or substance. Avoid
obstructions that might disrupt ultrasonic waves.

• Power on and Setup: Connect the sensor to the control interface or system. Set up sensor calibration mode per
manufacturer's instructions.

• Calibrate an empty container. This step establishes the "zero" reference point. Adjust the sensor to read zero
distance when the container is empty. This stage may require offset or baseline adjustments.

• Fill Container: Fill the container with the material to measure. Make the sensor see the material's surface.

• Measure sensor distance from material surface for calibration. This distance should be the maximum typical
operating level. Adjust sensor settings for this distance. Setting the maximum range or adjusting the sensor's
output to appropriately represent distance may be required.

• Verify Calibration: After calibrating the sensor, compare its values to manual measurements or container
material levels. If required, fine-tune the calibration.

• Finish Setup: Secure the sensor and integrate it into your control or monitoring system if you're pleased with its
calibration and functionality.
 Closed-Loop System

• Even though ultrasonic sensors utilize a

distinct sensing technique compared to
other sensors like pressure-type level
sensors, they function within a
closed-loop system just like other
sensors. They generate an electrical
output signal that corresponds to the
level.
It is essential to adjust the controller
parameters to align with the chosen
configuration, whether inverted or
non-inverted.
 Valve Types and Controller Settings

• When the sensor is configured for

non-inverted measurement and an
air-to-close valve is utilized, the
controller should be adjusted to be
reverse acting.
• For a non-inverted measurement and an
air-to-open valve, the controller should
be set as direct acting.
• When dealing with inverted
measurement, remember to set the
controller settings differently for
air-to-close valve and air-to-open valve.
 Types of Control

• Control systems are frequently utilized in

managing level systems due to their
ability to offer a rapid response and
eliminate offset.
• Adding derivative control can enhance
the system's response in case of
significant errors.
 Basic Temperature
Control
What are the functions of a temperature control
system?
• It maintains the temperature of a process fluid or material within a desired range
• It is equipped with a controller that senses temperature which opens up or closes the solenoid to
maintain the temperature needed
Operation of an on/off temperature
control system
• On/off control is the simplest and the most inexpensive type of
automatic process control. It gives an output of 100% or 0%
there is no in between
• It is commonly used in domestic heating system
Operation of on/off control system
(T5553-CF)
• Prepare the system by draining the fluids from the system
through the drain valve. Process fluid loops, hot water loops,
pump-priming valve, and extension plugs must be tightened.
• Fill the hot water until level switch, fill the process tank up to ¾
of maximum level, and connect the pressure regulator.
• Connect the electricals needed and start the system.
• Adjust the thermostat and ensure default settings provided.
Configuring and Operating a Honeywell
UDC 3500 Controller for on/off control
• For additional configuration, ConSoft software is required to
configure the temperature transmitters.
• After doing the configurations needed, restarting the application
is needed before doing anything else.
• After restarting the app, it is recommended to verify if the
configurations have been saved and working properly by
checking each tab and verifying it.
• After verifying the configurations, setup the desired units of
temperature, connection type, resistance, temperature range,
and save it
• After doing so, click the read button and save the file before
starting the operation.
Describe the operation of a closed loop
temperature control system
• Closed loop system has the ability to automatically maintain the
temperature at a specific point determined by the operator.
• It compares the PV to a setpoint contained in its memory which
adjusts if the signal values are different
• The significance difference is that control systems have a slower
response time and its feedback element is non-linear which is
then converted to a linear value.
Describe the effect of two types of
disturbances on a closed loop system
Supply Disturbances
• It occurs when the supply to the process changes
• If the temperature entering the heat exchanger decreases, the
process fluid exiting would also decrease due to heat loss
through a poorly insulated pipe.
• Supply disturbances result from increase or decrease in the
supply fluid temperature
Describe the effect of two types of
disturbances on a closed loop system
Demand disturbances
• It is any change downstream of the process that causes the
process system to change.
• When the flow rate of the hot water exiting the heat exchanger
decreases, but the flow rate and temperature of the steam stays
the same, the temperature on the outlet of the heat exchanger
begins to rise. (pipe curvature, valve closing, etc.)
Describe how to configure and operate a
Honeywell UDC 3500 controller for closed
loop control
• Setting up the UDC 3500 controller is the same the only
difference is that is setting the Set point using the arrow keys.
• Press the func loop ½ key until IN 1 TYPE appears and set the
parameter to 100 LO
• Repeat it until IN1 HIGH appears and set it to 149 C or 300 F
• Repeat the step until IN1 LOW appears and set it to -184 C or
-300F
• Repeat the step until BIAS IN1 appears and set it to 0
• Press setup repeatedly until ALGORITHM appears
• Press FUNC LOOP until CONT ALG appears and set it to PID A
• Set parameters in TUNING

• After configuring set it to automatic and start the process

Describe the function of loop controller
alarm outputs and give an application
• Loop controller alarms are devices that sounds when the state
reaches a condition that is dangerous.
• This is usually used in pump control panels where it buzzes to
alarm the person that the temperature exceeded the
temperature set.
Describe how to connect and operate
alarm outputs on a Honeywell UDC 3500
controller
• Prepare the system by draining the fluids from the system
through the drain valve. Process fluid loops, hot water loops,
pump-priming valve, and extension plugs must be tightened.
• Fill the hot water until level switch, fill the process tank up to ¾
of maximum level, and connect the pressure regulator.
• Connect the electricals needed and start the system.
• Adjust the thermostat and ensure default settings provided.
• Place the controller in manual mode and input the following
parameters:

• Set the following parameters in the ALARMS group:

• Change the setpoint to 37C or 98F

• Turn on hot water pump and process pump and look if the
temperature starts to rise
• Check if the alarm stays on when it exceeds the set
temperature. If its on turn it off and turn on CHILLER
• If the temperature reaches 21C or 70F turn of the chiller and set
the following parameters on different alarm setpoints.

• The alarm should turn on when the temperature is below 24C or

above 27C
• To shutdown, turn off hot water heater and process pump,
disable alarms, and turn off main circuit breaker
Describe how to configure and operate the
discrete inputs on a Honeywell UDC 3500
controller
• Prepare the system by draining the fluids from the system
through the drain valve. Process fluid loops, hot water loops,
pump-priming valve, and extension plugs must be tightened.
• Fill the hot water until level switch, fill the process tank up to ¾
of maximum level, and connect the pressure regulator.
• Connect the electricals needed and start the system.
• Adjust the thermostat and ensure default settings provided
• Set the following parameters in INPUT 1 group

• Press setup key repeatedly until you reach CONTROL group

• Press Func Loop ½ until LSPs parameter and set the parameter
to 2
• In the OPTIONS group, set parameter to DIG INIP1 to 2SP
• Set SP to 26C or 78F, set 2SP to 29C or 85F.
• Turn on hot water pump, process pump, and chiller.
• After the temperature settles at 2SP temperature, disconnect the
jumper across the discrete input terminals.
• To shutdown, turn off hot water heater and process pump,
disable alarms, and turn off main circuit breaker
THANK YOU FOR LISTENING