Computer Controlled Hot Water Production and Heating Teaching Unit

The computer controlled hot water and heating generation unit, is a didactic unit that the students can use to learn about heating installations and the production of domestic hot water, both for houses and colective blocks with a boiler in each dwelling.

ATENG 12703 — Computer Controlled Hot Water Production and Heating Teaching Unit

(for main items)

• With this unit there are several options and possibilities:
• Main items: 1, 2, 3, 4, 5 and 6.
• Optional items: 7, 8, 9, 10 and 11.
• Let us describe first the main items (1 to 6):
• 1 ATENG 12703. Unit:
  Anodized aluminum frame and panels made of painted steel.
  The unit includes wheels to facilitate its mobility.
  Main metallic elements made of stainless steel.
  Diagram in the front panel with distribution of the elements similar
  to the real one.
• Boiler, that works with gas-oil, with a useful power of 32 kW.
  The body of the boiler is made of cast iron with a three-way fumes
  pass and it is suitable to work with pressurized burnes for gas or
• gas-oil. This boiler includes:
• Stage gas-oil burner (32 kW), computer controlled.
  Circulation pump, computer controlled.
  Closed expansion tank.
• Safety valve (3 bar).
  Air purger.
  Safety thermostat.
  Drain valve.
  Portable tank for fuel (20 l).
  Fuel filter.
• Chimney made of stainless steel:
  Adapter at the outlet of the boiler.
• “T” of 90 °C. Two elbows of 45°. Two straight sections of 930 mm. Unit: ATENG 12703
  Cone for free outlet. Two wall clamps.
  Three-ways electronic valve, computer controlled, which distributes the water heated by the boiler-burner
  group into two primary circuits. One of them is the double jacket of the hot water tank to obtain domestic
  hot water, and the other is the radiator to generate heating.
  Hot water tank with double jacket made of stainless steel with a capacity of 150 l.
  Solenoid electrovalve, computer controlled, in the tap water inlet line to the hot water tank.
  Fin radiator of five elements and purger. Methacrylate receptable where the radiator is located. It is
  possible to control the temperature in the receptacle by means of a PID control through the software that
  acts on the threeways solenoid valve. The receptacle has a room thermostat inside, which also makes it
  possible to control the heating temperature.
• Nine temperature sensors “J” type, at the key points of the unit, to measure:
  Temperature of the hot water leaving the boiler.
  Temperature of the water outlet and inlet of the hot water tank primary circuit and the radiator.
  Temperature of the domestic hot water inside the hot water tank and the domestic hot water outlet.
  Temperature of the primary circuit´s water that recirculates to the boiler.
• Gas-oil flow sensor to measure the fuel flow consumed by the boiler, range: 0.4 – 4 kg/h.
• Three water flow sensors, range: 1.5 – 30 l/min, to measure:
  Water flow used for the primary circuit of the hot water tank.
  Water flow used for the primary circuit of the radiator to generate heating.
  Tap water inlet flow into the hot water tank.
  Combustion gases analyzer for the measurement of CO, CO, O, air excess, temperature of the
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  combustion fumes, combustion efficiency, etc.
• The complete unit includes as well:
  Advanced Real-Time SCADA and PID Control.
  Open Control + Multicontrol + Real-Time Control.
  Specialized Control Software based on LabVIEW.
  National Instruments Data Acquisition board (250 KS/s, kilo samples per second).
  Calibration exercises, which are included, teach the user how to calibrate a sensor and the
  importance of checking the accuracy of the sensors before taking measurements.
  Projector and/or electronic whiteboard compatibility allows the unit to be explained and
  demonstrated to an entire class at one time.
  Capable of doing applied research, real industrial simulation, training courses, etc.
  Remote operation and control by the user, as well as remote support from technical
  support, are always included.
  Totally safe, utilizing 4 safety systems (Mechanical, Electrical, Electronic & Software).
  Designed and manufactured under several quality standards.
  Optional ICAI software to create, edit and carry out practical exercises, tests, exams,
  calculations, etc. Apart from monitoring user's knowledge and progress reached.
  This unit has been designed for future expansion and integration. A common expansion is
  the Scada-Net (ESN) System which enables multiple students to simultaneously
  operate many units in a network.
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Complete Technical Specifications (for main items)

• EACC/CIB. Control Interface Box:
  The Control Interface Box is part of the SCADA system.
  Control interface box with process diagram in the front panel and with the same distribution that
  the different elements located in the unit, for an easy understanding by the student.
• All sensors, with their respective signals, are properly manipulated from -10V. to +10V. computer output.
  Sensors connectors in the interface have different pines numbers (from 2 to 16), to avoid
  connection errors.
  Single cable between the control interface box and computer.
  The unit control elements are permanently computer controlled, without necessity of
  changes or connections during the whole process test procedure.
  Simultaneous visualization in the computer of all parameters involved in the process.
  Calibration of all sensors involved in the process.
  Real time curves representation about system responses.
  Storage of all the process data and results in a file.
  Graphic representation, in real time, of all the process/system responses.
  All the actuators’ values can be changed at any time from the keyboard allowing the
  analysis about curves and responses of the whole process.
  All the actuators and sensors values and their responses are displayed on only one screen in the
  computer.
  Shield and filtered signals to avoid external interferences.
  Real time PID control with flexibility of modifications from the computer keyboard of
  the PID parameters, at any moment during the process. EACC/CIB
  Real time PID and on/off control for pumps, compressors, heating elements, control valves, etc.
  Real time PID control for parameters involved in the process simultaneously.
  Proportional control, integral control and derivative control, based on the real PID mathematical
  formula, by changing the values, at any time, of the three control constants (proportional, integral
  and derivative constants).
  Open control allowing modifications, at any moment and in real time, of parameters involved in the
  process simultaneously.
  Possibility of automatization of the actuators involved in the process.
  Three safety levels, one mechanical in the unit, another electronic in the control interface and
  the third one in the control software.
• 3 DAB. Data Acquisition Board:
  The Data Acquisition board is part of the SCADA system.
  PCI Express Data acquisition board (National Instruments) to be placed in a computer slot. Bus
  PCI Express.
• Analog input:
  Number of channels= 16 single-ended or 8 differential. Resolution=16 bits, 1 in 65536.
• Sampling rate up to: 250 KS/s (kilo samples per second).
• Input range (V)=±10 V. Data transfers=DMA, interrupts, programmed I/0. DMA channels=6.
• Analog output:
  Number of channels=2. Resolution=16 bits, 1 in 65536.
• Maximum output rate up to: 900 KS/s.
• Output range (V)=±10 V. Data transfers=DMA, interrupts, programmed I/0. DAB
• Digital Input/Output:
• Number of channels=24 inputs/outputs. D0 or DI Sample Clock frequency: 0 to 100 MHz.
• Timing: Number of Counter/timers=4. Resolution: Counter/timers: 32 bits.
  The Data Acquisition board model may change at any moment, providing the same or better
  features than those required for the unit.
  4 EACC/CCSOF. PID Computer Control + Data Acquisition + Data Management
• Software:
  The three softwares are part of the SCADA system.
  Compatible with actual Windows operating systems. Graphic and intuitive simulation of the
  process in screen. Compatible with the industry standards.
  Registration and visualization of all process variables in an automatic and simultaneous way.
  Flexible, open and multicontrol software, developed with actual windows graphic systems,
  acting simultaneously on all process parameters.
  Analog and digital PID control.
  PID menu and set point selection required in the whole work range.
  Management, processing, comparison and storage of data.
  Sampling velocity up to 250 KS/s (kilo samples per second).
  Calibration system for the sensors involved in the process.
  It allows the registration of the alarms state and the graphic representation in real time.
  Comparative analysis of the obtained data, after the process and modification of the conditions
  during the process. EACC/CCSOF
  Open software, allowing the teacher to modify texts, instructions. Teacher’s and student’s
  passwords to facilitate the teacher’s control on the student, and allowing the access to different work
  levels.
  This unit allows the 30 students of the classroom to visualize simultaneously all the results
  and the manipulation of the unit, during the process, by using a projector or an electronic
  whiteboard.
  5 Cables and Accessories, for normal operation.
• 6Manuals:
• This unit is supplied with 8 manuals: Required services, Assembly and Installation, Interface and
  Control software, Starting-up, Safety, Maintenance, Calibration & Practices manuals.
• References 1 to 6 are the main items: ATENG 12703 + EACC/CIB + DAB + EACC/CCSOF + Cables and Accessories + Manuals are included
  in the minimum supply for enabling normal and full operation.
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