PCT 40- Multi functional process control teaching system


The multifunctional process control PCT 40 is used for teaching a wide range of process control systems in a simple basic unit including temperature measurement and flow control.

This practice requires a PCT40 bench equipped with a process tank (large and small), and enough hoses. The PCT40 itself is connected to a computer via a USB connection.


Basic setup before using PCT-40:

Before starting the experiment students are required to carry out the following things:

  • Check the water tank: If the water level in the tank is approximately 1/3 of the tank height, report it to the supervisor or technician on duty. If it is appropriate, the power switch can be turned on by pressing the green button on the control panel. After this PCT40 and the computer can be turned on.

  • Set up tools: Run the PCT40 software and check the bottom right of the menu window if there is a message “IFD: Device Error”. The message indicates that a PCT40 connection has been failed to the computer.

  • Regulating Pressure Regulators:

For the safety of tools and valves, the main water flow rate is limited to 1350 mL/min and 1450 mL/min and is desired at 1mL/min.

To set the flow rate through a pressure regulator, do the following:

  1. Install the hose from the SOL1 valve to a large tank,

  2. Select Section 1: Level Control (inflow) on the File menu then select the icon for the mimic diagram screen and read the flow rate shown

  3. Open the faucet under the tank, valve SOL2 and SOL3 to remove water directly from the tank,

  4. Pull the grey knob outward (to the right). To increase the flow rate, the knob can be rotated slowly in a clockwise direction. Conversely, to reduce the flow rate, the knob is rotated slowly in an anti-clockwise direction. If the flow rate is appropriate, lock the regulator settings by pressing the knob inward (to the left)

Large process vessel (For Level measurement)

Large process vessel is used to study level measurement. The vessel includes a level scale. Tappings in the base of the vessel allow connections to pressure sensors, solenoid valves and pumps. A vertical overflow tube is included as a safety features.

Small Process Vessel (Hot Water Tank)

This vessel incorporates an electric element to heat the water. A thermostat and a level detector are incorporated into the container to prevent the heater from working if the water is too hot or the level in the container is too low. These safety devices are fixed and can not be used for experimental purposes.

Heating/Coiling Coil is mounted on a lid that is designed to fit inside the small process vessel around heating element. Fittings at the inlet and outlet of the coil accommodate thermocouple-type temperature sensors and allow connection to the water supply.

Manifold Block with Orifices and Pressure Tappings:

The manifold block incorporates three orifices with associated differential pressure sensors that can be used to measure the flow rate. The hole associated with the pressure sensors P1 and P2 has a diameter of 1.9 mm and is suitable for the low flow rates used in the PCT41 process vessel accessory. In use, the peristaltic pump tube is connected to the small quick release fitting at the front and the tube of the process vessel is connected to the splint at the rear so that the fluid flows into the reactor. The container passes through the hole.

Operating the Solenoid Valve On / Off:

There are 3 solenoid valves on / off, namely SOL1, SOL2 and SOL3. Manually setting valves can be done through the mimic diagram screen by clicking the switch button. The operation of the valves is shown on the switch button through code 0 for off (closed) and code 1 for on (open)

Operating the Proportional Solenoid Valve (PSV):

Manually setting the valve through the mimic diagram screen by typing in the percentage number of valve openings or by clicking the up or down arrow button