FluidLab® PA for Compact Workstation and EduKit® PA Manual
Process Control System EN 12/08
Intended use
This software has been developed and produced solely for vocational and further training purposes in the field of automation and communication. The company undertaking the training and / or the instructors is / are to ensure that trainees observe the safety precautions described in the manuals provided. Festo Didactic herewith excludes any liability for damage or injury caused to trainees, the training company and / or any third party, which may occur if the system is in use for purposes other than purely for training, unless the said damage / injury has been caused by Festo Didactic deliberately or through gross negligence.
Order No.: Description:
Manual
Designation:
Fluid Lab-PA Software
Status:
12/2008
Authors:
Jürgen Helmich, Adiro Automatisierungstechnik GmbH
Graphics:
Thomas Schwab, Adiro Automatisierungstechnik GmbH
Layout:
Jürgen Helmich, Adiro Automatisierungstechnik GmbH
© Festo Didactic GmbH & Co., D-73770 Denkendorf, 2004 Internet: www.festo.com/didactic http://www.festo.com/didactic/de/ProcessAutomation e-mail:
[email protected] The copying, distribution and utilisation of this document as well as the communication of its contents to others without express authorisation of is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration.
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Contents
1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8
Introduction ____________________________________________________ 5 Compact Workstation _____________________________________________ 7 Training contents ________________________________________________ 7 Important notes _________________________________________________ 8 Duty of the operating authority _____________________________________ 8 Duty of trainees__________________________________________________ 8 Risks involved in dealing with Process Lab ___________________________ 9 Warranty and liability _____________________________________________ 9 Use for intended purpose_________________________________________ 10
2
Notes on safety_________________________________________________ 11
3
Technical data _________________________________________________ 13
4
Transport / Unpacking / Scope of delivery__________________________ 15
5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20
Installation ____________________________________________________ 17 Package design _________________________________________________ 17 FluidLab® PA program files _______________________________________ 17 EzOCX driver ___________________________________________________ 18 © LabVIEW runtime engine 8.2.1 ___________________________________ 18 Hardware ______________________________________________________ 18 Cable connections_______________________________________________ 19 Starting installation _____________________________________________ 19 Selecting the set-up language _____________________________________ 19 Welcome window _______________________________________________ 20 License agreement ______________________________________________ 21 Licence data____________________________________________________ 22 Destination location _____________________________________________ 23 Components ___________________________________________________ 24 Start menu folder _______________________________________________ 26 Additional tasks ________________________________________________ 27 Ready to Install _________________________________________________ 28 The installation process __________________________________________ 29 Installation Active-X _____________________________________________ 30 Installation Run-Time Engine 8.2.1 ________________________________ 39 Uninstall the FluidLab® PA _______________________________________ 44
© Festo Didactic GmbH & Co. • FluidLab-PA Software
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Contents
4
6 6.1 6.2 6.3 6.4 6.4.1 6.4.2 6.5 6.6 6.6.1 6.7 6.8 6.8.1 6.9 6.9.1 6.9.2
Design and function _____________________________________________ 45 Start up window ________________________________________________ 45 Information ____________________________________________________ 47 Software setup _________________________________________________ 48 Changing texts__________________________________________________ 53 Window texts___________________________________________________ 53 Pop up’s _______________________________________________________ 55 Graph adjustment _______________________________________________ 56 Measuring and Control ___________________________________________ 57 Example of how to measure a system response ______________________ 59 Characteristics__________________________________________________ 60 Closed loop – 2 point ____________________________________________ 62 Procedure using EasyPort and Simulation ___________________________ 63 Closed loop - Continuous _________________________________________ 64 Procedure using EasyPort and Simulation ___________________________ 66 Saving results as ASCII files _______________________________________ 66
7 7.1 7.2
Trouble shooting _______________________________________________ 69 Measured values________________________________________________ 69 User interface __________________________________________________ 70
8 8.1 8.2 8.3 8.4
Appendix ______________________________________________________ 71 Examples for system responses ___________________________________ 71 Examples for closed loop controls__________________________________ 76 Controller parameters ___________________________________________ 80 Empty I/O assignment list ________________________________________ 81
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
1
Introduction
FluidLab®-PA start up window The FluidLab® PA software in combination with the EasyPort USB offers you the possibility to measure and analyze the signals of 8 digital/4 analog inputs. The electrical control interface (E/A Syslink and analog terminal) is the same like MPS. Three main functions are integrated in Process Lab: M C R
as in measurement, for signal detection and analysis of 8 digital/4 analog input signals as in open loop control, for binary or continuous control of 8 digital/2 analog outputs as in regulate a closed-loop system, free selectable closed-loop control elements for 2-point, P, I, PI and PID
© Festo Didactic GmbH & Co. • FluidLab-PA Software
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Introduction
With the Compact Workstation of the learning system for process automation you have the possibility to work with the following systems: • • • •
level controlled system flow rate controlled system pressure controlled system temperature controlled system
It is possible to work with the following functions by using the 4 closed-loop systems: • two point control of a level control system with a analog standard signal • continuous control of a level control system with a analog standard signal • continuous control of a flow rate control system with a pump as controlled system and with a analog standard signal • continuous control of a flow rate control system with a proportional valve as controlled system and with a analog standard signal • continuous control of a pressure control system with a pump as controlled system and with a analog standard signal • continuous control of a pressure control system with a proportional valve as controlled system and with a analog standard signal • two point control of a temperature control system with a analog standard signal
Alternatively you are able to work with a simulation environment, with which you can simulate the systems of a Compact Workstation. By using the simulation environment with the continuous loop control you can simulate the following functions: • level controlled system • flow rate controlled system • temperature controlled system By using the simulation environment with the continuous loop control you can simulate the following functions: • level controlled system • flow rate controlled system • temperature controlled system
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Introduction
1.1 Compact Workstation
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 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 Moreover, training can be provided to instill team spirit, willingness to cooperate and organisational skills. Actual project phases can be taught by means of training projects, such as: • • • • • • •
1.2 Training contents
Planning, Assembly, Programming, Commissioning, Operation, Maintenance and Fault finding.
Training contents covering the following subjects can be taught: • Process Engineering – Reading and drawing flow charts and documentation • Electrical technology – Correct wiring of electrical components • Sensors – Correct use of sensors – Measuring of non-electrical, process and control variables • Closed-loop control technology – basics of closed-loop control technology – Extension of measuring chains into closed control loops – Analyze a closed-loop system – P, I, D-control – Optimize a closed-loop system • Closed-loop controller
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Introduction
– Configuration, assigning operation parameters and optimization of a closed-loop controller • Commissioning – Commissioning of a closed-loop system – Commissioning of a process engineering system • Fault finding – Systematic fault finding on a process engineering system – Examination and maintenance of a process engineering system – Operation and observation of a process
1.3 Important notes
The basic requirement for safe use and trouble-free operation of FluidLab® PA is to observe the fundamental safety recommendations and regulations. These operating instructions contain important notes concerning the safe operation of FluidLab® PA. The safety recommendations in particular must be observed by anyone working on FluidLab® PA as well as for the used hardware. Furthermore, the rules and regulations for the prevention of accidents applicable to the place of use must be observed.
1.4 Duty of the operating authority
The operating authority undertakes to ensure that FluidLab® PA is used only by persons who: • are familiar with the basic regulations regarding operational safety and accident prevention and who have received instructions in the handling of Process Lab, • have read and understood the chapter on safety and the cautionary notes in these operating instructions and confirmed this by signing, • are regularly vetted to ensure safe working.
1.5 Duty of trainees
Prior to commencing work, all persons assigned to working on FluidLab® PA have a duty to: • observe the basic regulations regarding operational safety and the prevention of accidents, • read the chapter on safety and the cautionary notes in these operating instructions and to confirm that they have understood these by signing.
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Introduction
1.6 Risks involved in dealing with Process Lab
The Fluid Lab®-PA software is designed according to state of the art technology and in compliance with recognised safety regulations. However when using the system there is nevertheless a risk of physical or fatal injury to the user or third parties or of damage being caused to the machinery or other material assets. Fluid Lab®-PA is to be used only: • for its intended purpose and • in an absolutely safe conditions.
Faults impairing safety must be rectified immediately!
1.7 Warranty and liability
In principle all of our „Terms and Conditions of Sale“ apply. These are available to the operating authority upon conclusion of the contract at the latest. Warranty and liability claims for persons or material damage are excluded if these can be traced back to one or several of the following causes • Use of the machine not in accordance with its intended purpose • Incorrect assembly, commissioning, operation and maintenance of the machine • Operation of the machine using faulty safety equipment or incorrectly fitted or non operational safety or protective devices • Non observance of notes in the operating instructions regarding transport, storage, assembly, commissioning, operation, maintenance and setting up of the machine • Unlawful constructional modifications on the machine • Inadequate monitoring of machine components subject to wear • Incorrectly carried out repairs • Catastrophes as a result of foreign objects and acts of force major. Festo Didactic herewith rules out any liability for damage or injury to trainees, the training company and /or other third parties which may occur during the use / operation of the system other than purely in a training situation, unless such damage has been caused intentionally or due to gross negligence by Festo Didactic.
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Introduction
1.8 Use for intended purpose
This system has been developed and produced exclusively for vocational and further training in the field of automation and communication. The training authority and / or the instructors is / are to ensure that trainees observe the safety precautions described in the manual provided. The use of the system for its intended purpose also includes: • following all advice in the operating instructions and • carrying out inspection and maintenance work.
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Notes on safety
General • Trainees 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 are to be wired up or disconnected only when power is disconnected! • Use only low voltages of up to 24 V DC. Pneumatics • 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 machine is at rest. • The pump can be mounted horizontally or vertically. If mounted, the output of the pump must point upwards. The pump must be mounted so that is flooded (see also data sheet).
© Festo Didactic GmbH & Co. • FluidLab-PA Software
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Notes on safety
Process engineering • Before filling the tanks with water switch of power supply! Switch of power supply 24 VDC and 230 VAC (110 VAC)! • 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 +65 °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 FluidLab® PA by opening hand valve V105
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Technical data
Parameter
Value
Digital Inputs
8
Digital outputs
8
Analog inputs
4
Analog outputs
2
Voltage range analog input voltage analog output voltage
0…10VDC 0…10VDC
Use only voltage signals with EasyPort DA!
© Festo Didactic GmbH & Co. • FluidLab-PA Software
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Technical data
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Transport / Unpacking / Scope of delivery
Transport FluidLab® PA is delivered on CD in a systainer. The carrier and Festo Didactic are to be notified immediately of any damage caused during transport. Unpacking When unpacking, make sure that the CD has not been damaged. Check the CD for any possible damaged once unpacked. The carrier and Festo Didactic are to be notified immediately of any damage. Scope of delivery Check the scope of delivery against the delivery note and the order. Festo Didactic must be notified immediately of any discrepancies.
© Festo Didactic GmbH & Co. • FluidLab-PA Software
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Transport / Unpacking / Scope of delivery
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
5
Installation
®
Note
The installation routine described applies to the FluidLab PA version for the ® MPS PA Stations, as well as to the version for the Compact Workstation and EduKit PA.
5.1 Package design
The FluidLab® PA software is delivered on CD. It comes packed in a setup.exe. To start the installation process just launch the executable file out of the Windows® Explorer. FluidLab® PA needs several components of third party distributors to work successfully. See the description below for details. The basic components of the software package are: • FluidLab® PA program files • EzOCX driver © • LabVIEW Runtime environment (Version 8.2.1) optional • EasyPortUSB driver
5.2 FluidLab® PA program files
(Third party distributor files) (Third party distributor files) (Third party distributor files)
Table of the sub-folders created on your local system after the installation process has been finished successfully: Folder name
Description
addFiles
Folder for additional components like icons, internet links, etc.
Settings
Folder where pre-settings are stored in.
German
Files for the German version of Process Lab
English
Files for the English language version of Process Lab.
Spanish
Files for the Spanish language version of Process Lab
French
Files for the French language version of Process Lab.
Swedish
Files for the Swedish language version of Process Lab.
Chinese
Files for the Chinese language version of Process Lab.
EzOCX
Driver for the connection with the EasyPor digital, analog.
National
Runtime for FluidLab-PA
Instruments
Note
A main folder is defined in the setup routine where the folders specified above are copied to. It is possible that files from third party distributors are copied to other folders.
© Festo Didactic GmbH & Co. • FluidLab-PA Software
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Installation
5.3 EzOCX driver
The EcOCX driver is needed for communication between FluidLab® PA software and EasyPort USB via USB cable.
5.4 © LabVIEW runtime engine 8.2.1
Because FluidLab® PA is developed with LabVIEW of National Instruments the software uses a runtime environment to be executed on your system.
5.5 Hardware
Required hardware:
©
©
• PC (min.: Pentium II 450MHz, 128MB RAM, 100MB free memory) • MPS® PA Compact Workstation or EduKit® PA with I/O-board 6
7
8
2
2.32
X2
XMA1
5
4
1 3
Hardware connections Compact Workstation – EasyPort USB
18
1
EasyPort USB
2
I/O terminal Syslink
3
SysLink cable
4
Analog terminal
5
Analogue cable, 15-PIN, parallel
6
Power supply 24 V DC, 4,5 A
7
Labor cable with Safty plug(red/blue)
8
USB Cable oder PC data cable RS 232
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
5.6 Cable connections
All cable connections are described as an example for a Compact-Workstation with EasyPort USB • EasyPort USB – station: connect the Port 1 (Digital I/O) of the EasyPort with the XMA1 socket of the I/O terminal (2) of the Compact-Workstation with a SysLink cable (3). • EasyPort USB – station: connect the Port 3 (Analog I/O) of the EasyPort with the X2 socket of the analog terminal(4) of the PCS Compact-Workstation with a analog cable (5). • EasyPort USB – PC: connect USB port of the EasyPort with PC with a USB cable (8). • EasyPort USB – Power supply: connect the EasyPort power socket (- 24V +) to a 24VDC voltage supply
5.7 Starting installation
®
It is advisable to exit all other programmes before you start installing FluidLab PA. Insert the installation CD into the CD drive. An installation routine should start automatically and assists you throughout the installation process. If the installation routine does not start automatically, open Windows Explorer and click the icon of the CD drive into which the CD has been inserted. Then click the “setup.exe” file.
5.8 Selecting the set-up language
Various languages can be selected for the installation routine including German, English, Spanish, French or Swedish. The language selection takes place in the first dialog box.
Select language
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Installation
5.9 Welcome window
®
The FluidLab PA version and the installer version are displayed in the welcome window.
Welcome window
All of the subsequent windows included in the installation routine have the same layout. Click the “Next” button in order to continue to the next window. Click the Cancel button in order to abort the installation process. In the windows that follow, you can click the “Back” button to return to the previous window.
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
5.10 License agreement
®
In order to install FluidLab PA software, you must accept the licence agreement. Read the licence agreement carefully. If you accept the agreement, select the “I accept the agreement” option.
License agreement
Click the “Next” button in order to continue the installation
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Installation
5.11 Licence data
®
In order to ensure that you are authorised to use the full version of FluidLab PA software, you’ll need to enter your licence data during the installation process. The needed information can be found on the back site of your CD-ROM cover (fields labelled “User Name” and “Serial number”). Be sure to enter these fields correctly. Upper case letters, lower case letters and blanks must be entered as seen below! If any entries are incorrect, it will only be ® possible to use the demo version of FluidLab PA which has limited functionality.
Licence data
After completing your entries, click the “Next” button. Note
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 FluidLab® PA. This file can be found in the main installation. Also for demo mode or false input the license can be changed in the information window. The file has to be layouted as follows: First line: License name + carriage return + line feed Second line: License key
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
5.12 Destination location
®
Select a destination folder to which all of the files for FluidLab PA software are to be copied.
Destination location
Click the “Next” button in order to continue the installation.
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Installation
5.13
Components
Select the components that you would like to install.
Components
After selecting the desired components, click the “Next” button List of components
Parameter
Description
optional
Fluid Lab®-PA for
All required program files (without required files from other
Yes
CWS/EduKit PA
manufacturers)
Fluid Lab®-PA für
All required program files (without required files from other
MPS® PA
manufacturers)
LabView Runtime Environment. 8.2.1
Runtime for Fluid Lab®-PA
Yes
EzOCX
Driver for data communication via RS 232
Yes
®
®
Yes
Manuals MPS PA
Manuals for MPS PA in English and German
Yes
- Manuals
Manuals for Compact Workstation in English and German
Yes
Compact Workstation
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
Component selection
Parameter ®
Components
FluidLab® PA ®
for MPS PA
FluidLab® PA for ®
MPS PA
FluidLab PA for Compact Workstation
Yes
®
LabView Runtime Env. 7.1
MPS PA EzOCX Manuals
Compact Workstation Manuals
Yes
Yes
Yes
Yes
Yes
Yes
X
X
X
X
X
X
Yes
Yes
Yes
Yes
Yes
Yes
®
FluidLab PA for Compact Workstation User defined installation Full installation
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Yes
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Installation
5.14 Start menu folder
®
Select the folder in the start menu, where the shortcuts required for FluidLab PA will be created.
Select start menu folder
Created shortcuts inside the start menu folder: • “Fluid Lab®-PA (CWS or EduKit PA)” – to start the software for Compact Workstation • “Fluid Lab®-PA (MPS-PA)” – to start the software for MPS®-PA • “Uninstall Fluid Lab®-PA” – to uninstall the FluidLab® PA software • Internet sub folder with: – Link to Festo Didactic home page – Link to Adiro home page • “Manuals” –Sub folder with links to the installed manuals • Click the “Next” button in order to continue the installation.
Click the “Next” button in order to continue the installation. Note:
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You need an active Internet connection to use the Internet shortcuts.
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
5.15 Additional tasks
®
You can choose whether or not a desktop icon will be created for FluidLab PA.
Create a desktop icon
Click the “Next” button in order to continue the installation.
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Installation
5.16 Ready to Install
This window displays a summary of all of the selections you have made so far.
Ready to install
Click the “Install” button in order to start the installation. Note
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The appearance of this window may vary depending upon the components to be installed.
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
5.17 The installation process
The window shown below appears during installation. All required files are copied to the hard disk. A progress bar shows the current status of the installation process. Please wait until the installation process has been completed. The length of time required for installation depends upon the PC specification.
Installation process
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Installation
5.18 Installation Active-X
The installation of the Active-X is automatically started.
Select Language
Select language and click on „OK“.
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
EzOcx32
Click on the “Next” button in order to start the installation.
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Installation
In order to install EasyPort Active X Control, you must accept the licence agreement. Read the licence agreement carefully. If you accept the agreement, select the “I accept the agreement” option.
End User License Agreement
Click on the “Next” button.
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
Select User Group
Selec user groupe and click on the “Next” button.
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Installation
Select the destination folder to which the driver files will be copied
Select Destination Folder
Click the “Next” button in order to continue the installation.
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
Select Program Manager Group
Click on the “Next” button in order to continue the installation.
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Installation
Acknowledge once again if you want to install the driver.
Start Installation
Click on the “Next” button in order to start the installation.
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
Driver installation has been successfully completed.
Installation Completed
Click on the “Finish” button in order to end the installation.
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Installation
After a successful installation of the FluidLab® PA software program files a window will appear as shown below. This is the end of the FluidLab® PA installation routine. Click the “Finish” –button to complete.
Installation complete
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
5.19 Installation Run-Time Engine 8.2.1
The following window appears when the driver installation process has been completed.
Run-Time Engine Setup
Click the “Next” button to start the installation.
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Installation
In order to install Runtime Engine 8.2.1, you must accept the licence agreement. Read the licence agreement carefully. If you accept the agreement, select the “I accept the licence agreement” option“.
Licence Agreement
Click the “Next” button in order to continue the installation.
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
Select Features
Click the “Next” button in order to continue the installation.
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Installation
Acknowledge once again if you want to install Runtime Engine 8.2.1.
Ready to Install the Application
Click the “Next” button in order to start the installation.
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Installation
Driver installation has been successfully completed.
Installation complete
Click the “Finish” button to exit installation.
Notice
It is recommended to restart your system after installation.
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Installation
5.20 Uninstall the FluidLab® PA
®
FluidLab PA software can be automatically removed from your PC. Click ® “Uninstall FluidLab PA” in the start menu folder. ®
Please note that only FluidLab PA files are removed during the uninstall process, not files from other manufacturers.
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
6
Design and function
6.1 Start up window
After the software is launched either by double clicking the icon on the desktop or clicking the shortcut in the start menu folder or double clicking the executable in the Windows Explorer the following window will appear.
®
FluidLab -PA icon for Compact Workstation/EduKit PA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 Start up window
© Festo Didactic GmbH & Co. • FluidLab-PA Software
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Design and function
This window is the central element of the software. From here you have access to all functionality. Number
Function
1
Open the “Measurement and Control” window for analyzing the system (not available in simulation mode)
2
Open the “Characteristics” window (not available in simulation mode)
3
Open the “Closed loop – 2 point” window for realizing a 2 point closed loop control for the level system e.g.
4
Open the “Closed loop - continuous” window for realizing a continuous closed loop control
5
Open the “Setup” window for setting up the FluidLab® PA software.
6
“Open” button for loading existing FluidLab® PA setup files.
7
“Save” button to create a new FluidLab® PA setup file or overwrite an existing one.
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8
Show information about FluidLab® PA software and license input for false input or demo mode.
9
Language settings
10
“Demoversion” if there is no valid serial number or user name
11
Version of FluidLab® PA
12
Initialise communication to EasyPort
13
Indication of conneted EasyPort
14
License name
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Design and function
6.2 Information
Click the “Information” button in the main window. A window appears containing various information such as copyrights and system requirements.
Information window
If running in demo mode or at false input of the license the button “Lizenz” is visible.
License input
Please enter your license name and code again. On right input the window will automatically close. See backside of the Fluidlab-PA CD for license information.
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Design and function
6.3 Software setup
Click at the setup button in the start up window. The following window will appear.
Setup window
Note
Please note that this software in combination with the EasyPort DA is only for measuring voltage signals from 0 to 10VDC. Check all functions of each binary sensor and actuator.
Digital inputs/outputs in the setup window
Check functions of analog actuators.
Analog outputs in the setup window
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Design and function
Note
Output channel 0 and 1 of the EasyPort DA are swapped according to the assignment of the analog interface of the station (EduTrainer)!
Analog input channel 0
The analog signal of the sensor, normally 0...10V, has to be calculated, so the physical value can be shown. = measure value * factor + Offset
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
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Design and function
This conversion is based on a straight line equation: Y =a
⋅x +b
Where: a = factor; b = Offset; x = measure value and y = physical value Example: A flow sensor reads out a voltage signal within a range of 0 to 10 V for a measuring range of 0.3 to 9.0 litres per minute. In this case, factor “a” is calculated as follows:
a=
y − b 9.0 − 0 = = 0 .9 x 10
The offset is found by shifting of the line’s initial point to the origin.
x=
y − b 0 .3 − 0 = = 0.33 a 0 .9
b = − X 0 , = −0.33
L/min 0,9 0,9
} X
Bb 0
Y Y X
A
a 10 V
Graph of straight line equation
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© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Design and function
Example, factor: Sensor: 0..200 bar Signal: 0..10V so the factor has to be = 20 Example, offset: Sensor: 0..100 bar Signal: 0..10V, for measurement 5 bar should be = 0V. 55 bar should be 5 Volt so the offset has to be = -5 Eventually the factor has to be adjusted, too.
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Design and function
Analog input channel description
Component
Description
Channels
Analog input channels 0…3
Volts
Input voltage of EasyPort
Factor
Factor for multiplying the input voltage; Standard value:
Offset
Zero offset factor Standard value:
Filter
1
0
For filtering the input signal (average value 0..90 times); Standard value:
0
The average value filter physical value
Indication of physical value
Einheitenfeld
Input field for physical unit
Max. physical
Input field for maximum shown physical value for scale
value
Simulation
You can configure this software so you do not have to work with a Compact Workstation but in a simulation mode. To do so, switch the button from “EASYPORT” to “Simulation” and close the setup window.
Inverting control ratio
It is possible to change the direction of the control ratio for 2-point and continous controllers. Inverting control ratio
Description
0
Positive control ratio
1
Negative control ratio
y-offset-pump
For continous controller the pump can be set to an offset value of the controller ouput.
Note
At the startup of Fluid Lab®-PA always the file “default.txt” in the sub folder “Settings” is loaded. If you want to have the simulation mode selected every time you start Fluid Lab®-PA you should save the simulation settings in this file. Alternatively you have to load your preferred configuration every time you start Fluid Lab®-PA.
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Design and function
It is recommended to test every component before starting with FluidLab® PA to ensure that all hardware connections have been established successfully.
Note
6.4
Changing texts
FluidLab® PA is designed with multi language support. The displayed window and popup texts are available in following languages: • • • • • • •
German English French Spanish Swedish Chinese ... other languages available upon request
6.4.1
Window texts ©
The window texts in FluidLab® PA can be changed. Use an editor like Microsoft Editor e.g. The relevant files are located in subdirectories of the FluidLab® PA directory and differ by virtue of their suffix (file name extension): • • • • • • •
German language text English language text French language text Spanish language text Swedish language text Chinese language text ...
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
...\German\ Regeln.GER ...\English\ Regeln.ENG ...\French\ Regeln.FRA ...\Spanish\ Regeln.SPA …\Swedish\Regeln.SWE ...\Chinese\ Regeln.CHN
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Design and function
©
Microsoft Editor for editing window texts
Layout of the text file
Every line starts with a number and a following colon. Behind the colon the caption text begins. It is recommended not to change this layout. Only edit the text behind the colon!
Note
It is recommended to choose short texts for the window texts.
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6.4.2
Pop up’s
FluidLab® 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 for just a split second a text will come up to show 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 subdirectories of the FluidLab® PA directory and differ by virtue of their suffix (file name extension): • • • • • • •
German pop up texts English pop up texts French pop up texts Spanish pop up texts Swedish pop up texts Chinese pop up texts ...
...\German\ popup.GER …\English\ popup.ENG …\French\ popup.FRA ...\Spanish\ popup.SPA …\Swedish\popup.SWE ...\Chinese\ popup.CHN
©
Microsoft Editor for editing the pop up texts
Layout of the text file
Every line starts with a number and a following colon. Behind the colon the pop up text begins. It is recommended not to change this layout. Only edit the text behind the colon!
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Design and function
To edit the text for the proportional valve for example (see picture below) edit line “21A4” in the text file.
Pop up for the proportional valve
Note
Please note that the length of the text must not exceed about 54 signs. If the text is longer it will be cut off. Mulitline popup´s can be created with a spacer “#”. All text files are prepared for the use of FluidLab® PA with the PCS Compact -Workstation.
6.5 Graph adjustment
The colors, line styles, line width etc. of the single graphs in the diagram can be modified. To do this, position the mouse cursor on the displayed line and press the left mouse button. A submenu for setting will be opened.
Graph adjustment
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6.6 Measuring and Control
The Measuring and Control window is to analyze your actual system and to control every single element of it. The “Measuring and Control” –function can be selected at the main window.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Measuring and Control window
Note
This function is only available when used in combination with an EasyPort. In the simulation mode this function is disabled.
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Design and function
Tabelle der verfügbaren Funktionen im Messen und Steuern Fenster Number
Function
1
Switch on diagram zoom
2
Switch off diagram zoom
3
Select zoom zone
4
Switch courser to basic form
5
Select signals and colouor of the curves
6
Select cycle time (min. 40ms or higher)
7
Digital input and outputs
8
Pull-down menu fort he manipulated value, can be switched ON/OFF by the button “control value ON/OFF”
9
Analogue outputs 0 … 10V
10
Start/Stop reading of the values
11
control value ON/OFF
12
Cursor analysis fort he recorded curves
13
Reset cursor to the left upper corner of the graph
14
Print window (screenshot) Save window (screenshot) as JPG Save values to ASCII file
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15
Auto scaling ON/OFF
16
Start postion of curser
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Design and function
6.6.1
Example of how to measure a system response
This example describes how to measure a system response of the flow rate system for working with the PCS Compact-Workstation. The window is layouted to be able to work in the easiest way possible. Just start at the top of the tool bar at the right side of the window and move down step by step. After you have done that do your measurement and solve the exercise. 1.
Choose the analog input channel to display at the graph. (To work with the flow rate sensor choose channel 1) 2. Presetting: Click the “delete”-button to delete an old measurement. It is recommended to do this step before every new measurement exercise. 3. Choose the digital outputs. Flow rate system: Ensure output bit 2 is disabled (digital control of the pump) 4. Set manipulated value to „DOUT3 pump“ 5. Press the “start”-button to start the measurement. After that it will change to a “stop”-button with which you will have to stop the measurement again before proceeding. 6. Stellgröße ein- und ausschalten um ein Signal auf die Pumpe zu geben. 7. Use the “Cursor analysis” for analyzing the system response. 8. Documentation: Save the window as a picture (JPG-file) on your system or print it to a connected printer.
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Design and function
6.7 Characteristics
Characteristic curves can be mearued in this menu. • flow rate of the pump for the voltage 0 … 10V and 10V … 0V • pressure rate of the pump for the voltage 0 … 10V and 10V … 0V • coherence between flow rate and pressure for a specific voltage
1 2 3 4 5 6 7 8 9 10 11 12 Window Characteristics
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Tabelle der verfügbaren Funktionen im KennlinieFenster Number
Function
1
Curve
2
Clear diagram or open a bmp file
3
Selection of recording characteristic curve –experiment: 1.
flow rate of the pump for the voltage 0 … 10V and 10V … 0V
2.
pressure rate of the pump for the voltage 0 … 10V and 10V … 0V
3.
coherence between flow rate and pressure for a specific voltage
4
Digital inputs
5
Analogue inputs
6
Digital outputs
7
Select analogue output
8
Setting of the experiment time [s] for experiment 1. or 2.
9
Indication of the voltage curve for experiment 1. or 2., input slider for experiment 3.
10
Start/Stopp experiment
11
Cursor analysis
12
Print window (screenshot) Save window (screenshot) as JPG Save values to ASCII file
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6.8 Closed loop – 2 point
With the “Closed loop – 2 point”-function you are able to realize a closed loop 2- point control for example for the level system.
1 2 3 4 5 6
7 8 9 10 11 12 Closed loop – 2 point control window in simulation mode
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Design and function
Tabelle der verfügbaren Funktionen im Regeln Zweipunkt Fenster Nummer
Funktion
1
Curve
2
Clear diagram or open a bmp file
3
Select control system
4
Switch ON/OFF simulation window (only accessible if using Simulation mode)
5
Digital inputs
6
Select manipulated output
7
Setting set point value SP
8
Setting of switching distance
9
Simulation window of the system
10
Start/Stopp experiment
11
Print window (screenshot) Save window (screenshot) as JPG Save values to ASCII file
12
6.8.1
Auto scaling ON/OFF
Procedure using EasyPort and Simulation
• Select control system (3) • diagram and settings are set automatically • Set controller’s parameters (6) – Set point (7) and switching difference (8). • For simulation additionally: select simulation switch ON(3) • Start the closed loop control with the “Start”-button(10). • Stop the closed loop control with the “Stop”-button(10) • Documentation(13)
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Design and function
6.9 Closed loop - Continuous
With the “Closed loop – continuous”-function you are able to realize a continuous closed loop control for the pressure system for example.
1 2 3 4 5 6 7 8 9 10 11
12 13 14 Window of closed loop control (continuous) of the level system in simulation mode
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Design and function
Number
Function
1
Curve
2
Clear diagram or open a bmp file
3
Select Closed-Loop
4
Switch ON/OFF simulation window (only accessible if using Simulation mode)
5
Settings for process value will be automatically selected
6
Setting setpoint
7
Select manipulated output
8
Setting set point value SP
9
Simulation window of the system (only accessible if using Simulation mode)
10
Setting of controller type and parameters
11
Open controller block function diagram
12
Start/Stopp experiment
13
Print window (screenshot) Save window (screenshot) as JPG Save values to ASCII file
14
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Auto scaling ON/OFF
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Design and function
6.9.1
Procedure using EasyPort and Simulation
• • • •
Select control system (3) For simulation additionally: select switch ON(4) Choose the controller you prefer and set its parameters( 10). Start the closed loop control with the “Start”-button (12). – Watch and work with the closed loop control. • Stop the closed loop control with the “Stop”-button (12) • Documentation(13)
manual / automatic operation
In the middle of the window you can find a switch(?). You are able to choose between automatic or manual operation At manual operation activated a slide bar. With this slide bar you are able to influence the set point.
6.9.2
Saving results as ASCII files
Using this function (the button 13 _Excelbutton can be found in the lower right corner in the screenshot above) you are able to save the graph values in an ASCII © file. This file can be imported in Microsoft Excel e.g. for further documentation. ©
Example how to import the data file into Microsoft Excel: 1 2 3 4 5
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Record the measuring Click the button „ASCII“(13) to save the values to a file © Open Mircosoft Excel Open the saved file (Menu “File” Open - as the case may be you have to change the file filter in the appearing open dialog to “all files (*.*)”) Follow the convert assistant as shown below
© Festo Didactic GmbH & Co. • Fluid Lab®–PA Software
Design and function
©
Microsoft Excel convert-assistant, Step 1 of 3
Options to choose at Step 1 of 3: Original file type: separated Click on „Next >“
©
Microsoft Excel convert-assistant, Step 2 of 3
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Design and function
Options to choose at Step 2 of 3: Use successive separators as one sign Separator: tabulator blank Sign to identify text: “ Click on „Next >“
©
Microsoft Excel convert-assistant, Step 3 of 3
Options to choose at Step 3 of 3: Data format of columns:
Standard
Click on „finish“
The data will now be imported into Excel.
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Trouble shooting
7.1 Measured values
No measured values appear • Check whether voltage is applied to the system • Check whether all cables are properly connected. • The green connection status LED on the EasyPort must flash.
on off
t
LED flashes with short pause and long pulse – connection active
on off
t
LED flashes with same pause and pulse – connection inactive
• Terminate the software after changing the value and save the data (diskette icon); then quit the menu and restart the software. • Check whether the mode dip switches of the EasyPort are correctly set.
Measured values are wrong! If the values do not correspond with the physical quantities, then factor and offset must be set in the setup window (spanner icon).
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Trouble shooting
7.2 User interface
FluidLab® PA does not start • LabVIEW Runtime environment not installed
Window image too small • The software is set to 800 x 600 pixels or higher. © Set your window to this resolution in Windows .
Measured values appear, but there are no lines in the diagram • Check the minimum and maximum scale values. You may have to set them to the momentary measured values. • Check the colors of the characteristic curves (white on white?)
Measured values exhibit extreme oscillation • Change the default for filtering of the signals.
For online support please contact our competence center for process automation
[email protected]
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Appendix
8.1 Examples for system responses
See screen shots below for detailed information of how to measure system responses with FluidLab-PA. All results shown refer to the work with PCS Compact-Workstation.
System response flow rate system
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Appendix
System response level system without compensation
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Appendix
System response of level system with compensation
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Appendix
System response pressure system
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Appendix
System response of temperature system
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Appendix
8.2 Examples for closed loop controls
See screen shots below for detailed information of how to run closed loop controls with Process Lab. All results shown refer to the work with PCS Compact-Workstation.
Closed loop control of level system
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Appendix
Closed loop control of flow rate system with disturbances
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Appendix
Closed loop control of pressure system via pump
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Appendix
Closed loop control of pressure system via proportional valve
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Appendix
8.3 Controller parameters
Controller
The following table shows examples for controller parameters for the work with PCS Compact-Workstation.
Flow rate pump
Level
Flow rate prop. valve
Pressure pump
Pressure prop. valve
Temperature
switching 2-point
X
-
-
-
-
X
w = 0,5
-
-
continuous P
w = 0,3
w = 0,3
KP = 5,0
KP = 5,0
KP = 1,5
wmax= 0,6
wmax= 0,55
wmax= 1,0
-
w = 0,3
I
-
TN = 2,0 wmax= 0,6 w = 0,3
PI
-
KP = 5,0 TN = 6,0 wmax= 0,6 PI (DIN)
PID
w = 0,3
w = 0,15
w = 0,5
w = 0,5
KP = 1,0
KP = 1,0
KP = 1,0
KP = 1,0
TN = 2,0
TN = 1,0
TN = 1,0
TN = 1,0
wmax= 0,6
wmax= 0,3
wmax= 1,0
wmax= 1,0
w = 0,5
w = 0,5
KP = 1,0
KP = 0,4
TN = 1,0
TN = 3,0
TV = 0,1
TV = 1,0
wmax= 1,0
wmax= 1,0
-
-
better KP = 0,6 - no oscillation
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Appendix
8.4 Empty I/O assignment list
Digital in- and outputs Output Bit
Description
0
1
2
3
4
5
6
7
Input Bit
Description
0
1
2
3
4
5
6
7
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Appendix
Analog in- and outputs Output Channel
Description
0
1
2
3
Input
Description
Channel 0
1
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