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RT 580 Fault Finding in Control Systems
Education / GUNT Hamburg / Process Engineering / Complex Process Engineering Control Systems /

The RT 580 facilitates practical learning in the control of three controlled variables which are commonplace in process engineering.
  A circuit with a collecting tank, pump and graduated tank is provided for control of level and flow rate. A pneumatic control valve is used as the actuator. There is a valve in the tank outlet to generate a disturbance variable in level control. Cascade control is possible whereby the level in the tank is controlled by way of the flow rate.
  Two circuits are used in the control of the temperature. A refrigeration system cools the water in the collecting tank. A pump circulates the water via a heat exchanger (cooling circuit). A heater heats the water in the graduated tank. Another pump also circulates the warm water via the heat exchanger. In the heat exchanger the water in the cooling circuit is heated. The controlled variable is the temperature of the water in the cooling circuit after heating in the heat exchanger. The actuator is the pneumatic control valve which adjusts the flow rate of the warm water. Cascade control is also possible to control the temperature.
  Two industrial controllers are supplied which can be employed as the master and slave in the implementation of cascade control. They have a Profibus DP interface. This enables the trainer to be controlled by way of a software. The software also permits recording of the process variables and parameterisation of the controllers on the PC.

  The trainer is equipped with a PLC for monitoring of safety devices, such as a low water cut-off which protects the heater. On the switch

cabinet there are also pushbuttons for the simulation of typical faults such as failure of sensors or cable breaks.


Learning Objectives / Experiments

- familiarisation with industrial control loop

- setup, parameterisation and configuration on the

- optimisation of controller settings
- level control
- flow rate control
- temperature control
- cascade control, level - flow rate
- cascade control, temperature - flow rate
- plotting step responses
- fault finding


[1] control of level, flow rate, temperature and cascade control
[2] main circuit with collecting tank, graduated stirred tank with heater, pneumatic control valve and centrifugal pump
[3] cooling circuit with pump, heat exchanger and rotameter
[4] refrigeration system and pump to cool the water in the collecting tank
[5] pneumatic control valve in main circuit as actuator for all controls
[6] sensors for the measurement of the controlled variables; level, flow rate and temperature
[7] 2 parameterisable industrial controllers
[8] 6 pushbuttons for fault simulation
[9] PLC to monitor safety devices
[10] LabVIEW process control software via Profibus DP interface under Windows XP or Windows Vista


Technical Data

- graduated tank with stirrer: approx. 7L
- collecting tank: approx. 90L 
Main circuit centrifugal pump
- max. flow rate: approx. 75L/min
- max. head: approx. 20m
2 pumps, cooling circuit and refrigeration system
- max. flow rate: approx. 60L/min
- max. head: approx. 4m
Heater power output: approx. 2kW
Controller parameterisable as
- P, PI or PID controller
Sensor measuring ranges
- level: 0...350mm
- flow rate: 0...1.999L/h
- temperature: 0...100°C


Dimensions and Weight

LxWxH: 1.920x800x1.530mm
Weight: approx. 245kg

Required for Operation
230V, 50/60Hz, 1 phase or 230V, 60Hz, 3 phase
Compressed air: 3...8bar
Scope of Delivery

1 trainer
2 controllers

1 Satz Kabel

1 Profibus card
1 CD with PLC programming software
1 LabVIEW software CD
1 set of instructional material

Order Details

080.58000  RT 580  Fault Finding in Control