FLUID POWER
MANUFACTURING/MECHATRONICS TECHNOLOGY
z
z
z
z
z
z
REFRIGERATION, AIR CONDITIONING & HEATING
EXPLORING TECHNOLOGY
INSTRUMENTATION & PROCESS CONTROL
COMPUTER-BASED ELECTRONICS TRAINING SYSTEM
ELECTRIC POWER/CONTROLS
DIGITAL MICROPROCESSOR & COMPUTER
ELECTRICITY & ELECTRONICS
TELECOMMUNICATIONS
WORLD LEADER IN TECHNICAL TRAINING SYSTEMS
95016-00 REV. D
ELECTRICAL & MECHANICAL SYSTEMS
FLUID POWER
INSTRUMENTATION & PROCESS CONTROL
WEB-BASED INDUSTRIAL TRAINING
AUTOMATION & ROBOTICS
EXPLORING TECHNOLOGY
M A N U FA C T U R I N G / M E C H AT R O N I C S T E C H N O L O G Y
AUTOMATION & ROBOTICS
Technical Training Systems
Electric Power and Control
z
-
- Electromechanical
- Power Electronics and Drives
- Power Transmission, Distribution,
and Protection
- Industrial Controls
z
Telecommunications
-
z
z
Digital and Analog
Radar Technology
Microwave Technology
Antenna
Telephony
Fiber Optic Communications
z
Mechanical Systems
Fluid Power
Instrumentation and Process Control
Web-Based Industrial Training
A utomation and Robotics
Exploratory Technology
Communications
Transportation
Construction
Manufacturing
Bio-Related
T e c h - W o r l d ®®
-
Manufacturing / Mechatronics
-
T e c h - D e s i g n ®®
Applications
Applications
Technology
in
in
Manufacturing
Information
Computer-Based Learning for
E l e c t r o n i c s T r a i n i n g ( F A C E T ®)
- Basic Principles of Electricity and
Electronics
- Circuit Simulations
- Digital and Microprocessor
Electronics
- Telecommunications
- Industrial Electronics
MANUFACTURING AND CENTRAL
SALES OFFICES
LAB-VOLT SYSTEMS, INC.
P.O. Box 686
Farmingdale, New Jersey, USA 07727
Telephone (732) 938-2000 Fax (732) 774-8573
Toll Free U.S. Telephone (800) LAB-VOLT
E-MAIL: us@labvolt.com
LAB-VOLT LIMITED
675, rue du Carbone
Charlesbourg, Québec, CANADA G2N 2K7
Telephone (418) 849-1000 Fax (418) 849-1666
Toll Free Canada Telephone (800) LAB-VOLT
E-MAIL: ca@labvolt.com
LAB-VOLT’S WEB SITE
www.labvolt.com
©Copyright 2006, Lab-Volt Systems, Inc. All rights reserved. All products featured in this guide are subject to change without
notice. Lab-Volt recognizes all product names used herein as trademarks or registered trademarks of their respective holders. LabVolt is not responsible for typographical errors.
MANUFACTURING TECHNOLOGY
z
Intr oducing Lab-Volt’s
Training Systems for
Manufacturing &
Mechatr onics
Technology
Lab-Volt Systems, Inc. is recognized as
the leading designer and manufacturer of
world-class technical training systems that deliver the highest standards of quality, service,
and educational integrity. Lab-Volt is recognized for its commitment to hands-on
training curriculum that empowers students to progress directly from the classroom to the workplace.
Mechatronics, a relatively new engineering discipline, integrates mechanical energy
with electronic and intelligent computer
control in the design and manufacture of
industrial products and processes.
Lab-Volt’s training systems in Manufacturing and
Mechatronics Technology include modular courseware,
hardware, and carefully structured learning systems that
span a variety of manufacturing applications. These include:
Lab-Volt Technical Training Systems are used
world-over in secondary and post-secondary
vocational programs, trade and technical
schools, military installations, government
training centers, and industrial job training
programs.
z Electrical & Mechanical Systems the transition from
classroom to workplace is seamless with Lab-Volt's modular training units featuring industrial quality equipment
and task-based training in mechanical, pumps, rigging,
and wiring systems.
z Fluid Power a series of modern, state-of-art modular
training units and computer-based curriculum covering a
broad range of applications in hydraulics and pneumatics.
z Instrumentation and Process Control an extensive
series of hands-on systems that provide basic to
advanced troubleshooting and repair skills in most major
areas of industrial-level processing systems.
z Web-Based Industrial Training delivers a broad range
of online and CD-ROM-based fundamental and specialty
industrial training courses designed to build a more competent, qualified, and efficient workforce.
z Automation & Robotics (Lab-Volt Automation™),
comprising a line of high-precision, industry-standard
equipment, courseware, and software that provide integrated training in mechatronics through the study of
robotics, CNC milling, CNC turning, and PLC-operated
flexible manufacturing systems.
z Exploring Technology a series of modular training
units that introduce students to the concepts and operations underlying important manufacturing processes,
including Mechanisms, Sensors, and Electricity.
MANUFACTURING TECHNOLOGY
Table of Contents
Electrical & Mechanical Systems
Lab-Volt’s Mechanical Systems . . . . . . . . . . . . . . . . . . .4
Product Profiles
Mechanical Training System, Model 46101 . . . . . . . . . . .5
Industrial Wiring Training System, Model 46102 . . . . . .6
Pumps Training System, Model 46106 . . . . . . . . . . . . . . .7
Rigging System, Model 46109 . . . . . . . . . . . . . . . . . . . . . .8
Industrial Controls Training System, Model 3100 . . . . . .9
Variable Speed Drives, Models 3250 and 3260 . . . . . . .10
Fluid Power
Fluid Power Training for Industrial Applications . . . . .11
Simulation Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Product Profiles
Hydraulics Fundamentals, Model 6080-1 . . . . . . . . . . .13
Electrical Control of Hydraulic Systems,
Model 6080-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Pneumatics Training Systems, Model 6081-1 . . . . . . . .15
Electrical Control of Pneumatic Systems,
Model 6081-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Hydraulics and Pneumatics Applications - PLC,
Model 6082-X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Servo / Proportional Control of Hydraulic Systems,
Model 6080-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Servo / Proportional Control of Pneumatic Systems,
Model 6081-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Sensors Training System, Model 6085 . . . . . . . . . . . . . .18
Hydraulics Simulation Software (LVSIM®-HYD) . . . . .19
Pneumatics Simulation Software (LVSIM®-PNEU) . . .19
Fundamental Fluid Power Trainer, Model 6059 . . . . . .20
Instrumentation and Process Control
Instrumentation & Process Control Training Systems .21
Product Profiles
Process Control Trainer, Model 3521 . . . . . . . . . . . . . . .21
Temperature/Flow Process, Model 3522 . . . . . . . . . . . .22
Process Control and Simulation Software (LVPROSIM),
Model 3674 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Process Control Training System, Model 6090 . . . . . . .24
Instrumentation and Process Control Training System,
Model 3500-M0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Pressure Process Station, Model 3501-M0 . . . . . . . . . . .27
Flow Process Station, Model 3502-M0 . . . . . . . . . . . . . .28
Level Process Station, Model 3503-M0 . . . . . . . . . . . . .29
Temperature Process Station, Model 3504-M0 . . . . . . .30
Multi-Process Station, Model 3505 . . . . . . . . . . . . . . . . .31
Heat Exchanger Process Substation, Model 3507-M0 .32
Analytic Process Substation, Model 3508-M0 . . . . . . . .33
Calibration Station, Model 3550-M0 . . . . . . . . . . . . . . . .34
Web-Based Industrial Training
Industrial Training Zone by Lab-Volt . . . . . . . . . . . . . . .35
Product Profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Industrial Mechanical, Model 47904 . . . . . . . . . . . . . . .35
PLC Fundamentals, Model 47910 . . . . . . . . . . . . . . . . . .35
Industrial Hydraulics, Model 47901 . . . . . . . . . . . . . . . .36
Mobile Hydraulics, Model 47906 . . . . . . . . . . . . . . . . . .36
Industrial Pneumatics, Model 47902 . . . . . . . . . . . . . . .37
Pneumatic Specialist, Model 47909 . . . . . . . . . . . . . . . .35
Industrial Electrical, Model 47903 . . . . . . . . . . . . . . . . .38
Mobile Electrical, Model 47907 . . . . . . . . . . . . . . . . . . . .38
AC/DC Motors and Drives, Model 47908 . . . . . . . . . . . .38
Automation & Robotics
Introducing Lab-Volt Automation . . . . . . . . . . . . . . . . .39
Robots and Robot Software . . . . . . . . . . . . . . . . . . . . . .40
RoboCIM Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
CNC Lathes and Mills . . . . . . . . . . . . . . . . . . . . . . . . . . .42
CNC Software for Mill and Lathe . . . . . . . . . . . . . . . . . .43
Fabricus Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
CAD/CAM Software for Mill and Lathe . . . . . . . . . . . . .45
Product Profiles
Teach Pendant-Controlled Robot System,
Model 5100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Computer-Controlled Robot System, Model 5150 . . . .46
Servo Robot System, Model 5250 . . . . . . . . . . . . . . . . . .47
Robot Equipment Options . . . . . . . . . . . . . . . . . . . . . . .48
Bench Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
CNC Lathe, Model 5300 . . . . . . . . . . . . . . . . . . . . . . . . . .50
CNC Lathe, Model 5500 . . . . . . . . . . . . . . . . . . . . . . . . . .51
CNC Mill, Model 5400 . . . . . . . . . . . . . . . . . . . . . . . . . . .52
CNC Mill, Model 5600 . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Manufacturing Conveyor System, Model 3509 . . . . . . .54
Flexible Manufacturing System, Model 5900 . . . . . . . .55
Flexible Manufacturing System, Model 5901 . . . . . . . .56
Programmable Logic Controller (PLC)
Training System, Model 3240 . . . . . . . . . . . . . . . . . . . . .57
PLC Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . .58
PLC Simulation Softwares, (P-SIM 1000 and P-SIM 2000),
Models 91826 and 91773 . . . . . . . . . . . . . . . . . . . . . . . . .59
Exploring Manufacturing Technology
Lab-Volt Exploring Technology Series . . . . . . . . . . . . . .60
Product Profiles
Exploring Sensors, Model 3341 . . . . . . . . . . . . . . . . . . . .60
Exploring Mechanisms, Model 3342 . . . . . . . . . . . . . . .61
Exploring Electricity, Model 3343 . . . . . . . . . . . . . . . . . .61
Courseware Ordering Information
. . . . . .62
3
ELECTRICAL & MECHANICAL SYSTEMS
ELECTRICAL & MECHANICAL SYSTEMS
The Transition Fr om Classr oom to W orkplace
is Seamless with Lab-Volt’s Industry-Relevant Training
Lab-Volt understands the need for highly skilled
employees in many sectors of the economy, including
manufacturing, health care, service and leisure industries, government, education, and the military. LabVolt's mechanical training systems provide trainees
with all the knowledge, skills, and practical experiences needed for a rewarding career in industrial
maintenance, whether they are college-bound or aim
for employment after graduation.
Each model consists of comprehensive courseware, including a training manual and instructor guide.
These materials provide everything needed to ensure
safe, effective training and verification of trainees' skill
development.
FEATURES
z Industrial grade equipment
z Task-based learning through job sheets, work
orders, and reference material
z Workplace topics such as health, electrical safety,
and tool safety are enforced
z Interdisciplinary learning allows for flexible career
options
z Trainees gain solid employability skills, such as
communication, troubleshooting, teamwork, work
measurement, problem solving, and critical thinking
z Optional workbenches and simulation software
save training dollars and space
z Modular design and various lab configurations
allow for customization of curriculum
Heavy-duty motor mounting base from
the Mechanical Training System
Students follow job sheets to complete
tasks safely and efficiently
Models include:
MECHANICAL TRAINING SYSTEM
Model 46101
INDUSTRIAL WIRING TRAINING SYSTEM
Model 46102
PUMPS TRAINING SYSTEM
Model 46106
4
RIGGING SYSTEM
Model 46109
INDUSTRIAL CONTROLS TRAINING SYSTEM
Model 3100
VARIABLE SPEED DRIVES
z DC Variable Speed Drive, Model 3250
z AC Variable Speed Drive, Model 3260
MANUFACTURING TECHNOLOGY
Mechanical Training System
Model 46101
The Lab-Volt Mechanical Training System, Model
46101, familiarizes students with the selection, installation, use, maintenance, and troubleshooting of
mechanical drive components.
Engineered for extreme ease of use, the system
comes with a universal steel base unit on which the
students prepare the setups using T-slotted extrusion
bars. This innovative design allows the base to be configured as required by the task. The universal base
includes a disconnecting switch, current meter, and
the controls required to operate the motors and
clutch-brake. It also includes a Start/Stop push-button
station for local and remote operation.
The curriculum is based on practical, hands-on
tasks using industrial grade components. This ensures
that students are well prepared for today’s competitve
workforce.
TOPIC COVERAGE
Belt Drives
Chain Drives
Gear Drives
Lubrication
Couplings
Shaft Alignment
z
z
z
z
z
z
z
z
z
z
z
z
Bearings
Ball Screws
Gaskets and Seals
Clutches and Brakes
Laser Alignment
Vibration Analysis
FEATURES
z Universal base unit can be mounted on a regular
table as well as optional Lab-Volt benches
z Fully illustrated job sheets direct students to complete
tasks safely and efficiently
z Lockout/tagout on the disconnecting switch and safety
panels ensure student safety
z Working space can be increased by adding a slave base
unit
z Quality industrial components are mounted on panels
for storage and inventory control
5
ELECTRICAL & MECHANICAL SYSTEMS
Industrial Wiring Training System
Model 46102
The Lab-Volt Industrial Wiring Training System, Model
46102 faithfully reproduces an industrial environment
where students can develop their skills in the installation
and wiring of industrial electrical equipment, in compliance with the National Electrical Code® (NEC®). The system can also be used to teach trainees how to adjust and
maintain industrial electrical equipment as well as
enforce the safety rules to be followed when working at
industrial sites.
Due to its modular design, the Industrial Wiring
System can be configured to fit various training needs. A
versatile, mobile workstation is the basis of the system.
A variety of equipment packages, tool packages, and
industrial application packages are available to adjust
the curriculum to customized training levels. Packages
of consumable goods such as conduits, conduit fittings,
dummy electrical enclosures and boxes, and reels of
electrical wire are also available.
TOPIC COVERAGE
z Cabinet Installation
z Conduit Installation
6
z
z
z
z
z
z
z
Industrial Equipment Wiring
Electrical Safety
Electrical Diagrams
Power Distribution
Motor Starters
AC/DC Drives
Industrial Applications
FEATURES
z Supports up to four equipment setups at the same
time, allowing multiple student groups to work at a
single workstation
z Two or more equipment setups can be grouped
together to form complex industrial applications
z Selection of equipment packages allow the system
to meet a wide range of training objectives
z Fully illustrated courseware guides students
through various tasks
z Mobile workstation features swivelling casters
with a lock mechanism for easy motion and stable
operation
z Sized to fit through standard door openings
MANUFACTURING TECHNOLOGY
Pumps Training System
Model 46106
The Lab-Volt Pumps Training System, Model 46106,
familiarizes students with maintenance tasks such as
pump installation, lubrication, shaft alignment, inspection, and component replacement. Students also learn
how to start up, operate, and troubleshoot industrial
pumps in different configurations. Furthermore, during
these hands-on activities they will discover the impact
of valve restriction, air injection, and NPSH on pumps
efficiency by using a cavitation valve, a load valve, and
two different water reservoirs.
The modularity of the system permits the selection of models required to meet customized training
objectives.
TOPIC COVERAGE
z Pump Installation
z Lubrication
z Shaft Alignment
z Inspection
z Component Replacement
z Valve Restriction
z Air Injection
z Pump Wiring
z Fluid Mechanics
z Pump Maintenance
z Laser Alignment
z Vibration Analysis
FEATURES
z Thirteen different types of pumps
z Latest 3-phase AC drive included to vary the speed of
motor-driven pumps
z Easy electrical connections between the drive and motor
can be made using banana jacks or terminal blocks
z Configure variable speed drives using local panels, or
remotely using optional computer software
z Transparent pump cover allows cavitation observation
Industrial quality pumps are used for the
most realistic training
7
ELECTRICAL & MECHANICAL SYSTEMS
Rigging System
Model 46109
Moving machines is a basic requirement for any industrial plant. Machines to be moved are all different since they
are usually built for a special application. They have different shapes and are often asymmetrical. Their weight,
which is not evenly balanced on the machine supports,
creates difficulties to the rigger. Therefore, installation
requires skilled and highly qualified riggers.
To help acquire these basic skills, the Lab-Volt
Rigging System was created to cover the fundamentals of
rigging practices. Students practice the techniques that
must be developed and used to install and move a
machine safely.
Work orders help students develop the skills required
for rigging practice and are an excellent test bench for the
students.
TOPIC COVERAGE
z Moving machines using rollers
z Lifting and handling odd-shaped loads
8
z Moving loads according to center of gravity and
weight
z Handling machines with wire rope pullers
z Identify different types of rope, cut rope properly,
z
z
z
z
and make knots
Assemble a wedge socket on a wire rope
Install hoist trolleys, chain links, chain hoist, and
electric hoist on the gantry crane
Move a machine from ground position to a
pedestal
Lift an unbalanced load
FEATURES
z Storage for all material
z Work orders for task-based learning
z Industrial-grade equipment
MANUFACTURING TECHNOLOGY
Industrial Controls Training System
Model 3100
The Industrial Controls Training System, Model 3100,
has unique controls training capabilities, enhanced by
its modularity and instructor-inserted faults. The system allows trainees to select and mount control
devices to form typical control circuits, and to troubleshoot them once a
fault is inserted.
Each module is
equipped with up to
four faults that can be
inserted using switches mounted behind
the faceplate. Typical faults include open coils and
contacts, dirty contacts, and shorted connections.
The modules of the Industrial Controls Training
System can be interconnected with those of other
Lab-Volt training systems for interdisciplinary training
applications. Connections are made using flexible
PVC-insulated connecting leads terminated with 4mm safety banana plugs. These leads allow safe connection of components, since the live parts of their
plugs are concealed and insulated so they cannot be
contacted accidentally.
TOPIC COVERAGE
z Introduction to Motor Control
z Pilot Devices
z Circuit Layout Connections and Symbols
z Basic Control Circuit
z AC Reduced-Voltage Starters
z Three-Phase, Multispeed Controllers
z Wound-Rotor Motor Controllers
z Synchronous Machine Controls
z Direct Current Controllers
z Standard industrial quality controls devices, capa-
ble of handling 1 horsepower machine
z Can be interconnected with any of Lab-Volt's elec-
tronics and digital control trainers for interdisciplinary training applications
z Schematic diagrams silk-screened on front panels
z Open motor ends allow observation of motor wind-
ings
FEATURES
z Comprehensive, competency-based courseware is
adjustable to both self-paced and lock-step
instructional methods
z Up to four fault insertion switches can be front
activated on each module by an instructor
9
ELECTRICAL & MECHANICAL SYSTEMS
Variable Speed Drives
Models 3250 and 3260
The DC and AC Variable Speed Drives enable trainees to
develop competence in operating and troubleshooting control systems that include industrial-type drives. They can be
used with the Industrial Controls Training System, Model
3100, as well as most commercial motors.
Courseware includes an Operation Manual and Project
Job Sheets addressing setup and operation of the drives and
their controls.
The DC Variable Speed Drive, Model 3250, is an industrial-type drive whose power circuitry is composed of a halfbridge with two thyristors and two diodes. A full-wave field
voltage is provided for shunt wound motors. The drive
Model 3250
includes controls for Minimum Speed, Maximum Speed,
DC Variable Speed Drive
Acceleration, IR Compensation (Regulation), and Current
Limit by means of five potentiometers located on the main
circuit board. The speed of the motor is set by the means of
a potentiometer located on the faceplate of the drive, or an
insulated voltage course of 0 to 12 V dc.
The AC Variable Speed Drive, Model 3260, uses the latest solid-state PWM technology to control a three-phase
squirrel-cage induction motor. A keypad and an LCD screen
allow modification and visualization of many different
parameters, such as min/max speed, acceleration/deceleration time, and torque. The V/Hz output characteristic is userselectable for constant torque, pump, and fan applications.
Up to eight preset speeds may be programmed. Speed can
be controlled using either the digital keypad or the analog
input on the front of the module.
Model 3260
The AC Variable Speed Drive is available in two versions:
AC Variable Speed Drive
Models 3260-1 and 3260-2. Model 3260-1 requires 120-V, 60 FEATURES
Hz power available from any standard wall outlet. This sin- DC Variable Speed Drive
gle-phase option is not available for 220 V and 240 V, 50 Hz, z Adjustable horsepower settings up to 1 HP
line supplies. Model 3260-2 requires three-phase supply. The z Designed for DC permanent magnet, shunt wound,
three-phase supply is applied at the 4-mm banana jacks on
and some universal (AC/DC) motors
the module front panel.
z Converts incoming AC voltage to adjustable fullwave rectified DC for armature circuit A full wave
TOPIC COVERAGE
field voltage is provided for shunt wound motors
DC Variable Speed Drive
z Incorporates transient voltage protection with
z Trainer Familiarization
adjustable current limit and an AC fuse for protecz Maximum Speed Trimpot Adjustment Characteristics
tion
z Minimum Speed Trimpot Adjustment Characteristics
z Adjustable minimum and maximum speeds along
z Speed Regulation Trimpot Adjustment Characteristics
with adjustable acceleration and IR compensation
z Current Limit Trimpot Adjustment Characteristics
z Acceleration Trimpot Adjustment Characteristics
AC Variable Speed Drive
z Remote Control Characteristics
z Designed for three phase induction motors up to 1
z System Configuration
HP (220/240V)
z Combines power bi-polar, MOS devices, and hybrid
AC Variable Speed Drive
drivers
z Trainer Familiarization
z Inverter produces an output frequency range of 2z Maximum Speed Control Characteristics
100 Hz with a constant V/F ratio between 2-48 Hz,
z Minimum Speed Control Characteristics
suitable for constant torque applications, and a
z Acceleration Control Characteristics
reducing V/F ratio between 48-100 Hz giving an
z Deceleration Control Characteristics
approximate constant HP characteristic
z Boost Control Characteristics
z Adjustable controls for low frequency boost, miniz System Configuration
mum speed, ramp up, ramp down
10
MANUFACTURING TECHNOLOGY
FLUID POWER TRAINING
FOR INDUSTRIAL APPLICATIONS
Innovative Design Offers Exceptional Options
Lab-Volt offers the most comprehensive and flexible
course in fluid power available. Lab-Volt’s premier training system for fluid power technology consists of two programs. The Hydraulics Training System, Model 6080, and
the Pneumatics Training System, Model 6081. Both are
innovative, modular systems that use state-of-the-art
hardware and courseware to deliver job training in fluid
power.
The entire fluid power series has been designed for
educational growth. Using either the Hydraulics or the
Pneumatics Training Systems, students gain a solid foundation in, and hands-on experience with, fluid power
components and circuits; the principles and concepts
underlying fluid power systems and applications; and
methods of troubleshooting and testing fluid systems.
Each lesson builds upon previous lessons, making this an
ideal job-training program.
Engineered for extreme ease of use, the core system
begins with a work surface assembly consisting of a solid
metal, universal drip-tray hinged to a perforated, tiltable
work surface that serves as a panel onto which hydraulic
or pneumatic components are mounted. By adding
optional expansion panels, the work surface can be configured to accommodate a wide variety of space and
teaching needs. Mounting and dismounting components
is easy with push-lock fasteners that snap easily into the
perforation on the work surface. The tilting work surface
facilitates instructor demonstration to an entire class.
The scope of the entire Lab-Volt Fluid Power product
line addresses the diverse needs of secondary and postsecondary technology programs. The interfacing of electronics, sensors, robots, and controls makes the Lab-Volt
program an ideal cornerstone of any job-training program
in Mechatronics, Electromechanical Systems, or
Automation.
The courseware includes reference textbooks,
optional video tapes and courseware illustrations. The
illustrations are available in the form of transparencies
and on CD-ROM.
The courseware for Hydraulics Fundamentals and
Pneumatics Fundamentals is also available in a
Computer-Based Learning format. The CBL version
enables electronic grading of review questions and unit
tests. For those who purchase this version, an Instructor
Answer Key is provided. All other hardware and supporting materials remain the same as the book course.
VERSATILE AND FLEXIBLE SYSTEMS FIT ANY
CLASSROOM CONFIGURATION
The basic Lab-Volt Hydraulics Training System consists
of a power unit, work surface assembly, industrial grade
components, hoses, hose rack, metering instruments,
and related courseware. The basic Pneumatics Training
System consists of a work surface assembly, pneumatic
components, measuring instruments, accessories, and
related courseware. All components in both systems
exceed industrial safety standards, and are identified
with ANSI symbols. Optional equipment includes a
mobile support bench with expandable storage shelves,
dress panels, and additional expansion panels.
Operating on a standard electrical supply, the
Hydraulics system requires no special wiring. The
power unit was designed to match components with
training needs. The pump delivers flow to components
at a rate that allows observation and is powerful enough
to provide pressures in excess of 6200 kPa (900 psi).
11
FLUID POWER
SIMULATION SOFTWARE
FOR HYDRAULICS AND PNEUMATICS
Ideal for Training Centers Tight on Budget and Space
To provide training centers and
students with a fast and effective
instructional tool, Lab-Volt has created a series of Windows®-based
simulation software programs
(LVSIM®) that cover the same
material and produce the same
results as actual laboratory equipment. The Lab-Volt Hydraulics and
Pneumatics training systems,
Models 6080-1/2 and 6081-1/2, are
also available as simulation software programs through the
LVSIM® trademark.
LVSIM®-HYD (Model 6385)
and LVSIM®-PNEU (Model 6485)
cover the same courseware as the
standard programs, but standard
laboratory equipment is replaced
by computer-screen images that
fully simulate the mechanical characteristics of the actual hydraulic and
pneumatic modules. Using the mouse,
students can select and set up virtual
equipment for a given exercise, make the
necessary connections between the simulated modules, and obtain the same
results as with the real equipment.
Used either as a complement to the
actual laboratory equipment or as a
stand-alone product, LVSIM® is a costeffective tool that enables students to
safely and accurately perform experiments and become familiar with the
equipment configuration and laboratory
setup before they enter the lab. As a
result, their time spent in duplicating
hands-on tasks in the actual laboratory
may be reduced significantly, resulting in
the need for less physical hardware per
student. With these cost-saving features,
institutions with tight budgets can deliver a quality program in hydraulics and
pneumatics with limited investment.
An additional advantage to LVSIM® is
its protected portability. Students can
install the software onto their own personal computers in order to practice and
prepare in advance for their lab exercises,
but measurement capability is restricted
by means of a security hardlock device.
12
MANUFACTURING TECHNOLOGY
PRODUCT PROFILES
HYDRAULICS FUNDAMENTALS TRAINING SYSTEM
Model 6080-1
The Hydraulics Fundamentals Training
System, Model 6080-1, gives students a
solid foundation in, and hands-on experience with, hydraulic components and
circuits; the transmission of force
through liquids; conversion of force to
pressure; the control of power; and
methods of troubleshooting hydraulic
systems.
The standard modular system
consists of a perforated work surface, components for the Hydraulics Fundamentals
course, a drip tray attached at the bottom
of the work surface, a hose rack with
hydraulic hoses, and a mobile power unit
with a dead-weight stand.
The work surface of the 6080-1 can
be placed on a table or an optional bench,
containing sliding channels for storing
additional work surfaces, or on a lockable,
paneled bench.
TOPIC COVERAGE
z Introduction to Hydraulics
- Familiarization with the Lab-Volt Hydraulics
Trainer
- Demonstration of Hydraulic Power
z Fundamentals
- Pressure Limitation
- Pressure and Force
- Flow Rate and Velocity
- Work and Power
z Basic Circuits
- Cylinder Control
- Cylinders in Series
- Cylinders in Parallel
- Regenerative Circuits
z Functional Circuits
- Accumulators
- Hydraulic Motor Circuits
- Pressure Reducing Valves
- Remotely-Controlled Pressure Relief Valves
z Troubleshooting
- Hydraulics Pump
- Directional Valve Testing
- Flowmeter Accuracy
- Effects of Temperature on System Operation
FEATURES
z Engineered for extreme ease of use
z Workstation can be configured to accommodate a
wide variety of space and teaching needs.
z Components mount/dismount with push-lock fasteners
z Optional support benchs and dressing panels are
available
z Components exceed industrial safety standards
Components for Hydraulics Fundamentals
Work surface on optional
bench without dressing panels
SYSTEM VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED PROGRAM HOURS
40 hours
LANGUAGE VARIATIONS
English, French, Spanish
13
FLUID POWER
ELECTRICAL CONTROL OF HYDRAULIC SYSTEMS
Models 6080-2
Electrical Control of Hydraulic Systems, an add-on to the
Hydraulics Fundamentals Training System, introduces
students to electrical concepts and electrically controlled
hydraulic systems. Through hands-on experimentation,
students gain familiarity with functional and industrial
electrically controlled hydraulic systems while learning
systematic methods of troubleshooting and testing
electrically controlled hydraulic systems.
The same perforated work surface, drip tray, hose rack
and hose, and power supply unit are used with the
Electrical Control of Hydraulic systems.
TOPIC COVERAGE
z Introduction to Electrical Controls of
Hydraulic Systems
- Familiarization with the
Equipment
z Electrical Control Principals
- Basic Electricity
- Ladder Diagrams
- Basic Electrically-Controlled System
z Fundamental Systems
- Hydraulic Sequencing of Cylinders
- Electrical Sequencing of Cylinders
- Speed Regulation and Braking of Hydraulic
Motors
- Continuous Reciprocation with Dwell Period
z Industrial Applications
- Drilling System
- Safety Circuits
- Counting of Actuator Cycles
- Multi-Pressure Systems
- Rapid-Traverse Slow-Feed Systems
z Troubleshooting
- Troubleshooting Electrical Control Circuits
- Troubleshooting Electrically Controlled
Hydraulic Systems
Components for Electrical Control of Hydraulic Systems
FEATURES
z Seamless integration with Hydraulics
Fundamentals System
z Prepares students for jobs and advanced
education in state-of-the-art fluid power applications
z Provides add-on capabilities for PLC operations, Servo/Proportional Control, and
Sensors
z Integrates with Electrical Control of
Pneumatic Systems
SYSTEM VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED PROGRAM HOURS
60 hours
LANGUAGE VARIATIONS
English, French, Spanish
14
Work surface with “A” frame on optional bench with
dressing panels and lockable doors.
MANUFACTURING TECHNOLOGY
PNEUMATICS TRAINING SYSTEMS
Models 6081-1 AND 6081-2
Model 6081-1
Components of Pneumatics Fundamentals
The Lab-Volt Pneumatics Training System is an innovative, modular system that uses state-of-the-art hardware
and courseware to deliver comprehensive training in the
principles of pneumatic energy and its control applications. The Pneumatics Training System uses the same
workbench and many electrical components of the
Electrical Control of Hydraulic Systems, Model 6080-2,
providing a convenient interconnection between both
systems.
The system comes with a work surface assembly consisting of a solid metal, universal drip-tray, hinged to a
perforated tiltable work surface. This work surface provides a large area for mounting the pneumatic components, using easy push-lock fasteners. All components
meet industrial safety standards and are identified with
ANSI symbols.
The Pneumatics Fundamentals Training System,
Model 6081-1, gives students a solid foundation in, and
hands-on experience with, pneumatic components and
circuits; the transmission of force through liquids; conversion of force to pressure; the control of power; and methods of troubleshooting pneumatic systems.
In the second level, Electrical Control of Pneumatic
Systems, Model 6081-2, students are introduced to electrical concepts and electrically controlled pneumatic systems. Through hands-on experimentation, students gain
familiarity with functional and industrial electrically controlled pneumatic systems while learning systematic
methods of troubleshooting and testing electrically
controlled pneumatic systems.
The student laboratory manuals provided with the
trainer are objective-based and self-paced with procedures that direct the student with step-by-step instructions. A general reference text is also provided for theory and background studies.
Additional options, including a mobile bench with
lockable and expandable storage shelves, dress panel,
and work surfaces are also available.
TOPIC COVERAGE
Pneumatics Fundamentals
z Introduction to Pneumatics
- Familiarization with the Lab-Volt Pneumatics
Trainer
- Introduction to Pneumatics
- Air Conditioning and Distributing Equipment
z Basic Physical Concepts
- Pressure vs Force Relationship
- Pressure vs Volume Relationship
- Pressure Drop vs Flow Relationship
- Vacuum Generation
z Basic Controls of Cylinders
- Directional Control Valves
- Directional and Speed Control of Cylinders
- Cylinders in Series
- Cylinders in Parallel
15
FLUID POWER
Pneumatics Training Systems,
Models 6081-1 & 6081-2
(Continued)
Model 6081-2
Components of Electrical Control of Pneumatic Systems
z Basic Controls of Pneumatics Motors
- Indirect Control Using Pilot-Operated Valves
- Pneumatic Motor Circuits
- Pneumatic Motor Performance
Electrical Control of Pneumatic Systems
z Introduction to Electrical Control of Pneumatic
Systems
- Familiarization with the Equipment
z Electrical Concepts
- Basic Electricity
- Ladder Diagrams
- Basic Electricity Controlled Pneumatic Circuits
- Basic AND and OR Logic Function Circuits
z Functional Systems
- Basic Memory and Priority Electropneumatic
Circuits
- Multi-Pressure Systems
- Sequencing Pneumatic Circuits
- Time-Delay Electropneumatic Applications
z Industrial Applications
- Pneumatic Actuator Deceleration Circuits
- Counting of Actuator Cycles
- Industrial Drilling System and Safety Circuits
- Garbage Compactor Simulation Circuit
z Troubleshooting
- Troubleshooting Electrical Control Circuits
- Troubleshooting Electrically Controlled
Pneumatics Systems
16
FEATURES
z Engineered for extreme ease of use
z Workstation can be configured to accommodate a
wide variety of space and teaching needs
z Components mount/dismount with push-lock
fasteners
z Optional support bench and dressing panels are
available
z Components exceed industrial safety standards
SYSTEM VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED PROGRAM HOURS
Pneumatics Fundamentals:
40 hours
Electrical Control of Pneumatic Systems: 60 hours
LANGUAGE VARIATIONS
English, French, Spanish
MANUFACTURING TECHNOLOGY
ADVANCED FLUID CONTROLS APPLICATIONS
Models 6082, 6080-4, 6081-4 and 6085
HYDRAULICS & PNEUMATICS APPLICATIONS - PLC
Model 6082
Using a PLC with either the Hydraulics or Pneumatics
Training System, students learn how to send instructions to the PLC and download ladder programs in
order to operate fluid power circuits by means of
switches, sensors, and solenoid-operated directional
valves. The PLC also allows students to make comparison with relay-operated control circuits and
design time-delay circuits, up and down counting circuits, latch and unlatch circuits, and more.
Three PLC models are available: Allen Bradley,
Omron, and Siemens. Each of them may be programmed using an advanced programming software.
TOPIC COVERAGE
z Programmable Logic Controller Review
z Timer Instructions
z Counter Instructions
z Latching and Comparison Instructions
z Time-Delay Control of Hydraulic Actuators
z Counting Actuator Cycles
z Safety Control of Actuators
z PLC-Controlled Clamp and Work System
z Troubleshooting
z Designing a PLC-Controlled Punching Press (Hydraulics)
z Designing a PLC-Controlled Conveyor System (Hydraulics)
z Designing a PLC-Controlled Die Casting Machine (Hydraulics)
z Designing a PLC-Controlled Stamping Machine (Pneumatics)
z Designing a PLC-Controlled Conveyor System (Pneumatics)
z Designing a PLC-Controlled Injection Molding Machine
(Pneumatics)
SERVO/PROPORTIONAL CONTROL
Model 6080-4 Servo/Proportional Control of Hydraulic
System and Model 6081-4 Pneumatic Servo/Proportional
Control of Pneumatic Systems
The Servo/Proportional Control module is an add-on to the
Electrical Control system for both Hydraulics and
Pneumatics. Through hands-on operation of signal conditioners, pressure and position transducers, P.I.D. controller,
proportional directional control valve, feedback devices,
and corresponding interface hardware and courseware,
students are trained in the precise controls used in industrial applications such as robotics, aviation, CNC
machines, marine, mobile equipment, and material handling.
All exercises require Basic and Electrical Control of
Hydraulic and/or Pneumatic Systems.
TOPIC COVERAGE
Servo/Proportional Control of Hydraulic Systems,
Model 6080-4
z Proportional Directional Control Valves
z Acceleration and Deceleration Control
z Open-Loop Control of Motor Speed
Model 6082
SYSTEM VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED PROGRAM HOURS
45 hours for each program
LANGUAGE VARIATIONS
English, French, Spanish
Model 6080-4
z Proportional (P) Control of Motor Speed
z Proportional-Plus-Integral (PI) Control of Motor
Speed
z Proportional-Plus-Integral-Plus-Derivative (PID)
Control of Motor Speed
z Open-Loop Control of Cylinder Rod Position
z Closed-Loop Control of Cylinder Rod Position
z Closed-Loop Control of Cylinder Pressure
17
FLUID POWER
Servo/Proportional Control of Pneumatic Systems,
Model 6081-4
z Introduction to Servo Control Valves
z Acceleration and Deceleration Control
z Open-Loop Position Control
z Closed-Loop Position Control, Proportional (P)
Mode
z Closed-Loop Position Control, ProportionalPlus-Integral (PI) Mode
z Open-Loop Speed Control
z Closed-Loop Speed Control, Proportional-PlusIntegral-Plus-Derivative (PID) Mode
z Closed-Loop Pressure Control, ProportionalPlus-Integral (PI) Mode
SYSTEM VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED PROGRAM HOURS
45 hours for each program
Model 6081-4
LANGUAGE VARIATIONS
English, French, Spanish
ELECTRONIC SENSORS SET
Model 6085
The Lab-Volt Sensors Training System, Model 6085-A,
is designed to familiarize students with the operation
of various sensor types. This training system is an addon to Electrical Control of Hydraulic Systems, Model
6080-2 and Electrical Control of
Pneumatic Systems, model 6081-2. It
is also available as a stand-alone
system. The Sensors Training
System contains a selection of
photoelectric, inductive and
capacitive sensors representative
of what can be found in the industry.
Each sensor is mounted on a
flexible support attached to a
metallic base which can be
snapped into the perforations of the
Hydraulics and Pneumatics Trainer
work surfaces. The sensors are protected against reverse polarity and can be
used in conjunction with Programmable Logic Controller
to achieve advance fluid control applications.
As a stand-alone system, the Sensors Training System
includes also a power supply, pilot lamps, leads, and a work
surface.
TOPIC COVERAGE
z Introduction to Sensors
z Diffuse Reflective Photoelectric Switches
z Background Suppression Photoelectric Switches
z Fiber-Optic Photoelectric Switches
z Polarized Retroreflective Switches
z Capacitive Proximity Switches
z Inductive Proximity Switches
18
Model 6085-A
SYSTEM VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED PROGRAM HOURS
18 hours
LANGUAGE VARIATIONS
English, French, Spanish
MANUFACTURING TECHNOLOGY
HYDRAULICS AND PNEUMATICS SIMULATION SOFTWARE
(LVSIM®-HYD & LVSIM®-PNEU)
Model 6385 and 6485
The Hydraulics (LVSIM®-HYD) and Pneumatics
(LVSIM®-PNEU)
Simulation
Software
are
Windows®-based programs that cover the same
courseware as Hydraulics and Pneumatics
Fundamentals (Models 6080-1 and 6081-1) and
Electrical Control of Hydraulic and Pneumatic
Systems (Models 6080-2 and 6081-2).
LVSIM®-HYD and LVSIM-PNEU® recreate a
three-dimensional classroom laboratory on a computer screen. The actual equipment of the Lab-Volt
Hydraulics & Pneumatics Training Systems is
replaced with three-dimensional images, which
students can manipulate on the computer screen.
Using the mouse, students can install virtual
hydraulic and pneumatic equipment in the laboratory, interconnect the equipment, perform a lab
exercise, and obtain the same results as with the
actual Lab-Volt training equipment.
Sophisticated mathematical models accurately simulate the mechanical and electrical characteristics of the hydraulic and pneumatic components (valves, cylinders, motors, flowmeter, and
others) and electrical control devices (switches,
relays, pilot lamps, etc.) in the actual Lab-Volt
Hydraulics and Pneumatics Training Systems. All
components and devices contained in the LVSIM®HYD and LVSIM-PNEU® software feature the same
functionality and appearance as the actual equipment. Detailed cutaway views of the components
can be displayed to observe fluid flow inside components.
Used either as a complement to the actual
Hydraulics or Pneumatics Training System or as a
stand-alone product, LVSIM®-HYD and LVSIM®PNEU are cost-effective tools that enable students
to perform the experiments provided in the
courseware mentioned above. Students may copy
the LVSIM®-HYD or LVSIM®-PNEU software onto
their own personal computers in order to practice
and prepare in advance for their lab exercises.
However, measurement capability is restricted by
means of a security device.
FEATURES
LVSIM®-HYD and LVSIM®-PNEU enable students to perform the following tasks:
z Install, move, and remove hydraulic and pneumatic
components and electrical control devices
z Modify or remove connections at any time
z Zoom in or out to adjust the view
z Perform measurements of flow, pressure, force, velocity
and rotation speed
z Observe motor rotation, as well as the extension and
retraction of cylinder rods
z Observe fluid flow inside hydraulic and pneumatic
components
z Save and restore equipment setups (including the virtual classroom laboratory environment)
Model 6385
Hydraulics Simulation Software LVSIM®-HYD.
Model 6485
Pneumatics Simulation Software LVSIM®-PNEU.
VIRTUAL EQUIPMENT
All components from the subsystems for Fundamentals
(Hydraulics-6080-1; Pneumatics-6081-1) and Electrical
Control (Hydraulic Systems-6080-2; Pneumatic Systems6081-2) are simulated in LVSIM®-HYD and LVSIM®-PNEU.
PERSONAL COMPUTER REQUIREMENTS
A Pentium personal computer, running under one of the
following Microsoft® operating systems, Windows® NT,
Windows® 98,Windows® ME,Windows® 2000, or
Windows® XP is required to run this software.
LANGUAGE VARIATIONS
English, French, Spanish
19
FLUID POWER
FUNDAMENTAL FLUID POWER TRAINER
Model 6059
The Fundamental Fluid Power Trainer, Model 6059, is an
introductory program in fluid power concepts, devices,
and circuits. The comprehensive Fundamental Fluid
Power Trainer includes two instructional trainer modules, and a correlated, two-volume set of student manuals plus instructor guides.
The Fundamental Fluid Power Trainer can be purchased as a complete training program (volumes 1
and 2), or in stages by purchasing Volume 1 and the
Volume 2 at a later time. Volume 1 introduces fluid
power principles. Volume 2 expands on these principles and covers new fluid power components.
Fluid power components are permanently mounted on removable
trays that are stored in a
lockable cabinet. Valves
and cylinders are made of
clear plastic to allow students to view internal
parts and better comprehend component functions.
The two-volume set of
manuals is presented in eight
and six instructional units, respectively. Each unit covers a broad area of
fluid power, and contains an objective, a
discussion of fundamentals, and several
practical exercises that present the material
in small instructional segments. Following stepby-step procedures, each student builds simple
fluid power circuits using pneumatic components
that demonstrate the principles explained in the discussion.
TOPIC COVERAGE
Volume 1, Fundamentals of Fluid Power
z Getting to Know the Trainer
z Fluid Power Fundamentals
z Introduction to Fluid Power
z Compressors and Pumps
z Pressure-Control Valves
z Directional Controls
z Actuators
z Flow Measurement and Control
Volume 2, Fundamentals of Fluid Power
z Getting to Know the Trainer
z Pilot-Operated Valves
z Cam Operated Valves
z Solenoid Operated Valves
z Special Components
z Advanced Applications
20
FEATURES
z Self-contained cabinet with electric power supply
and air compressor
z Easy-to-use controls
z SI and imperial units of measurements
z “Fix-it Shops” that illustrate everyday applications
of concepts covered
z Manual, electric, and pilot control
z Clear plastic components to allow viewing of
internal parts
z Transparent cabinet top to allow visual inspection
and observation of pneumatic power source components
SYSTEM VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED PROGRAM HOURS
46 hours
LANGUAGE VARIATIONS
English
MANUFACTURING TECHNOLOGY
INSTRUMENTATION AND PROCESS CONTROL
Sophisticated Training Systems for Measur ement and
Contr ol of Flow, Level, Pr essur e, and Temperatur e
PRODUCT PROFILES
PROCESS CONTROL TRAINER
Model 3521
The Process Control Trainer, Model
3521, is a portable, bench-top unit
designed to familiarize students
with
the
fundamentals
of
Instrumentation and Process control. The trainer uses a temperature
process whose characteristics can
be altered to provide several
degrees of stability and damping.
TOPIC COVERAGE
z Open-Loop Process Control
z Positive and Negative Feedback
in Closed-Loop Process Control
z Basic Measurement Channel
z Basic Measurement Channel
Instrument Characteristics
z Process Characteristics
z Two-Position Controller
z Proportional Controller
z Proportional Plus Integral Controller
z Proportional Plus Derivative Controller
z Proportional Plus Integral Plus Derivative Controller
z Alarms in Process Control Systems
z Troubleshooting
FEATURES
FEATURES
z Standard industrial grade components
z Silk-screen diagrams on module
z Temperature process with overheat protection
z Digital temperature meter
z Level comparator with adjustable hysteresis for on-off
control
z Solid state relay able to supply up to 50 watts to the
heating element and able to modify output power to
alter the process dynamics
z Adjustable process dynamics
z Equipped for thermoelectric cooling/heating processes
z Temperature transmitter to introduce the concept of
zero and span adjustments
z Proportional, Integral, Derivative (PID) controller with
low pass filter, error detector, independent P, I and D
amplifiers, summing amplifier and limiter, and integrator anti-reset
Model 3521
z Alarms capability, with selectable high-low alarm
z
z
z
z
z
type and selectable latching/non-latching action
DC source and DC voltmeter
Triangle-wave generator
Noise generator to study the effect of noise and
filtering in process control
Fault insertion capabilities
Easy interface with computer for data acquisition
or direct digital control through standard 0 to 5
Vdc input and output voltages
SYSTEM INTERFACES
INTERFACES WITH
Lab-Volt Process Control Simulator (LVPROSIM),
Model 3674
SYSTEM VOLT
VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED
ESTIMATED PROGRAM HOURS
Open
LANGUAGE VARIA
TIONS
VARIATIONS
English, French, Spanish
21
INSTRUMENTA
INSTRUMENTATION AND PROCESS CONTROL
TEMPERATURE/FLOW PROCESS TRAINING SYSTEM
Model 3522
The Temperature/Flow Process Training System, Model
3522, is a portable, bench-top unit designed to familiarize
students with the fundamentals of instrumentation and
process control. Advanced concepts such as cascade and
TOPIC COVERAGE
z Familiarization with the Trainer
z Open-Loop Process Control
z Closed-Loop Process Control
z Measurement Channel Characteristics
z Process Characteristics
z Proportional (P) Control
z Proportional plus Integral (PI) Control
z Proportional plus Integral plus Derivative (PID) Control
z Open-Loop Tuning Method
z Ultimate-Cycle Tuning Method
z Troubleshooting Temperature and Flow Processes
FEATURES
FEATURES
z Temperature process including temperature sensor
and transmitter, heater, and heater driver
z Temperature process control using either heating or
cooling
z Flow process including venturi element, flow transmitter, fan, and fan driver
z Process control achieved through any external controller compatible with either standard 4-20 mA or 0-5 V
signals
z Temperature and flow transmitters to introduce the
concept of zero and span adjustments
z Fault insertion capabilities
z Easy interface with a computer for data acquisition
z Built-in power supply
22
feed-forward control can also be studied. The trainer provides a temperature process and a flow process. Process
control is achieved through an external controller that is
compatible with either standard 4-20 mA or 0-5 V signals.
SYSTEM INTERFACES
INTERFACES WITH
Lab-Volt Process Control Simulator (LVPROSIM),
Model 3674, through the Lab-Volt I/O Interface,
Model 9065
SYSTEM VOLT
VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED
ESTIMATED PROGRAM HOURS
Open
LANGUAGE VARIA
TIONS
VARIATIONS
English, French, Spanish
MANUFACTURING TECHNOLOGY
LVPROSIM - PROCESS CONTROL AND SIMULATION SOFTWARE
Model 3674
The Lab-Volt LVPROSIM - Process Control and Simulation
Software, Model 3674, provides computer-based training
in generic process control and simulation of the Lab-Volt
Model 3521 Process Control Trainer.
Using the LVPROSIM software, students can simulate
a generic process with system configurations for
adjustable process time constants, dead time, process
gain, and disturbance time constant. At the same time,
students can use the software to study and simulate
process dynamics and regulation, which they can later
apply with the Lab-Volt Model 3521 Process Control
Trainer.
LVPROSIM offers a selection of preconfigured experiments for the generic process simulator, as well as for the
3521 Process Control Trainer simulator. The students can
also design new experiments for the generic process simulator. A series of pre-programmed tests can be selected
from the main menu. User-defined tests and experiments
can also be created using the test generator and experiment creator, which can be password protected to limit
access to the instructor.
TOPIC COVERAGE
z Introduction to process control
- Closed-loop control
z Process dynamics
- Reaction curve of a first-order process
- Frequency response of a first-order process
- Reaction curve of a second-order process
- Frequency response of a second-order process
z Proportional plus integral control mode
- Open-loop response of a PI controller
- Frequency response of a PI controller
- Proportional plus integral control
z Proportional plus derivative control mode
- Open-loop response of a PD controller
- Frequency response of a PD controller
z The PID controller
- Open-loop response of a PID controller
- Tuning of a PID controller
FEATURES
FEATURES
z Trend recorder
z PID (Proportional, Integral, Derivative) Controller
z Function Generator
z Test function
z Self-tuning
z FOPDT (First Order Plus Dead Time) modeling
COMPUTER REQUIREMENTS
z Pentium type
z Windows® 95, Windows® 98, Windows® NT, Windows®
2000, or Windows® ME
ESTIMATED
ESTIMATED PROGRAM HOURS
35 hours
LANGUAGE VARIA
TIONS
VARIATIONS
English
23
INSTRUMENTA
INSTRUMENTATION AND PROCESS CONTROL
PROCESS CONTROL TRAINING SYSTEM
Model 6090
The Lab-Volt Process Control Training System, Model 6090,
familiarizes students with the fundamentals of instrumentation and process control. It demonstrates the control of
pressure, flow, level, temperature, and pH processes. It can
also demonstrate advanced process control techniques,
such as feed-forward control, second-order control, and
cascade control when used with a controller featuring
these functions.
The basic trainer demonstrates PID (proportional, integral, derivative) control of flow, pressure, and level processes. It comes with a variable-speed pump, a tank, a column,
two-way valves, pressure gauges, flexible hoses, a venturi
tube, an orifice plate, a rotameter, a paddle wheel flow
transmitter, and a differential pressure transmitter. A work
surface, consisting of a solid metal perforated plate hinged
to a drip tray, provides a large area on which components can be mounted.
Mounting and removal of the components are made especially easy with pushlock fasteners that snap effortlessly into the
perforations of the work surface. The components can be interconnected by means
of flexible hoses equipped with quick
disconnect fittings that permit easy and
fast component connections without the
use of tools. The hose fittings contain
check valves to prevent water from running out of the hoses when they are
disconnected.
The trainer processes can be controlled by a computer-based PID
Controller implemented with a personal computer, the included
Process Control and Simulation
Software (LVPROSIM), Model 3674,
and the I/O Interface, Model 9065. Any
conventional PID controller compatible
with standard 4-20 mA or 0-5 V signals can
also be used.
To demonstrate PID control of temperature process,
additional components can be added to the basic trainer.
The additional components include a heating unit, a cooling unit, and temperature transmitters. Cascade and second-order process control can also be studied with the
basic trainer by having the students from two workstations
work together at a single workstation.
The pH Process Control System allows students to
learn fundamentals of pH control by studying acidic, basic,
and buffer solutions. They also learn how to characterize
pH processes and how to control basic and complex pH
processes using different methods. The system includes
sampling pumps, chemical tanks, pH transmitter, pH controller, and many accessories.
TOPIC COVERAGE
Pressur
e, Flow,
Pressure,
Flow, and Level Process
Process Control
Control
z Introduction to Process Control
- Familiarization with the Training System
z Pressure Processes
- Pressure Measurement
- Pressure Losses
- Centrifugal Pumps
- Characterization of a Pressure Process
24
Model 6090-1
Shown with optional equipment
z Flow Processes
- Rotameters and Paddle Wheel Flow Meters
- Orifice Plates
- Venturi Tubes
- Permanent Pressure losses Compared
- Characterization of a Flow Process
z Level Processes
- Float Switches
- Differential-Pressure Level Meters
- Zero Suppression and Zero Elevation
- Wet Reference Legs
- Characterization of a Level Process
- Bubblers (Optional Exercise)
z PID Process Control
- Pressure Process Control
- Flow Process Control
- Level Process Control
- Cascade Process Control (Optional Exercise)
- Second-Order Process Control (Optional
Exercise)
MANUFACTURING TECHNOLOGY
Lab-Volt Pr ocess Contr ol Training System,
Model 6090
(Continued)
Model 6090-2
Temperature
emperature Process
Process Controls
Controls
z Introduction to Temperature Process Control
- Familiarization with the Training System
z Temperature Measurement
- Resistance Temperature Detectors (RTD’s)
- Thermocouples
- Thermal Energy Transfer in Temperature
Processes
z Characterization of a Temperature Process
- Characterization of a Temperature Process in the
Heating Mode
- Characterization of a Temperature Process in the
Cooling Mode
z PI Control of Temperature Processes
- PI Control of a Temperature Process in the
Heating Mode
- PI Control of a Temperature Process in the
Cooling Mode
pH Process
Process Control
Control
z Introduction to pH Process Control
- Familiarization with the Training System
z pH Processes
- pH Measurement
- Titration Curves of Strong Solutions
- Titration Curves of Weak Solutions
- Titration Curve of Buffer Solutions
z Characterization of pH Processes
- pH Characterization of a Strong Solution
- pH Characterization of a Weak Solution
- pH Characterization of a Two-Stage Reactor
z pH Process Control
- pH Process Control Using a PID Controller
- pH Process Control Using a On-Off Controller
- pH process Control Using Two Controllers
Model 6090-3
FEATURES
FEATURES
z Modular design
z Pressure, flow, and level processes
z Optional sets of components are available to implement
temperature process
z Designed for use with any PID controller compatible
with either 4-20 mA or 0-5 V signals
z Work surface can be configured to accommodate a wide
variety of space and training needs
z Components mount easily on the work surface through
push-lock fasteners
z Easy component interconnection through flexible hoses
terminated with quick-connect fittings
z Optional equipment (Models 3674 and 9065) provides
interface with a computer for data acquisition and
process control
z Optional workbench and dressing panels are available to
provide the work surface with mobility and storage
space
z Comprehensive courseware
z Cost-effective alternative to systems using industrial
grade components
ESTIMATED
ESTIMATED PROGRAM HOURS
Pressure, Flow, and
Level Process Control:
50 hours
Temperature Process Control:
30 hours
pH Process Control:
30 hours
25
INSTRUMENTA
INSTRUMENTATION AND PROCESS CONTROL
MOBILE INSTRUMENT & PROCESS CONTROL TRAINING SYSTEM
Model 3500-MO
Model 3501
Model 3503
Model 3502
The Mobile Instrumentation and Process Control
Training System, Model 3500-M0, is a series of self-contained mobile workstations that provide hands-on training in the measurement, control, and troubleshooting of
Pressure, Flow, Level, Temperature, Heat Exchanger, and
Analytic Process Loops.
Each workstation, which is constructed on a sturdy
steel frame with casters, can operate independently or in
combination configurations to simulate complex
processes which simulate real-world time lag and
process responses.
The course begins with the basic characteristics of
the major process variables: pressure, flow, level, and
temperature - and progresses to measurement devices
and calibration of sensors, transducers, and transmitters.
From there, students learn the principles and operation
of the microprocessor-based controller and progress to
the basics of closed loop control and methods of controller tuning.
FEATURES
FEATURES
z Fault-insertion capabilities
z Patch-connected signal conditioners, controllers, and
transmitters to permit alternate control schemes and
for flexibility in incorporating new technology as it is
developed
26
Model 3504
z
z
z
z
Realistic process response times
Multi-element and ratio control capability
Microprocessor-based controllers
Comprehensive courseware
COMPRESSED AIR REQUIREMENT
700 kPa (100 psi) at 0,95 l/s (2 SCFM) of dry air to each
station
COMPUTER CONTROL SYSTEM
z Supervisory Control and Data Acquisition (SCADA)
z Alarms
z Graphics
SYSTEM ENHANCEMENTS
z Calibration Station
z Computer Process Control Trainer
z Flow Elements - Flow and Level Stations
z Flow Assemblies - Flow Station
SYSTEM VOLT
VOLTAGES
120, 220, 240 V - 50/60 Hz
MANUFACTURING TECHNOLOGY
PRESSURE PROCESS STATION
Model 3501-MO
The Pressure Process Station, Model
3501-M0, consists of two air tanks that
can be patch-connected individually, in
series, or in parallel. Used individually,
each tank demonstrates a single capacity process with single volume and minimal lag; connected in parallel, the tanks
demonstrate a single capacity process
with dual volume; and connected in
series, the tanks show a dual capacity
process, both with interacting lag.
The process load consists of an
exhaust assembly connected to a muffler. Needle valves at the tank connections and exhaust assembly permit the
introduction of demand and supply disturbances and allow for varying degrees
of restriction to all loop configurations,
thereby providing a variety of process
rates and responses. An I/P converter,
electronic pressure transmitter, and
diaphragm-actuated valve have all supply and signal lines terminated at quickconnect fittings on the main control
panel. Mounted on the main panel are
the microprocessor-based controller,
strip chart recorder, pressure gauges,
flowmeter, orifice assembly, and two
alarm lamps.
Supporting courseware is written
specifically for the Mobile Pressure
Process Station.
TOPIC COVERAGE
z Pressure Transmitter Time Response
Characteristics
z Pressure Process Characteristics
z Pressure Process Proportional
Control
z Pressure Process Proportional and
Integral Control
z Pressure Process Proportional and Integral
and Derivative Control
z Notch Tuning of a Pressure Process
z Ultimate Period Tuning of a Pressure Process
z Open Loop Tuning of a Pressure Process
z Operation of a Pressure Measurement Channel
z Troubleshooting a Pressure Measurement Channel
z Operation of a Pressure Control Channel
z Troubleshooting a Pressure Control Channel
z Calibration of an Air Flow Transmitter
z Air Flow vs Differential Pressure for an Orifice
z Operation of an Air Flow Measurement Process
z Troubleshooting an Air Flow Measurement
Process
z Operation of an Air Flow Control Process
z Troubleshooting an Air Flow Control Process
SYSTEM VOLT
VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED
ESTIMATED PROGRAM HOURS
40 hours
LANGUAGE VARIA
TIONS
VARIATIONS
English, French, Spanish
27
INSTRUMENTA
INSTRUMENTATION AND PROCESS CONTROL
FLOW PROCESS STATION
Model 3502-MO
The Flow Process Station, Model 3502-M0, has
clear PVC pipes in series with two header assemblies, a flowmeter, and a water reservoir. The
header can receive optional, interchangeable
assemblies for the measurement of flow, including orifice plates, pitot tubes, and other flow
measuring instruments or transmitters. The large
header allows for differential pressure measurement across customer-specific assemblies, such
as a series of 90-degree elbows or sudden
enlargement pipe. Mounted on the main control
panel are the microprocessor-based controller
and strip chart recorder with all connections terminated at banana jacks.
Coupling unions allow the Flow Process
Station to be directly coupled with the Level
Process Station, thereby creating Flow control
using a diaphragm-actuated control valve as the
control element, or level control using the variable frequency pump drive. Coupling the two
stations also provides for the two differential
transmitters necessary to configure more
advanced interactive control loops such as feedforward or cascade control. A venturi element
mounted in a header assembly is included with
the station.
Supporting courseware for this system is
written specifically for the Flow Process Trainer.
TOPIC COVERAGE
z Flow Transmitter Time Response
Characteristics
z Flow Process Characteristics
z Flow vs Differential Pressure for a Venturi
z Calibration of a Flow Transmitter
z Flow Process Proportional Control
z Flow Process Proportional and Integral Control
z Flow Process Proportional and Integral and
Derivative Control
z Ultimate Period Tuning of a Flow Process
z Notch Tuning of a Flow Process
z Open Loop Tuning of a Flow Process
z Operation of a Flow Measurement Channel
z Troubleshooting a Flow Measurement Channel
z Operation of a Flow Control Process
z Troubleshooting a Flow Control Process
z Bottom Drain Level Control
z Emergency Feed Water Injection System
FEATURES
FEATURES
z All required, switches, manometers, patchcords,
hoses, and flow elements included in process stations
z Transparent piping for student observation of system
operation
z Interconnectable workstations to allow training in
complex systems
z Quick disconnects for rapid system configuration
z Multi-element and ratio control capability
z Standard industrial instrumentation
28
SYSTEM VOLT
VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED
ESTIMATED PROGRAM HOURS
45 hours
LANGUAGE VARIA
TIONS
VARIATIONS
English, French, Spanish
MANUFACTURING TECHNOLOGY
LEVEL PROCESS STATION
Model 3503-MO
The Level Process Station, Model 3503-M0, contains a
Plexiglas cylinder with diaphragm-actuated control valve,
pipe-mounted differential transmitter and I/P
converter mounted on the side of the cabinet
and terminated at quick-connect fittings on
the main control panel. Also mounted on the
main panel are the microprocessor-based
controller, strip chart recorder, and two
alarm lamps. A regulator needle valve controls air flow to a bubbler pipe for level
measurement. In addition, at the base of
the level column are two valved taps to permit connection of the D/P cell, optional
manometers low-pressure gauges, and wet
leg standpipe.
Coupling unions allow the Level
Process Station to be directly coupled with
the Flow Process Station, thereby permitting flow control using a diaphragm-actuated control valve as the control element.
Coupling of these two stations provides the
two differential transmitters necessary to
configure more advanced interactive control loops such as feed-forward and cascade
control.
Supporting courseware is written
specifically for the Mobile Level Process
Station.
TOPIC COVERAGE
z Level Transmitter Time Response
Characteristics
z Level Process Characteristics
z Calibration of a Level Transmitter
z Level Measurement with a Bubbler
z Level Measurement with an Open Tank
z Level Measurement with Zero
Suppression
z Level Measurement with a Wet
Reference Leg
z Level Process Proportional Control
z Level Process Proportional and Integral
Control
z Level Process Proportional Integral and Derivative
Control
z Notch Tuning of a Level Process
z Ultimate Period Tuning of a Level Process
z Open loop Tuning of a Level Process
z Operation of a Level Measurement Channel
z Troubleshooting a Level Measurement Channel
z Operation of a Level Control Process
z Troubleshooting of Level Control Process
z Operation of a Flow Measurement Channel
z Operation of Flow Control Process
z Operation of a Two-Element Control Process
z Operation of a Three-Element Control Process
FEATURES
FEATURES
z All required gauges, switches, manometers, patchcords, hoses, and flow elements included in process
station
z Transparent piping and valves for student obser-
vation of system operation
z Interconnectable workstations to allow training in
complex systems
z Quick disconnects for rapid system configuration
z Multi-element and ratio control capability
z Standard industrial instrumentation
SYSTEM VOLT
VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED
ESTIMATED PROGRAM HOURS
Open
LANGUAGE VARIA
TIONS
VARIATIONS
English, French, Spanish
29
INSTRUMENTA
INSTRUMENTATION AND PROCESS CONTROL
TEMPERATURE PROCESS STATION
Model 3504-MO
The Temperature Process Station, Model
3504-M0, consists of a 20-2000 C (70-4000 F)
oven operated manually as an on-off process
using a 24 Vdc relay, or proportionally controlled by a triac driver with 4-20 mA input.
The oven is modified with an air cooling injector and adjustable damper for load and
process disturbances.
The unit features a pipe-mounted on-off
capillary bulb temperature controller with two
sets of contacts terminated at banana jacks on
the main control panel. Also featured are a
pipe-mounted thermocouple to current temperature transmitter, complete with type “J”
thermocouple, and RTD to current transmitter,
complete with 100-Ω platinum RTD, with all
supply and signal connections terminated at
banana jacks on the main control panel.
Mounted on the control panel are the microprocessor-based controller, strip chart
recorder, two alarm lamps, and a pneumatic
air regulator.
TOPIC COVERAGE
z Temperature Transmitter Time Response
Characteristics
z Temperature Process Characteristics
z Calibration of a Temperature Transmitter
z Temperature Measurement with a
Thermocouple
z Temperature Measurement with an RTD
z On-Off Temperature Control
z Temperature Process Proportional Control
z Temperature Process Proportional Plus
Integral Control
z Temperature Process Proportional,
Integral, Plus Derivative Control
z Notch Tuning of a Temperature Process
z Ultimate Period Tuning of a Temperature Process
z Open Loop Tuning of a Temperature Process
z Operation of a Temperature Measurement Channel
z Troubleshooting a Temperature Measurement
Channel
z Operation of a Temperature Control Process
z Troubleshooting a Temperature Control Process
z Hard-wired Alarms Using Capillary Bulb Switch
z Microprocessor-Based Controller Software Alarms
FEATURES
FEATURES
z Quick disconnects for rapid system configuration
z Standard industrial instrumentation
30
SYSTEM VOLT
VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED
ESTIMATED PROGRAM HOURS
Open
LANGUAGE VARIA
TIONS
VARIATIONS
English, French, Spanish
MANUFACTURING TECHNOLOGY
MULTI-PROCESS STATION
Model 3505
The Multi-Process Station, Model 3505, consists of a
Plexiglas cylinder, an inner column for dual volume
process characteristic, a pump, a diaphragm-actuated
control valve, two pipe-mounted differential pressure (D/P)
transmitters, and a current-to-pressure (I/P) converter. A
microprocessor-based controller, a variable frequency AC
drive, a dual-pen strip chart recorder, and two alarm lamps
are also mounted on the main panel. A regulator needle
valve controls air flow to a bubbler pipe for level measurement.
In addition, at the base of the level column are two
valve taps that permit connection of the D/P cell or optional manometers. A low-pressure gauge and a compoundpressure gauge are mounted on the side of the control
cabinet. A pressure cap on the level process tank permits
level control of a pressurized vessel. Two headers allow
insertion of flow measurement devices on both the inflow
and the outflow of the level process tank. The station
includes a rotameter flow indicator in series with the
process piping, and a Venturi flow-element.
Coupling unions allow the Multi-Process Station to be
directly coupled to other stations to achieve more
advanced interactive control loops such as temperature,
pH, and ratio control. Pressure taps are provided on the
system piping to permit measurement of pressure drops
around the system and to thoroughly evaluate system performance.
TOPIC COVERAGE
z Level Measurement I - Dry Method using a Bubble
Pipe
z Level Measurement II - Calibration of a Level
Transmitter
z Pressure Measurement
z Flow Measurement: Differential Pressure vs Flow
Using a Venturi or Orifice Plate
z Level Process Characteristics with Control Valve
z Level Process Characteristics with Variable Speed
Pump
z Flow Process Characteristic with Control Valve
z Pressure Process Characteristics
z Proportional Control - Level Process with Control
Valve
z Proportional Control - Flow Process with Variable
Speed Pump
z Proportional Plus Integral Control - Level Process with
Control Valve
z Proportional Plus Integral Control - Pressure Process
z Proportional Plus Integral Plus Derivative Control Level Process with Control Valve
z Proportional Plus Integral Plus Derivative Control Flow Process with Variable Speed Pump
z Ultimate Period Tuning of a Level Process
z Ultimate Period Turning of a Flow Process-Approximation
Method
z Open Loop Tuning of a Level Process using the
Reaction Rate Method
z Open Loop Tuning of a Pressure Process
z
z
z
z
Troubleshooting a Level Control Process
Operation of a Two-Element Control Process
Three-Element Control Process
Auto-Tune Controller
FEATURES
FEATURES
z All required gauges, switches, manometers, patch
cords, hoses, and flow elements are included
z Transparent piping and valves for student observation of system operation
z Interconnectable workstations to allow training in
complex systems
z Quick-disconnect fittings for a rapid system configuration
z Multi-element and ratio control capability
z Standard industrial instrumentation
SYSTEM VOLT
VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED
ESTIMATED PROGRAM HOURS
Open
LANGUAGE VARIA
TIONS
VARIATIONS
English
31
INSTRUMENTA
INSTRUMENTATION AND PROCESS CONTROL
HEAT EXCHANGER STATION
Model 3507-MO
The Heat Exchanger Station, Model 3507-M0,
is an add-on station requiring interconnection
with the Level Process Station, Model 3503MO, providing hands-on training in the measurement and control of temperature and heat
exchanger processes.
The process consists of a water process
tank with two pumps: one circulates water
through a 6-kW electric water heater powered
by a three-phase solid state drive with a 4-20
mA driver control circuit; the other circulates
water through the tube side of a shell and tube
heat exchanger, and then returns it to the water
process tank.
Supply and signal lines to an I/P converter,
RTD to current, thermocouple to current converters, diaphragm-actuated control valve, and
solid state drive are terminated at quick-connect fittings on the main control panel.
Mounted on the main panel are the microprocessor-based controller, a two-pen strip
chart recorder, and pump controls.
TOPIC COVERAGE
z Temperature Measurement Using a
Thermocouple
z Temperature Measurement Using an
RTD
z Calibration of a Thermocouple
Transmitter
z Calibration of a RTD Transmitter
z Response Time Comparison:
Thermocouple vs RTD
z Temperature Process Characteristics
z Operation of a Temperature
Measurement Channel
z Temperature Process - Proportional Control
z Temperature Process - Proportional Plus Integral
Control
z Temperature Process - Proportional Plus Derivative
Control
z Temperature Process - Proportional Plus Integral Plus
Derivative Control
z Temperature Process - Triac Drive Heater Control
z Calibration of a Control Valve
z Temperature Control Loop - Cooling Process
z Two-Element Temperature/Flow Control Loop
z Two-Element Temperature/Level Control Loop
z Cascade Control Loop
z Feed-Forward Control
FEATURES
FEATURES
z Industrial shell and tube heat exchanger
z Self-contained, cold water supply with fan-cooled
chiller and separate recirculating pump
z Self-contained, hot water supply with a triac-controlled heater and separate recirculating pump
32
z Diaphragm control valve to control the hot water
process
z Manual valves to select and disturb processes
z Thermowells to monitor temperature
z Capable of demonstrating most common boiler
control systems when connected to the Level
Process Station, Model 3503-MO
SYSTEM VOLT
VOLTAGES
120/208 V, 60 Hz, 3 phases
220/380 V, 50 Hz, 3 phases
240/415 V, 50 Hz, 3 phases
ESTIMATED
ESTIMATED PROGRAM HOURS
Open
LANGUAGE VARIA
TIONS
VARIATIONS
English
MANUFACTURING TECHNOLOGY
ANALYTIC PROCESS STATION
Model 3508-MO
The Analytic Process Station, Model
3508-M0, is an add-on system process
station which requires interconnections
with the Lab-Volt Model 3503-MO Level
Process Station.
The add-on unit offers an alternative
for classes small enough to allow use of
the level station as part of the analytic
process. The trainer consists of a main
water circulation system with a water
heater, pump, cartridge-type demineralizer, and water reservoir. A variable-speed
sampling pump draws water from the
reservoir and circulates it through a path
containing one pH and one conductivity
transmitter, then returns it to the reservoir.
The unit features expanded microprocessor-based PID Controller, two-pen
recorder, pH transmitter, conductivity
monitor, one sampling pump, two chemical metering pumps, pH and temperature
meter, dissolved oxygen meter, temperature transmitter, electric water heater,
thermostat control, two chemical reservoirs, piping, and valving.
TOPIC COVERAGE
z Measurement of pH
z Relationship of pH and Temperature
z Measurement of Dissolved
Oxygen
z Manual pH Control for Acid
Range 0-7
z Manual pH Control for Base
Range 7-14
z Automatic pH Control
z Automatic pH Control Near Neutral
pH 7.0
FEATURES
FEATURES
z Variable-speed, recirculating pump, for
processing and mixing
z Two tanks for acid and base feeds that are piped into
the main process tank by variable-speed, electronically
controlled, metering pumps
z Demineralizer
z Conductivity and pH transmitters
z Microprocessor-type Water Analyzer with measurements in temperature, dissolved oxygen, pH, and conductivity
SYSTEM VOLT
VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED
ESTIMATED PROGRAM HOURS
21 hours
LANGUAGE VARIA
TIONS
VARIATIONS
English
SYSTEM INTERFACES
INTERFACES WITH
Lab-Volt 3503-MO Level Process Control Trainer
33
INSTRUMENTA
INSTRUMENTATION AND PROCESS CONTROL
INSTRUMENTATION AND CALIBRATION STATION
Model 3550-MO
The Instrumentation and Calibration Station, Model 3550M0, is a workstation designed for basic study of the operation and calibration of instruments. Complete with its
own regulated instrument power supply, this workstation
functions as a two-student instrument bench.
The station has a pipe stand for instrument mounting,
a digital multimeter with analog bar graph display (Fluke),
a digital instrument calibrator for mV, mA and V inputs,
and an AC Duplex receptacle with a lighted circuit breaker. The station has two regulated-pressure air outputs
with large pressure indicator.
Options such as a mobile bench or other calibrators
are also available.
TOPIC COVERAGE
z Calibration of a Pressure Gauge
z Calibration of a Pressure Transmitter
z Calibration of a Differential Pressure Transmitter
z Calibration of a Temperature Transmitter
z Calibration of a Current to Pressure Converter
z Calibration of a Strip Chart Recorder
z Alignment of a Control Valve
34
SYSTEM VOLT
VOLTAGES
120, 220, 240 V - 50/60 Hz
ESTIMATED
ESTIMATED PROGRAM HOURS
15 hours
LANGUAGE VARIA
TIONS
VARIATIONS
English, French, Spanish
MANUFACTURING TECHNOLOGY
WEB-BASED INDUSTRIAL TRAINING
Delivering the Difference in Industrial Training
with E-learning and CD-ROM-Based Courses
Industrial
Training
Zone by Lab-Volt delivers a broad range of
online and CD-ROMbased fundamental and specialty industrial training
courses designed to help instructors build a more
competent, qualified, and efficient workforce.
Engaging training systems feature 3D simulations, course narrations, a virtual guide, testing, and
quizzes to promote learning retention and use on the
job.
Courses are available online or via CD-ROM. Each
Online CoursePack™ contains one training pass (good
for one student to take one course), an online reference
manual, online assessment and certification passes,
and a ToolBox™ user account. Each CD CoursePack™
contains a CD training perpetual license, course-specific CD and printed reference manual, online assessment and certification passes, and a ToolBox™ user
account.
Mechanical, Electrical, and Fluid Power training
programs for both industry and mobile systems are
available online or via CD-ROM.
Model 47904
Mechanical Speed Reduction Learning Lab
z Compare clutches and their components, capabilities,
and applications
z Understand how bearings are used within mechanical
FEATURES
z Premier training interface organizes curriculum in a
logical sequence
z Interactive learning builds content mastery and
troubleshooting expertise
z Pre- and post-test certification ensures mastery of
skills
z 3D animations illustrate in real time how equipment works
z Self-paced learning increases retention and job
skills
z Video narrations guide training step by step
z Courseware is updated and reviewed regularly to
ensure accuracy
MECHANICAL TRAINING
Lab-Volt’s Industrial Mechanical Course, Model 47904,
gives trainees an overview of the basic physics laws,
schematics, and systems design associated with
mechanical power transmissions. Trainees learn about
the various components found in a typical mechanical
system, and how these components function and
interact with each other.
TOPIC COVERAGE
z Review energy, torque, and horsepower
z Learn how linear actuators convert rotational
motion into linear motion
power transmissions
z Review gears, how they operate, and when they are best
used to transmit power
z Review belt and chain drives, how they are designed,
and their operation
z Study the features, applications, and functions of differ-
ent couplings
PLC FUNDAMENTALS
The Programmable Logic Controller (PLC) course delivers
an interactive training experience designed to teach
trainees PLC operation, how to connect devices to a PLC,
and how to read and write basic PLC ladder-logic software
programs.
TOPIC COVERAGE
z Learn how PLC hardware differs from other computers
z Discover the math functions related to PLCs
z Learn how PLC systems store data, memory processes,
and data operations
z Master the language of PLCs and learn how to upload to
and download from a PLC
z Apply logic to a process by connecting your PLC to
another device
z Link your PLC to your production time, and control when
operations happen
z Tally the quantity of your automated processes with PLC
counters
35
WEB-BASED INDUSTRIAL TRAINING
WEB-BASED INDUSTRIAL TRAINING
For Fluid Power Applications
HYDRAULICS TRAINING
Lab-Volt offers online and CD-ROM-based hydraulics
training for both industrial and mobile markets. The
Industrial Hydraulics course familiarizes students with
the components, functions, and interactions of
hydraulic systems. Mobile Hydraulics covers the
basics of hydrostatic transmissions, valves, and maintenance systems common to most combustion
engines.
TOPIC COVERAGE
Industrial Hydraulics, Model 47901
z Review horsepower, torque, heat, flow, and pressure
z Study gear, vane, and piston pumps, and their fluid
displacement capabilities and applications
z Study force manipulation using control valves, the
two basic designs and their operation
z Observe how directional control valves operate,
start, stop, and change the direction of fluid flow
z Study fluid conditioning and temperature implications
z Understand the function of different valves and
where they are used
z Study conductors and how they carry fluid to various components in hydraulic circuits
z Review basic symbols and layout of a hydraulic
schematic
z Study components, pictures, and labeling of
hydraulic power units
Mobile Hydraulics, Model 47906
z Learn how actuators convert hydraulic horsepower
into mechanical horsepower
z Study the basic operation of hydrostatic circuits
z Study force manipulation using control valves
z Experience the application and location of flow
control valves
z Learn how modular control valves enhance system
design
z Study fluid conditioning and temperature implications
z Study how conductors carry fluid to various components in hydraulic circuits
z Review basic symbols and layout of a hydraulic
schematic
36
3D Simulation of a Piston Pump
Cutaway View of a Closed Circuit
Hydrostatic Transmission
MANUFACTURING TECHNOLOGY
WEB-BASED INDUSTRIAL TRAINING
For Fluid Power Applications
PNEUMATICS TRAINING
Lab-Volt’s Industrial Pneumatics course focuses on
the basic physics laws, schematics, and system
design associated with pneumatic systems and fluid
power.
In addition to this course, a Pneumatic Specialist
course has been developed in collaboration with the
Fluid Power Society and CFC-Solar to help trainees
understand the concepts related to the successful
design and interaction of pneumatic systems as a
Certified Pneumatic Specialist.
TOPIC COVERAGE
Industrial Pneumatics, Model 47902
z Review energy, torque, and horsepower
z Safely and efficiently operate compressors
z Discover the way air is dried to help preserve
metal parts exposed to air pressure
z Study the steps to filter, regulate, and lubricate
air before use
z Review the designs, techniques, port layouts,
and pressure configurations for operation
z Learn interface components that convert pneumatic energy into mechanical energy
z Review airline conductors and how they carry air
throughout the pneumatic circuit
z See demonstrations on how vacuum is created to
help systems work
z Identify the basic symbols of a pneumatic
schematic and learn to read system layouts
Pneumatic Specialist, Model 47909
z Review ratios, torque, speed, and friction
z Compute air cylinder pressure and identify the
fault in a pneumatic circuit
z Study air cylinder velocity, circuits, conductor
sizes, and input components
z Calculate pressure, cfm, oil flow rate and pressure, torque output, and kinetic energy
z Analyze control components and systems such
as electrical, position feedback, series-parallel,
pneumatic, and logical control circuits
z Prepare for the certification exam using the
study guide and other references
Overview of Pilot-Operated Valves
Pressure Differential Learning Lab
37
WEB-BASED INDUSTRIAL TRAINING
WEB-BASED INDUSTRIAL TRAINING
Electricity & Electronics
Electrical Training
Lab-Volt’s Industrial Electrical course delivers an
interactive training experience designed to help
trainees understand the fundamental concepts of electrical systems. This course is popular among those
who need to understand the workings of electrical
systems on the production floor.
Mobile Electrical covers electrical systems of
mobile equipment, including the basic electrical system common to most combustion engine vehicles.
AC/DC Motor and Drives helps trainees understand how electrical motors and drives work with each
other and other systems. Trainees also learn about the
safety considerations associated with operating
electromechanical systems.
TOPIC COVERAGE
Industrial Electrical, Model 47903
z Review basic physics laws that govern electrical
systems
z Study circuit components and laws governing circuit voltage and current
z Analyze the effects of circuit components connected in various configurations
z Learn how magnetic fields interact with each other
z Understand how electrical circuit components convert electrical energy into other energy forms
z Review how technology has improved electrical
testing, and study safety guidelines
Mobile Electrical, Model 47907
z Review basic physics laws that govern electrical
systems
z Study circuit components and laws governing circuit voltage and current
z Analyze the effects of circuit components connected in various configurations
z Learn how magnetic fields interact with each other
z Understand how electrical circuit components convert electrical energy into other energy forms
z Study how lead-acid batteries operate, and how
charging and starting systems work in most combustion engine vehicles
AC/DC Motors and Drives
Model 47908
z Basic terms and principles of motors and drives
z How torque and magnetism produce power
z Learn what to consider when selecting a replacement drive
z Review fuses and filtering devices
z Learn what causes electrostatic discharge and how
to avoid this
z Learn about the functions, components, and
firmware of different drives
38
Demonstration of a Ground Fault
Overview of Charging & Starting Systems
z Compare different braking methods and their
advantages and disadvantages
z Study five different electrical measuring tools used
to diagnose problems
z Program, maintain, and troubleshoot drives using a
human interface module (HIM)
MANUFACTURING TECHNOLOGY
The Ultimate
Manufacturing/Mechatr onics
Training System
For Jobs in CAD/CAM, Robotics, and CNC
As a long-standing leader in industrial technical training
systems, Lab-Volt is proud to offer this line of products for
hands-on training in automation and robotics. This line of
equipment, software, courseware, and accessories is
designed to provide students with industry-standard
training in integrated manufacturing technology and
processes that will prepare them for entry-level jobs in an
automated manufacturing environment.
All Lab-Volt Automation products are designed for
use in a variety of classroom configurations. They are
safe, table top applications, and include high-precision
equipment, integrated software, and comprehensive
courseware that encompass a wide range of manufacturing applications. The complete line of Lab-Volt
Automation products includes:
PLC TRAINING SYSTEM
Model 3240
MANUFACTURING CONVEYOR SYSTEM
Model 3509
FLEXIBLE MANUFACTURING SYSTEM
Series 5900
PROGRAMMABLE ROBOTS
z Model 5100
z Model 5150
z Model 5250
CNC LATHES
z CNC Lathe, Model 5300
z CNC Lathe, Model 5500
CNC MILLS
z CNC Mill, Model 5400
z CNC Mill, Model 5600
SOFTWARE
z File Transfer software for the Teach PendantControlled Robot System, Model 5100
z ROBOTUS® software for the Computer-Controlled
Robot System, Model 5150
z RoboCIM software for the Servo Robot System, Model
5250
z Lab-Volt CNC software for Mill and Lathe systems
z Fabricus software for the Mill system
z CAD/CAM Software for Mill and Lathe systems
COURSEWARE
z User Guides and Manuals
z Quick Start Manuals
z Student Manuals
z Instructor Guides
z Computer-Based Learning (CBL)
39
LAB-VOLT AUTOMATION
Large and Mid-Sized Robots
For Heavy and Light
Automated Tasks
The Lab-Volt Automation robots are powerful, precisionbuilt, articulated arm, 5-axes micro robots designed in
every way to emulate industrial robots in their
programming and operating features.
The Lab-Volt Robots, Models 5100 and
5150, are similar. However, the Model
5100 is controlled by a hand-held Teach
Pendant, while the Model 5150 is controlled by a PC host computer. The Servo
Robot, Model 5250, is controlled by
either a hand-held Teach Pendant or by a PC host computer.
Through the curriculum and hands-on exercises,
students learn to create automated workcells ideal for
flexible manufacturing systems (FMS) and computer
integrated manufacturing (CIM).
Models 5100 and 5150 are driven by six stepper
motors. They have a 432-mm (17-in) reach, 0.45-kg (16oz) load capacity, and a 3.2-mm (0.125-in) resolution.
The 5100 controller is equipped with a serial port to connect to a personal computer for uploading and downloading programs using the File Transfer software.
The larger robot, Model 5250, is driven by six DC
servo motors and can operate within a maximum radius
of 732 mm (28.5 in). It has a 1.4-kg (3-lb) load capacity
and weighs 20.4 kg (45 lb). The controller is a microprocessor based unit with 4 MB RAM and a floppy disk
drive for saving task/point programs. The hand-held
Teach Pendant has a four-line, 20-character LCD display,
and a 40-key membrane keypad for manual control. A
serial communication port is used to connect the robot
controller to a host computer for remote operation and
task editing with the host software.
An extensive list of optional equipment is available
for the robots to accommodate a variety of teaching
objectives. Equipment comprising a variety of feed
mechanisms and conveyors enables students to set up
workcells for computer-integrated manufacturing (CIM)
or flexible manufacturing systems (FMS). All components are provided with location devices that allow a
setup to be repeated when needed.
The robots feature advanced capabilities that distinguish them as high-precision, industrial quality systems,
ideal for training in state-of-the-art manufacturing technology.
40
ROBOT SOFTWARE
The Teach Pendant-Controlled Robot System,
Model 5100, comes with the File Transfer software
that enables students to download and upload programs created with the Teach Pendant. The
ROBOTUS® software for the Computer-Controlled
Robot System, Model 5150, allows the robot to be
directly controlled from the computer. This software
provides a real-time 3D simulation of the robot and its
immediate environment. Through an intuitive dragand-drop interface, users can directly control the position and movement of the robotic arm.
MANUFACTURING TECHNOLOGY
RoboCIM Softwar e
Menu-Driven Softwar e
for the Servo Robot
RoboCIM is a software used to simulate and control the operation of the Servo Robot System,
Model 5250, and external devices such as a gravity feeder and a linear slide. The software is also
used to create programs. In RoboCIM, the actual
equipment is replaced with three dimensionalimages. Sophisticated mathematical models accurately simulate the mechanical and electrical characteristics of the equipment.
One of the RoboCIM characteristics is to control and to visualize the motion of the system interactively. Two types of motion are available: joint
motion and Cartesian motion.
ROBOCIM SOFTWARE FEATURES
z Easy to use menu-driven software
z Simulation and control modes
z 3 dimensional (3D) virtual environment
z 7 predefined layout/camera view settings
z Control the movements of the Servo Robot
using "articular" and "Cartesian" coordinates
z Programming without actual equipment
z Point recorder panel to easily record, rename,
inform, hide, and delete points
z Create and run simple task programs using
icons and graphical tools (no typewriting
required)
z Create and run simple and complex task programs by typewriting all necessary commands
z Powerful set of task commands such as: Delay,
DO-Until, If-Else, Gosub, Home, Input, Output,
While-Repeat, and many others
41
LAB-VOLT AUTOMATION
CNC Lathes and Mills
Offering Flexibility, Variety, Safety and Accuracy
The skills required to perform simple to more sophisticated Computer Numerical Controlled (CNC) turning and
milling tasks are the focus of the Lab-Volt Automation
lathes and mills. All of these machines share many features that contribute to a superior CNC training system.
Each machine has an on-board microprocessor that
stores downloaded part programs, thereby eliminating
the need for a dedicated computer for operation. The
easy-to-use membrane keypad enables students to operate and control the machine by simply pressing buttons
on the control panel.
Each machine connects directly to an Ethernet or
RS-232 port of a personal computer to provide simultaneous programming and parts processing.
Each machine can be programmed using the LabVolt CNC Lathe/Mill software and CAD/CAM software.
The CNC Lathes and Mills, Models 5300, 5400, 5500,
and 5600, are designed to support low-voltage communications with robotic units and accessories to create automated workcells ideal for flexible manufacturing systems
(FMS) and computer integrated manufacturing (CIM). In
addition, they feature TTL connectors for communication
to an automation workcell. The TTL I/O and solenoid driver connectors are supported through the standard software. Also, on the rear or side panel are the main power
switch and fuses for easy maintenance, and the serial and
Ethernet ports for downloading part programs.
CONTROL PANEL FEATURES
z Key-released emergency stop push-button
z Ability to restart programs from stopping point after a
safety interruption
42
z 20-character by four-line LCD display
z Manual mode controls for:
- X-and Z-Axis positions on lathes; X-, Y- and Zaxis positions on mills
- Feed rate override
- Spindle speed override
- Tool change
- TTL and solenoid outputs
- Machine setup
z During execution, display of:
- X and Z positions on lathes; X-, Y-and Z-axis
positions on mills
- Feed rate
- Spindle Speed
- Tool change
- Current G and M codes
- TTL outputs status on lathes and mills
z Stall light indicator/push-button abort key
SAFETY FEATURES
z Full cover over bed and work area
z Key-released emergency stop push-button
z Sensor switches monitored by the machine for:
- Safety cover open
- Tool post too close to chuck
- Protection from over-travel on all axes
z Ability to restart programs from stopping point
after operator abort or safety interruption
While these machines do not require a dedicated
computer for operation, they do require an external
computer for creating and downloading the part programs.
MANUFACTURING TECHNOLOGY
Lab-Volt CNC Lathe/Mill Softwar e
Enhances Instruction With
Advanced Graphics and
Editing Featur es
Lab-Volt CNC Lathe/Mill software is a Windows®based, 32-bit application with the standard look and
feel of the Windows® 98, Windows® NT, Windows® 2000,
and Windows® XP operating systems. The software
features a parametric-based graphical tool editor, 3D
wireframe Tool Path Emulator with tool conflict view, a
wizard-style part program creation mode, and standard
Windows® interface.
Lab-Volt CNC Lathe/Mill software is compatible
with G and M part programs, which can be imported
from Computer-Aided Manufacturing (CAM) programs
that support the EIA standard G and M codes. The
software is supported by a complete curriculum, which
includes teacher and student manuals, worksheets,
course materials, and sample stock for milling and
turning.
LAB-VOLT CNC LATHE/MILL SOFTWARE FEATURES
z EIA-274-D standard G and M code programming
z Parametric, graphical view tool editor with support
for 20 tools
z Full G and M code help with graphical display
z Loading and saving tool offsets capability for the
lathes
z Editable material database with load and save features
z Full 3D tool path emulator with wireframe userdefined 3D perspective
z Wizard-style block part editor
z Selection of basic G and M codes from a drop-down
list
z AutoCAD.dxf file format import for the mills
z Simple CAD/CAM graphical development of part
programs for the lathes
z Integrated CIM/FMS cell support options and commands
z Serial and Ethernet download capabilities for the
Lab-Volt Automation CNC lathes and mills
z Support for custom machine configurations
Lab-Volt CNC
Lathe/Mill Softwar e
enlivens CNC pr ogramming
with colorful graphics
and quick-paced navigation
43
LAB-VOLT AUTOMATION
Fabricus Softwar e
Easy-To-Use CAD/CAM
Softwar e
Fabricus is an entry level CAD/CAM software program
used to easily create GM code files. The generated
codes are then used by CNC devices to repeatedly
manufacture complex parts.
FABRICUS SOFTWARE FEATURES
z Direct interface to Lab-Volt CNC Lathe/Mill
Software
z Simultaneously displays 4 screen views: top, front,
right side and 3D. Can display any view in full
screen. Zoom in and out, selection zooming, panning, fit to window and camera rotation (in 3D)
z Shows tool path & PRZ position
z Predefined stock selection or custom sizing
z Defined geometries include: rectangles, pentagons,
hexagons, heptagons, octagons, other polygons (up
to 20 sides), holes, ellipses, lines, polylines, Bezier
curves, arcs, pies
z Chamfers
z Draws pocket, grooves, ellipse cups and islands
z Outputs G & M code programs
z Program feed, speed and increments
z Mouse position, shape position, rotation angle, tool
and dimensions in a convenient toolbar
z A tree list of all the shapes present in the stock identified by names and icons and selectable for setting
properties
z Validation of tool paths given a tool diameter
z Multiple document interface: work on more than
one stock at a time
z Geometry right-click menu for most used commands
z Limit movement to x, y or z axes
z Shapes locking to prevent accidental movement
z 20 predefined tools and possibility to add more
z 2 predefined milling machines and possibility to add
more
44
MANUFACTURING TECHNOLOGY
CAD/CAM Softwar e for Mill and Lathe
Integrated, Industrial-Grade
Softwar e for Computer-Aided
Design and Computer-Aided
Manufacturing
CAD/CAM Software is a fully integrated, industrial
grade software package that makes it easy to teach,
learn, and use Computer-Aided-Design (CAD) and
Computer-Aided Manufacturing (CAM) programs.
CAD/CAM Software features colorful, graphical icons
and dialogue boxes that make commands visual and
intuitive. It has DXF and IGES translators that make it
possible to use geometry from other CAD programs.
CAD/CAM Software has extremely powerful editing
tools for both CAD and CAM. As an integrated software package, CAD/CAM Software does not require
students to switch back and forth between CAD and
CAM applications. Both are available from the same
screen menus.
CAD/CAM SOFTWARE GEOMETRY EXPERT
Geometry Expert allows geometry creations by both
freehand and spreadsheet methods. With a full set of
geometry editing tools, parts can be created in either
2D or 3D. Geometry Expert supports many types of
geometry, including NURBS splines. Text creating is
easy and contains a rich set of tools for spacing, formatting, and placing text around arcs and circles.
Geometry Expert enables the student to perform
facing, pocketing, drilling, contouring, swept, and
tapers.
CAD/CAM SOFTWARE FOR MILL AND LATHE
CAD/CAM Software is an easy-to-use, extremely flexible and powerful program featuring editable tool and
material libraries. Creating, redoing, and reordering
tool paths are made simple with the use of icons, dialogue boxes, and simple drag-and-drop capabilities.
The software includes powerful real-time renderings
of tool paths while displaying mill marks, with the
result that very few bad parts are produced. Postprocessors are available for all the popular educational and industrial CNC machines. Lathe processes
include roughing, finishing, and threading.
FEATURES
z Industrial grade software
z Dynamic viewing of parts from any direction
z Part previewing
z English and metric units
z Multiple software platforms
z Estimated run times
z Object-based graphic interface
CAD/CAM Softwar e
brings CAD and CAM to life on the
computer scr een with vibrant images,
high color, quick r esponse, and easy contr ols.
45
LAB-VOLT AUTOMATION
PRODUCT PROFILES
TEACH PENDANT- AND COMPUTER-CONTROLLED ROBOT SYSTEMS
Models 5100-20 and 5150-10
The Teach Pendant- and Computer Controlled Robot
Systems, Models 5100-20 and 5150-10, are low-cost solutions that provide a platform for training in the programming and operation of industrial-style robots. They are
ideally suited for use in high schools, vocational schools,
colleges, and universities.
The precision-built, articulated arm robot provides a
scale version of modern industrial counterparts. A stepper
motor, located in the base of the unit, provides horizontal
rotation while five additional stepper motors, located in
the shoulder, provide precision movement of the additional axes and end effector. The robot has five axes of rotational freedom plus a gripper and is able to move all axes
simultaneously to perform a programmed move sequence.
Movement of the elbow joint, wrist, and gripper mechanism is accomplished with cables and belts that link with
a series of gears and belt-driven pulleys.
The base of the unit includes one connector for an
external stepper motor, which can be used for further
experimentation, such as operating the Rotary Carousel.
The robot has four external TTL outputs and four TTL
inputs located on the base. Additionally, there are four 12
Vdc solenoid outputs, one located in the shoulder and the
remaining three in the base. The shoulder-mounted output
is provided for controlling end tooling. The I/O capabilities
can be used to allow the robot to interact with external
hardware and conditions.
Four feedback switches provide the ability to locate a
repeatable hard home position. The robot connects to a
lightweight 12 Vdc switching power supply. A USB port
interface on the robot base allows for direct control from a
standard computer printer port.
ROBOT FEATURES
z Six stepper motor drives
z Two-finger gripper
z Power transferred from the stepper motor to the joints
through mini HTP timing belts with anti-backlash
design
z 432-mm (17-in) reach, 0.45-kg (16-oz) load capacity,
3.2-mm (0.125-in) resolution, and 6.4-kg (14.0 lb) unit
weight
z Provided with push-lock fasteners for installation on
perforated work surfaces
z Hard sided carrying case
TOPIC COVERAGE
z Introduction and Familiarization
z Programming
z Program Editing and Control Instructions
z Industrial Activity Simulation 1
z Industrial Activity Simulation 2
z Industrial Activity Simulation using a Belt Conveyor
z Industrial Activity Simulation using a Rotary Carousel
z Industrial Activity Simulation using a Gravity Feeder
46
TEACH PENDANT-CONTROLLED ROBOT SYSTEM
MODEL 5100-20
The Teach Pendant-Controlled Robot System, Model
5100-20, is controlled by a teach pendant, which consists of a 24-key membrane hand-held keypad. It has
a four-line, 20-character LCD display for feedback to
the operator.
COMPUTER-CONTROLLED ROBOT SYSTEM
MODEL 5150-10
The Computer-Controlled Robot System, Model 515010, includes the Robotus® software that allows the
robot to be simulated offline and directly controlled
from the computer. This software provides a real-time
3-D simulation of the robot. Through an intuitive drag
and drop interface, users can control the position and
movements of the robot. A mouse-driven graphical
environment allows the user to create robot tasks
consisting of point-to-point robot movement, inputand-output control, and simple logic decisions.
MANUFACTURING TECHNOLOGY
SERVO ROBOT SYSTEM
Model 5250
The Servo Robot System, Model 5250, provides complete
training in the programming and operation of industrial
robots. Through the curriculum and hands-on experience gained in working with the Model 5250, students
learn to create automated workcells ideal for flexible
manufacturing systems (FMS) and computer integrated
manufacturing (CIM).
A precision-built, articulated-arm robot, Model 5250,
has five axes of rotation and six servo drives with closedloop control via optical encoders. The continuous path robot uses several joints simultaneously to perform a programmed
move sequence controlled by the
controller unit or a PC host computer.
Movement of the shoulder, upper
arm, forearm, and wrist is accomplished
with belts through a series of gears and beltdriven pulleys.
The controller unit is an embedded microprocessor with connections for inputs and outputs
as well as a floppy disk drive for saving task/point
programs. The hand-held teach pendant has a four-line,
20-character LCD display and a 40-key membrane keypad for manual control. A serial communication port is
used to connect the 5250 controller to a host computer
for remote operation and task editing with the host software.
TOPIC COVERAGE
z Introduction
z Familiarization with the Servo Robot System
z Point-to-Point Programs
z Task Programs
z Program Editing
z Control Overview
z Industrial Application Simulation Using a Gravity
Feeder
z Industrial Application Simulation Using a Belt
Conveyor
z Industrial Application Simulation Using a Pneumatic
Feeder
z Industrial Application Simulation Using a Rotary
Carousel
z Industrial Application Simulation Using a Linear
Slide
FEATURES
Servo Robot
z High torque servo motors
z Steel and aluminum construction
z Timing belts for power transfer (enclosed for safety)
z Easily adjustable belt tension pulleys to maintain
positional accuracy
z Oilite and UHMW (Ultra-High Molecular Weight)
bushings for durability, minimum maintenance, and
lubrication
z Boundary and current limit protection on all axes
z Push-lock fasteners for installation on perforated
work surfaces
Robot Controller
z On-board microprocessor
z 8 TTL input ports, color coded, and LED status indicators
z 8 TTL output ports, color coded, and LED status
indicators
z 4 relays, each provided with a set of normally open
and normally closed contacts and LED status indicators
z Servo Robot and external motor release switch, and
LED status indicator
z Floppy disk drive for program storage
z Hand-Held Terminal communication port
Safety Features
Key-Activated Emergency Stop Button module
RoboCIM Software
z Easy-to-use menu-driven software
z Direct keyboard control over all robot axes and
functions
z Control output ports and read instruction channels
z Task commands include do, if-else, gosub, input,
output, while-repeat conditions, and many others
z Point-to-point and task programming
47
LAB-VOLT AUTOMATION
ROBOT EQUIPMENT OPTIONS
Various Models
ROTARY CAROUSELS
Models 5208-10 and 5113-10
The Rotary Carousels demonstrate how parts can
be transferred to and from the robot in a repetitive,
rotational pattern. The Rotary Carousel, Model 520810, is driven by a DC servo motor and has a closedloop feedback system and a limit switch feedback
for hard home capabilities. The Rotary Carousel,
Model 5113-10, is driven by a stepper motor. Model
5113 interfaces with the 5100 and 5150 robots, and
Model 5208 interfaces with the 5250 robot.
ROTARY CAROUSEL
Model 5208-10
ROTARY CAROUSEL
Model 5113-10
BELT CONVEYOR
Model 5210
BELT CONVEYOR
Model 5118
GRAVITY FEEDER
Model 5119
GRAVITY FEEDER
Model 5121
LINEAR SLIDE
Model 5209
PNEUMATIC FEEDER CONTROLLER
BELT CONVEYORS
Models 5210 and 5118
Used in material handling experiments, the
Lab-Volt Belt Conveyors can interface with the
5100-20, 5150-10 and 5250 robots, or they can be
used as stand-alone units. The inputs enable the
motor power, stepper motor clock signal, and the
direction of the belt movement to be remotely controlled.
GRAVITY FEEDERS
Models 5119 and 5121
The Gravity Feeders are used in exercises that
require square or cylindrical stock. They have sensor
switches and feedback cables for connections to
other devices. They interface with the 5100-20,
5150-10, and 5250 robots.
LINEAR SLIDE
Model 5209
The Linear Slide provides a track on which the 5250
robot can move to perform programmed tasks. The
slide is driven by a DC servo motor, direct-coupled
to a precision ballscrew. It has a closed-loop feedback system and a limit switch feedback for hard
home capabilities. The slide is constructed of steel
and has a precision ballscrew with a recirculating
ball nut, guideways, and linear sealed bearings. It
connects to either of the external motor ports on the
rear of the 5250 Controller.
PNEUMATIC FEEDER CONTROLLER
Model 5149
The Pneumatic Feeder Controller is used to control
the Pneumatic Feeders, Models 5122-1 and 5142-1.
It includes a pneumatic valve, which supplies compressed air to the feeders. The operation of the
Pneumatic Feeder Controller is controlled by limit
switches in the feeder and storage sections of the
Pneumatic Feeders.
PNEUMATIC FEEDERS
Models 5122-1 and 5142-1
The Pneumatic Feeders have micro-switch triggers
to signal the Pneumatic Feeder Controller, which
will activate the feeder to push a block into the
receiving port once the previous block has been
removed. Model 5122-1 feeds square stock and
Model 5142-1 cylindrical stock to the 5100-20, 515010, and 5250 robots.
48
PNEUMATIC FEEDER
Model 5122-1
Model 5122-1
PNEUMATIC FEEDER
Model 5142-1
MANUFACTURING TECHNOLOGY
BENCHES
Various Models
Lab-Volt offers many types of benches to set up and
store equipment. They can be joined when extra space
is required, and configured to accommodate a wide
variety of space and teaching needs. They come in
many sizes and are provided with heavy-duty, lockable casters.
The top of the benches consists in perforated work surfaces on which the
components are mounted. Optional shelves, storage surfaces, dressing
panels, and lockable doors
can be added to the benches.
Mounting and removal of
the components are especially easy with push-lock fasteners
that snap effortlessly into the perforations of
the work surfaces. Many Lab-Volt models are provided with location pins that fit into the perforations to
locate the components with precision. This location
system is very useful when a setup has to be repeated.
49
LAB-VOLT AUTOMATION
CNC LATHE
Model 5300
The CNC Lathe, Model 5300, is a midsized turning system that provides complete, safe, and affordable training in
computer-aided manufacturing (CAM),
and computer-numerical controlled
(CNC) turning. The Lab-Volt curriculum
gives students experience with industry-standard software and high-precision equipment designed to prepare
them for jobs in manufacturing.
The 5300 CNC Lathe is a slant-bed
lathe constructed with a machined highgrade alloy bed, headstock, and tailstock.
Each axis on the Lab-Volt lathe is driven
by its own DC stepper motor whose
speed can be programmed from 0 to 36
cm/min (0 to 14 in/min). The spindle
motor is programmable from 0-to 2800r/min chuck speed.
The included Lab-Volt CNC Lathe software uses today’s industry-standard G&M
codes. The software features Tool Path Emulation
and CAD/CAM design, which allow the programmer
to make a drawing of a part, set up the tool paths and cut
steps, create the part program, and simulate tool motion
on a monitor to check the finished part prior to the actual cutting.
TOPIC COVERAGE
z History of CNC
z Identify Components of a CNC Lathe
z Safety
z Tool Movement
z Speed, Feed, and Cut Steps
z Lathe Program Codes
z The PRZ
z Lathe Setup
z On-Screen Emulation
z Turning a Part
z Input a Part Program
z Editing Commands
z CNC Programming
z Understanding and Using CAD/CAM
z Create a Part Using CAD/CAM Programming
z Careers in Turning
50
FEATURES
z Key-released emergency stop push-button
z Ability to restart programs from stopping point after
safety interruption
z On-board embedded microprocessor
z Stand-alone manual mode operation
z Batch mode for independent operation or operation
in CIM cells
z Software allowing the programming of up to 20 tools
z Tool post with HSS tool bit
z Three-jaw self-centering manufacturer-supplied
recommended chuck
z Side panel with connectors for TTL communication
with the 5250 robot, M-code supported solenoid
drivers, connects to host computer through RS-232
or Ethernet port
z Lathe constructed with a machined high-grade alloy
bed, headstock, and tailstock
z Each axis driven by its own DC stepper motor
z Programmable speeds from 0 to 36 cm/min (0 to 14
(in/min)
z 1/3-HP, DC variable speed spindle motor
z Spindle motor programmable from 0- to 2800-r/min
chuck speed
MANUFACTURING TECHNOLOGY
CNC LATHE
Model 5500
The CNC Lathe, Model 5500, is a heavy-duty,
industrial-grade training system for computeraided manufacturing (CAM), and computernumerical controlled (CNC) turning. The
5500 CNC Lathe is constructed with
heavy-duty cast-iron bed, headstock,
and tailstock. The lathe features stepper motor drives with ribbed timing
belts that operate recirculating
anti-backlash ball screws on the
X and Z axes, providing maximum positional accuracy. For ease of
maintenance, telescoping helical covers
protect the Z axis ballscrew. Each axis on the
5500 CNC Lathe is driven by its own stepper motor,
whose speed can be programmed from 0 to 76 cm/min (0
to 30 in/min). The spindle speed is also continuously variable from 0 to 3400 r/min and no belt or gear changes are
required.
The included Lab-Volt CNC Lathe software uses
today’s industry-standard G&M codes. The software features Tool Path Emulation and CAD/CAM design, which
allow the programmer to make a drawing of a part, set up
the tool paths and cut steps, create the part program, and
simulate tool motion on a monitor to check the finished
part prior to the actual cutting.
TOPIC COVERAGE
z History of CNC
z Identify Components of a CNC Lathe
z Safety
z Tool Movement
z Speed, Feed, and Cut Steps
z Lathe Program Codes
z The PRZ
z Lathe Setup
z On-Screen Emulation
z Turning a Part
z Input a Part Program
z Editing Commands
z CNC Programming
z Understanding and Using CAD/CAM
z Create a Part Using CAD/CAM Programming
z Careers in Turning
FEATURES
z Key-released emergency stop push-button
z Ability to restart programs from stopping point after
safety interruption
z On-board embedded microprocessor
z Using optical encoder feedback, the lathe is also
capable of reading
z An optional 10-tool automatic tool changer is available
z Stand-alone manual mode operation
z Batch mode for independent operation or operation
in CIM cells
z Software allowing the programming of up to 10
tools
z Tool post with HSS tool bit
z 1-HP constant torque DC spindle motor controlled
from within the program
z Three-jaw self-centering manufacturer-supplied
recommended chuck
z Rear panel with connectors for TTL communication
with the 5250 robot, M-code supported solenoid
drivers, connects to host computer through RS-232
or Ethernet port
z Main power indicator
z Heavy-duty DC spindle motor
z Cast iron chassis
z Recirculating anti-backlash industrial-grade ball
nuts and screws on X and Z axes
z Magnetic safety interlock
OPTIONAL EQUIPMENT
z 10-Tool Automatic Tool Changer
51
LAB-VOLT AUTOMATION
CNC MILL
Model 5400
The CNC Mill, Model 5400, is a state-of-the-art milling
system that provides complete training in
computer-aided manufacturing (CAM), and
computer numerical controlled (CNC) milling.
The 5400 CNC Mill is built to support safe,
low-voltage communications with robots and
devices to create automated workcells ideal
for flexible manufacturing systems (FMS). On
the side panel of the mill are connectors for
interacting to an automation workcell. A connector is provided for standard TTL I/O communications with robotics equipment. The TTL
I/O and solenoid driver connectors are “M”
code supported through the standard software
supplied. Also on the side panel are the main
power switch, and the serial and Ethernet
ports for downloading programs.
Each of the mill’s three axes is driven by its
own DC stepper motor which can be programmed from 0 to 36 cm/min (0 to 14 in/min)
movement rates which meet the requirements of
basic and advanced milling. The spindle speed is continuously variable and programmable to a range of 0 to
2800 r/min.
The included Lab-Volt CNC Mill software uses
today’s industry standard G&M codes. The software features Tool Path Emulation so students can check the finished part prior to the actual cutting. The software is also
capable of directly importing an AutoCAD.DXF file and
the computer will automatically generate the codes to cut
the drawing on the mill.
TOPIC COVERAGE
z History of CNC
z Identify Components of a CNC Mill
z Safety
z Speed, Feed, and Cut Steps
z Enter a Program into a Computer
z Identify and Operate Controls on a Mill
z Identify X, Y, and Z Axis Movements on a Mill
z Set-Up Controller and Mill to Machine a Part
z Machine a Part
z Write and Execute a Program to Mill a Shoulder and
Drill a Hole
z Write and Execute a Program to Mill a Pocket
z Calculate and Program Cutter Clearances
z Combine Subroutine and Repeat Loop Operations to
Machine a Complex Part
z Careers in CNC Machining
52
FEATURES
z Key-released emergency stop push-button
z Ability to restart programs from stopping point after
safety interruption
z On-board embedded microprocessor
z Stand-alone manual mode operation
z Batch mode for independent operation or operation
in CIM Cells
z Software allowing the programming of up to 20
tools
z Mill constructed with machined high-grade alloy
bed and head stock
z 12-key membrane keypad with 20-character by 4line LCD display
z Main power indicator
z Feed rate override
z Spindle speed override
z Stall indicator
z Removable side panel for access to robot
z Connects to host computer through RS-232 or
Ethernet port
MANUFACTURING TECHNOLOGY
CNC MILL
Model 5600
The CNC Mill, Model 5600, is a heavy-duty, state-of-theart machining system consisting of a cast iron chassis
with recirculating anti-backlash ball nuts and screws for
lower maintenance and maximum position accuracy.
The 5600 CNC Mill also features R8 tooling, which
provides complete compatibility with industrial machine tools. With the 5600 CNC Mill,
students can mill parts made of soft
materials such as aluminum, mild
steel, and brass. Training in the 5600
CNC Mill enables students to gain
skills that are directly transferable to
jobs in manufacturing.
Each of the mill’s axes is driven by
its own DC stepper motor which is
programmable from 1 to 50 cm/min (1
to 20 in/min). The spindle speed is continuously variable and programmable
to a range of 0 to 3400 r/min.
The included Lab-Volt CNC Mill software uses today’s industry standard G&M
codes. The software features Tool Path
Emulation so students can check the finished
part prior to the actual cutting. The software is also
capable of directly importing an AutoCAD.DXF file
and the computer will automatically generate the codes
to cut the drawing on the mill.
TOPIC COVERAGE
z History of CNC
z Identify Components of a CNC Mill
z Safety
z Speed, Feed, and Cut Steps
z Enter a Program into a Computer
z Identify and Operate Controls on a Mill
z Identify X, Y, and Z Axis Movements on a Mill
z Set-Up Controller and Mill to Machine a Part
z Machine a Part
z Write and Execute a Program to Mill a Shoulder and
Drill a Hole
z Write and Execute a Program to Mill a Pocket
z Calculate and Program Cutter Clearances
z Combine Subroutine and Repeat Loop Operations to
Machine a Complex Part
z Program Controller to Cut a Groove, Machine a
Pocket, and Drill a Hole
z Print a copy of a Part Program
z Load and Execute a Part Program
z Careers in CNC Machining
FEATURES
z Key-released emergency stop push-button
z Ability to restart programs from stopping point after
safety interruption
z On-board embedded microprocessor
z Stand-alone manual mode operation
z Batch mode for independent operation or operation
in CIM Cells
z Software allowing the programming of up to 20
tools
z Mill constructed with machined high-grade alloy
bed and head stock
z 12-key membrane keypad with 20-character by 4line LCD display
z Main power indicator
z Feed rate override
z Spindle speed override
z Stall indicator
z 1-HP motor
z Rear Panel Convertion for 5250 TTL Control
z Pneumatic Vise Output
z Connects to host computer through RS-232 or
Ethernet port
53
LAB-VOLT AUTOMATION
MANUFACTURING CONVEYOR SYSTEM
Model 3509
The Manufacturing Conveyor System, Model 3509, provides a mechanical manufacturing process comprised of
two belt conveyors and two workstations. The outer belt
has a rounded rectangular shape. The cross conveyor is
reversible and is used for transporting pallets to and from
the outer conveyor. It is on the cross conveyor that a
drilling operation is simulated, complete with a pneumatic drill which extends toward the pallet while spinning.
The second workstation is a stamping procedure, simulating a Quality Control approval stamp.
Simulating the operation of an assembly line, the
outer conveyor moves pallets carrying work pieces along
the conveyor at a fixed rate of speed. A programmable
Logic Controller (PLC) program directs the action of various mechanisms incorporated in the trainer. Based on the
inputs from the sensors, the PLC program instructs the
mechanisms to stop the pallet at a preset location, rotate
the pallet to a correct position and location, and perform
simulated drilling and stamping processes. Depending on
the application under study, the sensors, gates, stops,
transfer, and process stations can be mounted at different
locations along both conveyors by means of quick fasteners.
The operator station includes a flat panel with mimic
diagram and override switches giving manual and automatic control to the devices. The control station contains
a PLC with associated I/O modules.
All necessary connections from the PLC are hardwired to the Operator Station and the Remote Connector
54
Terminal. Sensor connections are made using quickconnect connectors on the Interconnection Panel. The
Stop and Gate devices are connected to the
Interconnection Panel output jacks using the supplied
leads terminated by miniature banana plugs.
TOPIC COVERAGE
The included User Manual instructs students on setup
and operation of the Conveyor System. The system
does not come with standard courseware. Additional
PLC software is optional.
FEATURES
z Fixed speed, oval/rectangular-shaped outer conveyor belt is made of interlocking plastic links for durability and ease of motion
z Fixed speed, reversible, cross conveyor with heavyduty rubber belt
z Light-weight aluminum framing provides mobility
within a classroom setting
z Each device can be mounted anywhere around the
conveyor with quick fasteners
z All required electrical leads and pneumatic tubings
are supplied
z Pneumatic components come with quick-connect
fittings
z A pressure regulator allows adjustment of the
process pressure at the desired value
MANUFACTURING TECHNOLOGY
FLEXIBLE MANUFACTURING SYSTEM
Model 5900
The Model 5250 Robot and Model 5400 Mill may be
connected to the Manufacturing Conveyor System,
Model 3509, to expand the capabilities and advance
the sophistication of the Programmable Logic
Controller (PLC) programming required.
By programming the PLC to adjust for the presence of the robot and mill, students can signal the
robot to pick up a piece of acrylic carried on the workpiece, place it in the pneumatic vise on the mill, and
trigger the milling operation to start. The ComputerNumerical Controlled (CNC) milling program, which
has been downloaded into the mill’s memory, will then
be carried out. During the milling procedure, the robot
will take a fresh piece of acrylic from the pneumatic
feeder and place it on the milling pallet on the outer
conveyor. The robot will then signal the conveyor that
a fresh piece of acrylic has been placed on the pallet
and can be released from Gate 1. After the milling procedure is complete, the robot will remove the milled
piece from the mill and place the cut part in a finished
goods location.
It is this type of flexibility which allows the 3509
Training System to be used to train students in
advanced PLC programming and ladder logic. A multitude of configurations or processes can be completed
using 3509, 5250 robot, 5400 CNC Mill, 5300 CNC
Lathe, or by incorporating other Lab-Volt training systems.
55
LAB-VOLT AUTOMATION
FLEXIBLE MANUFACTURING SYSTEM
Model 5901
Simulating the operation of a production line, the LabVolt Flexible Manufacturing System, Model 5901, allows
students to familiarize themselves with the start-up,
configuration, programming, optimization, and troubleshooting of manufacturing processes. The modularity of the system enables students to find a variety of creative solutions to solve a situation. Equipped with the
most recent industrial components, the training system
prepares students to be efficient with various technologies. All system operations are controlled via one or
many programmable logic controllers able to be networked together.
The modularity of this system permits the selection
of models required to meet the training objectives.
Competency based programs may require more wiring
skills, electrical schematic comprehension, and troubleshooting while advanced teaching programs will find
with this trainer the perfect tool to explore complex control scheme.
Models from the Robotics and Pneumatics product
line can also be added to the system to create more
sophisticated applications.
z Operator Panel - Develop different operator interfaces
FEATURES
z Artificial Vision - Create quality control routines to
verify, with advanced mathematical tools, the validity of the products by measuring the shape, color
shade and intensity, and more.
z
56
z
z
z
z
z
z
to monitor and control the whole process via a touch
screen panel or a PC-type computer.
Sensors - Explore the application of different types of
proximity switches and photoelectric sensors, develop applications using a color detection sensor, and
build a product identification system with a bar code
scanner.
Power Electronics - Configure and control a 3-phase
AC drive through a DeviceNet Network, tune closed
loop control of the position of a mobile part feeder
with a digital servo drive.
Wiring - Easy and fast setup using the front panel
banana jacks and the provided leads, or realistic
wiring using terminal blocks.
Networks - Explore different communication networks found in the industry such as Ethernet/IP,
DeviceNet, and Serial communication.
Pneumatics - Implement a pneumatic application in
a production line.
Troubleshooting - Enhance troubleshooting skills by
electrical fault insertion on the PLC, AC drive, artificial vision system, and part feeder.
PLC application - Learn how to program a PLC with
four different languages (relay ladder, structured text,
functional block, and sequential function chart), create new applications or improve existing ones, and
use the latest PLC technology.
MANUFACTURING TECHNOLOGY
PROGRAMMABLE LOGIC CONTROLLER
Model 3240
The Programmable Logic Controller (PLC), Model 3240,
enables students to develop competence in operating,
programming, and troubleshooting modern PLC-controlled circuits. The PLC trainer, Model 3240, is based on
the latest Allen-Bradley Micrologix™ 1200 controller, and is
supported by Lab-Volt instructional material.
Programming is achieved using the Windows®-based
RSLogix™ 500 software from Rockwell Software. The PLC
trainer can be used to achieve PLC control of typical
industrial applications implemented with a Mechanical
Process Simulator, and of virtual industrial processes simulated by the PLC Simulation Software (P-SIM 2000).
The PLC trainer can also be used with the Lab-Volt
Industrial Controls Training System, Model 3100, as well
as the Lab-Volt Electromechanical Systems, Models 8001
and 8006. The training program consists of two courses
covering basic programming to advanced applications.
The PLC trainer includes 12 fault-insertion switches for
troubleshooting training.
TOPIC COVERAGE
Basic Principles
z Familiarization with the PLC Trainer and RSLogix 500
z Programming Basics
z Online Operations
z Latching Instructions
z Timer Instructions
z Counter Instructions
z Sequencer Instructions
z Comparison Instructions
z Shift Register Instructions/The Force Function
Applications
z Introduction to the Mechanical Process Simulator
z Controlling a Line Welding System with a PLC
z Controlling an Automatic Component Insertion
Machine with a PLC
z Designing a PLC-Controlled Automated System
z Introduction to the P-SIM Simulation Software
z Controlling a Traffic Light System with a PLC
z Controlling a Filling Line with a PLC
z Controlling a Batch Mixing Process
FEATURES
z Allen-Bradley Micrologix™ 1200 PLC
z 12 Fault switches for troubleshooting
z 14 dual-voltage PLC inputs
z Seven PLC input switches (toggle-and push buttontype)
z Ten dual-voltage PLC outputs
z Expansion spacing for the addition of an optional
analog input/output module
z RS-232 DF1 full-duplex communication link
between the PLC and RSLogix
z Circuit-breaker protected
57
LAB-VOLT AUTOMATION
PLC TRAINING SYSTEM EQUIPMENT
Various Models
P-SIM TO PLC INTERFACE
Model 3243
The Allen-Bradley Micrologix™ 1200 PLC on
the PLC Trainer, Model 3240, can be used to
control the PLC Simulation software (P-SIM
2000), Model 91773, in order to simulate the
operation of typical industrial processes. To
do this, an interface is needed: the P-SIM to
PLC Interface, Model 3243.
EXPANSION MODULE
Model 3244
The Expansion Module provides greater PLC
input/output capability for advanced training
by permitting the user to add two analog
inputs and two analog outputs to the
Micrologix 1200 PLC of the trainer.
Model 3243
RSLogix 500 PROGRAMMING SOFTWARE
Model 3245
The RSLogix 500 Programming Software
Model 3245 from Rockwell Software provides
the capability to program the PLC with a personal computer. A direct communication link
(DF1 full duplex) is used to connect the PLC
to the computer, sparing the need for any
interface between them.
COMMUNICATION CABLE
Model 3246-40
The Communication Cable is used to connect
the computer to the PLC when using programming software.
Model 3244
Model 3245
MECHANICAL PROCESS SIMULATOR
Model 3290
The Mechanical Process Simulator, Model 3290,
is designed to simulate industrial mechanical
processes. It is used with the PLC Trainer to
study sequential, on/off control of typical production lines involving linear position control.
The process includes seven limit switches providing input signals to the PLC, and four output
load solenoids activated through programming
of the PLC outputs.
NETWORK INTERFACE DEVICES
The following network interface devices can be
added to the PLC for communications:
Advanced Interface Converter (AIC+) provides
an interface to DH-485 networks from an RS-232
port, DeviceNet Interface (DNI), and Ethernet
Interface (ENI).
58
Model 3246-40
Model 3290
MANUFACTURING TECHNOLOGY
PLC SIMULATION SOFTWARES (P-SIM 1000 AND P-SIM 2000)
MODELS 91826 and 91773
P-SIM demonstrates the programming and operation of
an actual programmable logic controller (PLC). The
functionality of P-SIM is representative of current trends
employed by PLC manufacturers.
Upon completion of the P-SIM 2000 course, students
will understand and will be able to program basic relay
inputs, output instructions, counters, timer circuits,
compare functions, and debugging procedures.
In order to proceed with P-SIM 2000, students must
demonstrate an understanding of basic relay logic control.
PLC SIMULATION SOFTWARE (P-SIM 1000)
Model 91826
P-SIM 1000 is a stand-alone, self-paced, interactive,
computer-based introductory tutorial for PLC technology. It serves as a prerequisite to the more advanced PLC
Simulation Software P-SIM 2000, Model 91773 and is
intended for students who have had no exposure to PLC
technology.
P-SIM 1000 incorporates colorful, animated graphics
to display PLC concepts, which are presented as industrial process simulations complete with interactive control functions.
PLC SIMULATION SOFTWARE (P-SIM 2000)
Model 91773
The P-SIM 2000 software enables an IBM-compatible
computer to act as a process simulator when demonstrating PLC operations. A built-in ladder logic program
editor allows students to create, test and debug industry-standard ladder logic programs to control animated
processes. The simulated PLC includes the five basic
input and output instructions, counters, timers, and
compare function blocks. It also incorporates logical
AND/OR operations in PLC programs by means of
branching.
Typical processes, such as batch mixing and material transfer, are graphically displayed as animations,
which respond to changes to the ladder logic program
in the same manner that actual process equipment
would respond.
With the optional P-SIM to PLC Interface, Model
3243, or Programmable Logic Controller, Model 3270,
students can write programs to control the on-screen PSIM simulations.
P-SIM I/O INTERFACE
PLC programming may be taught and practiced using
the built-in ladder logic program editor or, with the PSIM I/O interface, any PLC can be easily connected by
using industry-standard 24 Vdc I/O. The PLC is then
programmed to control the simulations within the PSIM program.
TOPIC COVERAGE
Model 91826
z Introduction to the PLC
z Introduction to Ladder Logic
z “AND’D” Normally Open Contacts
z “OR’D” Normally Open Contacts
z Normally Open/Normally Closed Contacts
z Interlocked Logic
z Lock-in Using Momentary Contacts
z On-Delay Time
z Traffic Light Logic
z Counter Application
Model 91773
z Familiarization with P-SIM 2000
z Rung Editor
z Basic Input/Output PLC Instructions
z Branching
z Timer and Counter PLC Instructions
z Comparison PLC Instructions
z Silo Simulation
z Batch Mixer Simulation
z Traffic Lights Simulation
z I/O Simulation
59
EXPLORING MANUFACTURING TECHNOLOGY
EXPLORING MANUFACTURING TECHNOLOGY
Compact Training Modules for a Hands-On
Intr oduction to Manufacturing Technology
Lab-Volt Systems developed the Exploring Technology
series of training modules to serve as a hands-on introduction to the principles and basic applications of sensors,
mechanisms, and electricity.
Each module in the Exploring Manufacturing
Technology series can accommodate two students.
Modules can be studied individually and then inter-connected with the use of electrical leads, allowing for further
study and problem solving by students who complete the
study of a module.
Included with each module is a fully illustrated manual containing ten exercises, written in an easy-to-read,
step-by-step format, divided into the following five units:
Objective
Discussion
Procedure
Conclusion
Questions
CHASSIS DIMENSION
Depth
Width
Height
24 cm
49 cm
33.5 cm
9-1/2 in
19-1/4 inc 13-1/4 in
POWER REQUIREMENTS
120, 220, 240 V - 50/60 Hz
ESTIMATED
ESTIMATED PROGRAM HOURS
Open
- A statement outlining the purpose of the
exercise
- A topic description with background information
- A step-by-step guide for performing experiments
- A brief review of the topic and related practical examples
- A multiple-choice test to determine the students’ comprehension
PRODUCT PROFILES: Exploring Manufacturing Technology
EXPLORING SENSORS
Model 3341
The Exploring Sensors module, Model 3341, allows students to explore the different uses of mechanical and electronic sensors from a security applications viewpoint.
Students are introduced to the variety and characteristics of sensors. They build a variety of circuits using
magnetic sensors, vibration/shock sensor, pulsed infrared
sensors, and motion sensors. Students also build alarm circuits using sensors, an electromechanical relay, and a
buzzer.
Sensors in this module include an infrared photoelectric beam sensor, an infrared motion detector, a mechanical switch, a vibration detector, and magnetic proximity
sensors.
TOPIC COVERAGE
z Getting to Know the Trainer: How to Connect Sensor
Circuits
z Control Panels
z Introduction to Mechanical Sensors - The Plunger
Switch
z Magnetic Proximity Sensors
z Shock/Vibration Sensors
z Electronic Active Sensors
z Electronic Passive Sensors
z Wiring Installation Techniques
z Automobile Alarm System
z Designing an Alarm System
60
FEATURES
FEATURES
z Regulated 12 V-DC source
z Proximity sensor, infrared-sensor, shock/vibration
sensor, and motion sensor
z Plunger switch
z Electromechanical relay
z Buzzer alarm and indicator lamps
LANGUAGE VARIA
TIONS
VARIATIONS
English, Spanish
MANUFACTURING TECHNOLOGY
EXPLORING MECHANISMS
EXPLORING ELECTRICITY
Model 3342
Model 3343
The Exploring Mechanisms module, Model 3342, introduces students to the world of mechanical power transmission. Using a fully operational elevator, the module
covers the topics of work, power, force, energy, and
torque. The module comes fully equipped with a collection of gears, belt drives, and a chain drive. Other topics
include direction of rotation and tension. Practical
examples and association with real world examples set
this module apart from others.
The Exploring Electricity module, Model 3343, plays a
vital role in every area of technology. This module
teaches students the basic characteristics of simple
electrical circuits.
The module is provided with a built-in regulated
12-Volt DC source. Other components include a digital
multimeter, an electromechanical relay, and an assortment of lamps, switches, and resistors.
Students build a variety of circuits using electrical
leads. These circuits are series circuits, parallel circuits,
and logic circuits. Students also learn how to calculate
electric values and measure then with the digital multimeter.
TOPIC COVERAGE
z Introduction to the Trainer
z Work and Power
z Friction
z Mechanical Advantage
z Inclined Plane
z Gears and Gear Trains
z Friction-Belt Drives
z Synchronous-Belt Drives
z Chain Drive
z Pulley System
FEATURES
FEATURES
z DC driving motor with control switch
z Assortment of gears, O-rings, chains, and belts
z Lift (elevator) with control switch, and upper/lower
sensors
z Hex keys and spring scale
LANGUAGE VARIA
TIONS
VARIATIONS
English
TOPIC COVERAGE
z Electric Circuits
z Measuring Voltage, Current, and Resistance
z Series Circuits
z Parallel Circuits
z Logic Circuits
z Three-Way Switching Circuits
z Ohm’s Law
z Ohm’s Law for Series Circuits
z Ohm’s Law for Parallel Circuits
z Electromechanical Relays
FEATURES
FEATURES
z Regulated 12 V-DC source
z Digital Multimeter
z Assortment of resistors, switches, relays, and
indicator
z Fan used as a circuit load
LANGUAGE VARIA
TIONS
VARIATIONS
English, Spanish
61
COURSEWARE ORDERING INFORMATION
MANUFACTURING/MECHATRONICS
COURSEWARE ORDERING INFORMATION
120 V - 60 HZ
220 V - 50 HZ
240 V - 50 HZ
MODEL DESCRIPTION
ENGLISH
46101-10
SPANISH
ENGLISH
46603-00
36737-20
36737-30
36737-60
36737-70
46612-00
36891-20
36891-30
36891-60
36891-70
46613-00
36892-20
36892-30
36892-60
36892-70
46614-00
36893-20
36893-30
36893-60
36893-70
46603-01
N/A
N/A
N/A
N/A
46612-01
N/A
N/A
N/A
N/A
46613-01
N/A
N/A
N/A
N/A
46614-01
N/A
N/A
N/A
N/A
46603-02
N/A
N/A
N/A
N/A
46612-02
N/A
N/A
N/A
N/A
46613-02
N/A
N/A
N/A
N/A
46614-02
N/A
N/A
N/A
N/A
46603-00
36737-20
36737-30
36737-60
36737-70
46612-00
36891-20
36891-30
36891-60
36891-70
46613-00
36892-20
36892-30
36892-60
36892-70
46614-00
36893-20
36893-30
36893-60
36893-70
46603-01
N/A
N/A
N/A
N/A
46612-01
N/A
N/A
N/A
N/A
46613-01
N/A
N/A
N/A
N/A
46614-01
N/A
N/A
N/A
N/A
46603-02
N/A
N/A
N/A
N/A
46612-02
N/A
N/A
N/A
N/A
46613-02
N/A
N/A
N/A
N/A
46614-02
N/A
N/A
N/A
N/A
46603-00
36737-20
36737-30
36737-60
36737-70
46612-00
36891-20
36891-30
36891-60
36891-70
46613-00
36892-20
36892-30
36892-60
36892-70
46614-00
36893-20
36893-30
36893-60
36893-70
46612-10
36963-20
36963-30
36963-60
36963-70
46613-10
36964-20
36964-30
36964-60
36964-70
46615-00
36965-20
36965-30
36965-60
36965-70
46616-00
36966-20
36966-30
36966-60
36966-70
46612-11
N/A
N/A
N/A
N/A
46613-11
N/A
N/A
N/A
N/A
46615-01
N/A
N/A
N/A
N/A
46616-01
N/A
N/A
N/A
N/A
46612-12
N/A
N/A
N/A
N/A
46613-12
N/A
N/A
N/A
N/A
46615-02
N/A
N/A
N/A
N/A
46616-02
N/A
N/A
N/A
N/A
46612-10
36963-20
36963-30
36963-60
36963-70
46613-10
36964-20
36964-30
36964-60
36964-70
46615-00
36965-20
36965-30
36965-60
36965-70
46616-00
36966-20
36966-30
36966-60
36966-70
46612-11
N/A
N/A
N/A
N/A
46613-11
N/A
N/A
N/A
N/A
46615-01
N/A
N/A
N/A
N/A
46616-01
N/A
N/A
N/A
N/A
46612-12
N/A
N/A
N/A
N/A
46613-12
N/A
N/A
N/A
N/A
46615-02
N/A
N/A
N/A
N/A
46616-02
N/A
N/A
N/A
N/A
46612-10
36963-20
36963-30
36963-60
36963-70
46613-10
36964-20
36964-30
36964-60
36964-70
46615-00
36965-20
36965-30
36965-60
36965-70
46616-00
36966-20
36966-30
36966-60
36966-70
46614-10
37855-20
37855-30
37855-60
37855-70
46617-00
37856-20
37856-30
37856-60
37856-70
46618-00
37857-20
37857-30
37857-60
37857-70
46614-11
N/A
N/A
N/A
N/A
46617-01
N/A
N/A
N/A
N/A
46618-01
N/A
N/A
N/A
N/A
46614-12
N/A
N/A
N/A
N/A
46617-02
N/A
N/A
N/A
N/A
46618-02
N/A
N/A
N/A
N/A
46614-10
37855-20
37855-30
37855-60
37855-70
46617-00
37856-20
37856-30
37856-60
37856-70
46618-00
37857-20
37857-30
37857-60
37857-70
46614-11
N/A
N/A
N/A
N/A
46617-01
N/A
N/A
N/A
N/A
46618-01
N/A
N/A
N/A
N/A
46614-12
N/A
N/A
N/A
N/A
46617-02
N/A
N/A
N/A
N/A
46618-02
N/A
N/A
N/A
N/A
46614-10
37855-20
37855-30
37855-60
37855-70
46617-00
37856-20
37856-30
37856-60
37856-70
46618-00
37857-20
37857-30
37857-60
37857-70
46619-02
N/A
N/A
N/A
N/A
46620-02
N/A
N/A
N/A
N/A
46619-00
37858-20
37858-30
37858-60
37858-70
46620-00
37859-20
37859-30
37859-60
37859-70
46619-01
N/A
N/A
N/A
N/A
46620-01
N/A
N/A
N/A
N/A
46619-02
N/A
N/A
N/A
N/A
46620-02
N/A
N/A
N/A
N/A
46619-00
37858-20
37858-30
37858-60
37858-70
46620-00
37859-20
37859-30
37859-60
37859-70
Mechanical Training System, Level 4
Clutches and Brakes
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
Ball Screws and Linear Bearings
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
62
FRENCH
Mechanical Training System, Level 3
Gear Drives 2
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
Bearings
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
Gaskets and Seals
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
46101-40
ENGLISH
Mechanical Training System, Level 2
Belt Drives 2
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
Chain Drives 1
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
Alignment and Couplings
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
Lubrication
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
46101-30
SPANISH
Mechanical Training System, Level 1
Introduction to Mechanical Drive Systems
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
Belt Drives 1
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
Chain Drives 1
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
Gear Drives 1
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
46101-20
FRENCH
46619-00
37858-20
37858-30
37858-60
37858-70
46620-00
37859-20
37859-30
37859-60
37859-70
46619-01
N/A
N/A
N/A
N/A
46620-01
N/A
N/A
N/A
N/A
MANUFACTURING TECHNOLOGY
MANUFACTURING/MECHATRONICS
COURSEWARE ORDERING INFORMATION
120 V - 60 HZ
MODEL DESCRIPTION
46101-50
ENGLISH
FRENCH
SPANISH
ENGLISH
46621-00
38606-60
38606-70
46622-00
38607-60
38607-70
46623-00
46621-01
N/A
N/A
46622-01
N/A
N/A
46623-01
46621-02
N/A
N/A
46622-02
N/A
N/A
46623-02
46621-00
38606-60
38606-70
46622-00
38607-60
38607-70
46623-00
46621-01
N/A
N/A
46622-01
N/A
N/A
46623-01
46621-02
N/A
N/A
46622-02
N/A
N/A
46623-02
46621-00
38606-60
38606-70
46622-00
38607-60
38607-70
46623-00
36971-60
N/A
N/A
36971-60
N/A
N/A
36971-60
37866-20
37866-30
37866-60
37866-70
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
37866-20
37866-30
37866-60
37866-70
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
37866-20
37866-30
37866-60
37866-70
37867-20
37867-30
37867-60
37867-70
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
37867-20
37867-30
37867-60
37867-70
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
37867-20
37867-30
37867-60
37867-70
46106-00
37894-20
37894-30
37894-60
37894-70
46106-10
37895-20
37895-30
37895-60
37895-70
46710-00
37896-60
37896-70
46711-00
37897-60
37897-70
46712-00
37898-60
37898-70
46713-00
37899-60
37899-70
46714-00
37900-60
37900-70
46715-00
37901-60
37901-70
46716-00
37902-60
37902-70
46717-00
37903-60
37903-70
46721-00
37904-60
37904-70
46723-00
37905-60
37905-70
46724-00
37906-60
37906-70
46106-01
N/A
N/A
N/A
N/A
46106-11
N/A
N/A
N/A
N/A
46710-01
N/A
N/A
46711-01
N/A
N/A
46712-01
N/A
N/A
46713-01
N/A
N/A
46714-01
N/A
N/A
46715-01
N/A
N/A
46716-01
N/A
N/A
46717-01
N/A
N/A
46721-01
N/A
N/A
46723-01
N/A
N/A
46724-01
N/A
N/A
46106-02
N/A
N/A
N/A
N/A
46106-12
N/A
N/A
N/A
N/A
46710-02
N/A
N/A
46711-02
N/A
N/A
46712-02
N/A
N/A
46713-02
N/A
N/A
46714-02
N/A
N/A
46715-02
N/A
N/A
46716-02
N/A
N/A
46717-02
N/A
N/A
46721-02
N/A
N/A
46723-02
N/A
N/A
46724-02
N/A
N/A
46106-00
37894-20
37894-30
37894-60
37894-70
46106-10
37895-20
37895-30
37895-60
37895-70
46710-00
37896-60
37896-70
46711-00
37897-60
37897-70
46712-00
37898-60
37898-70
46713-00
37899-60
37899-70
46714-00
37900-60
37900-70
46715-00
37901-60
37901-70
46716-00
37902-60
37902-70
46717-00
37903-60
37903-70
46721-00
37904-60
37904-70
46723-00
37905-60
37905-70
46724-00
37906-60
37906-70
46106-01
N/A
N/A
N/A
N/A
46106-11
N/A
N/A
N/A
N/A
46710-01
N/A
N/A
46711-01
N/A
N/A
46712-01
N/A
N/A
46713-01
N/A
N/A
46714-01
N/A
N/A
46715-01
N/A
N/A
46716-01
N/A
N/A
46717-01
N/A
N/A
46721-01
N/A
N/A
46723-01
N/A
N/A
46724-01
N/A
N/A
46106-02
N/A
N/A
N/A
N/A
46106-12
N/A
N/A
N/A
N/A
46710-02
N/A
N/A
46711-02
N/A
N/A
46712-02
N/A
N/A
46713-02
N/A
N/A
46714-02
N/A
N/A
46715-02
N/A
N/A
46716-02
N/A
N/A
46717-02
N/A
N/A
46721-02
N/A
N/A
46723-02
N/A
N/A
46724-02
N/A
N/A
46106-00
37894-20
37894-30
37894-60
37894-70
46106-10
37895-20
37895-30
37895-60
37895-70
46710-00
37896-60
37896-70
46711-00
37897-60
37897-70
46712-00
37898-60
37898-70
46713-00
37899-60
37899-70
46714-00
37900-60
37900-70
46715-00
37901-60
37901-70
46716-00
37902-60
37902-70
46717-00
37903-60
37903-70
46721-00
37904-60
37904-70
46723-00
37905-60
37905-70
46724-00
37906-60
37906-70
Industrial Wiring Training System
Enclosures and Conduits
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
Electrical Wiring
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
46106
SPANISH
Rigging Training System
Basic Rigging Student Work Orders (60)
46102
FRENCH
240 V - 50 HZ
Mechanical Training System, Level 5
Laser Alignment
Student Work Orders (60)
Instructor Work Orders (70)
Vibration Metering
Student Work Orders (60)
Instructor Work Orders (70)
Vibration Analysis
46109
ENGLISH
220 V - 50 HZ
Pumps Training System
Basic System
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
Multiple Pump System
Student Job Sheets (20)
Instructor Job Sheets (30)
Student Work Orders (60)
Instructor Work Orders (70)
External Gear Pump
Student Work Orders (60)
Instructor Work Orders (70)
Vane Pump
Student Work Orders (60)
Instructor Work Orders (70)
Flexible Impeller Pump
Student Work Orders (60)
Instructor Work Orders (70)
Progressive Cavity Pump
Student Work Orders (60)
Instructor Work Orders (70)
Peristaltic Pump
Student Work Orders (60)
Instructor Work Orders (70)
Pneumatic Diaphragm Pump
Student Work Orders (60)
Instructor Work Orders (70)
Metering Pump
Student Work Orders (60)
Instructor Work Orders (70)
Piston Pump
Student Work Orders (60)
Instructor Work Orders (70)
Stuffing-Box Seal Centrifugal Pump
Student Work Orders (60)
Instructor Work Orders (70)
Multi-Stage Vertical Centrifugal Pump
Student Work Orders (60)
Instructor Work Orders (70)
Magnetic-Drive Centrifugal Pump
Student Work Orders (60)
Instructor Work Orders (70)
63
COURSEWARE ORDERING INFORMATION
MANUFACTURING/MECHATRONICS
COURSEWARE ORDERING INFORMATION
120 V - 60 HZ
MODEL DESCRIPTION
ENGLISH
220 V - 50 HZ
240 V - 50 HZ
FRENCH
SPANISH
ENGLISH
FRENCH
SPANISH
ENGLISH
27073-00
27073-10
N/A
N/A
27073-02
27073-12
27073-00
27073-10
N/A
N/A
27073-02
27073-12
27073-00
27073-10
76097-20
76097-30
N/A
N/A
76097-22
76097-32
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
76098-20
76098-30
N/A
N/A
76098-22
76098-32
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
30794-00
30794-01
30794-02
30794-00
30794-01
30794-02
30794-00
31228-00
31305-00
31228-01
31305-01
31228-02
31305-02
31228-00
31305-00
31228-01
31305-01
31228-02
31305-02
31228-00
31305-00
31745-00
32606-00
31745-01
32606-01
31745-02
32606-02
31745-00
32606-00
31745-01
32606-01
31745-02
32606-02
31745-00
32606-00
30794-10
30794-11
30794-12
30794-10
30794-11
30794-12
30794-10
31290-00
31290-01
31290-02
31290-00
31290-01
31290-02
31290-00
31300-00
31726-00
31300-01
31726-01
31300-02
31726-02
31300-00
31726-00
31300-01
31726-01
31300-02
31726-02
31300-00
31726-00
31977-00
32606-00
31977-01
32606-01
31977-02
32606-02
31977-00
32606-00
31977-01
32606-01
31977-02
32606-02
31977-00
32606-00
31290-10
31290-11
31290-12
31290-10
31290-11
31290-12
31290-10
3100 Industrial Controls Training System
Student Manual
Instructor Guide
3250 DC Variable Speed Drive
Student Manual
Instructor Guide
3260 AC Variable Speed Drive
Student Manual
Instructor Guide
6080 Hydraulics Training System
Student Manuals:
Hydraulics Fundamentals
Electrical Control of Hydraulic
Systems
Hydraulics Applications -PLC
Servo/Proportional Control of
Hydraulics Systems
Sensors
Instructor Guide:
Hydraulics
6081 Pneumatics Training System
Student Manuals:
Pneumatics Fundamentals
Electrical Control of Pneumatics
Systems
Pneumatics Applications -PLC
Servo/Proportional Control of
Pneumatics Systems
Sensors
Instructor Guide:
Pneumatics
6385 Hydraulics Simulation Software (LVSIM®-HYD)
Student Manuals:
Hydraulics Fundamentals
Electrical Control of Hydraulics
Systems
Instructor Guide:
Hydraulics
User Guide:
Virtual Laboratory and Equipment
30794-00
30794-01
30794-02
30794-00
30794-01
30794-02
30794-00
31228-00
31228-01
31228-02
31228-00
31228-01
31228-02
31228-00
30794-10
30794-11
30794-12
30794-10
30794-11
30794-12
30794-10
32359-E0
N/A
32359-E2
32359-E0
N/A
32359-E2
32359-E0
6485 Pneumatics Simulation Software (LVSIM®-PNEU)
Student Manuals:
Pneumatics Fundamentals
Electrical Control of Pneumatics
Systems
Instructor Guide:
Pneumatics
User Guide:
Virtual Laboratory and Equipment
64
31290-00
31290-01
31290-02
31290-00
31290-01
31290-02
31290-00
31300-00
31300-01
31300-02
31300-00
31300-01
31300-02
31300-00
31290-10
31290-11
31290-12
31290-10
31290-11
31290-12
31290-10
32359-E0
N/A
32359-E2
32359-E0
N/A
32359-E2
32359-E0
MANUFACTURING TECHNOLOGY
MANUFACTURING/MECHATRONICS
COURSEWARE ORDERING INFORMATION
120 V - 60 HZ
MODEL DESCRIPTION
220 V - 50 HZ
240 V - 50 HZ
ENGLISH
FRENCH
SPANISH
ENGLISH
FRENCH
SPANISH
ENGLISH
81033-00
81033-01
81036-00
81036-01
81037-00
81037-01
81047-00
81034-00
81034-01
81038-00
81038-01
81039-00
81039-01
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
81033-00
81033-01
81036-00
81036-01
81037-00
81037-01
81047-00
81034-00
81034-01
81038-00
81038-01
81039-00
81039-01
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
81033-00
81033-01
81036-00
81036-01
81037-00
81037-01
81047-00
81034-00
81034-01
81038-00
81038-01
81039-00
81039-01
30416-00
30416-01
30416-02
30416-00
30416-01
30416-02
30416-00
32081-00
32081-10
N/A
N/A
32081-02
N/A
32081-00
32081-10
N/A
N/A
32081-02
N/A
32081-00
32081-10
N/A
30884-02
30884-00
N/A
30884-02
30884-00
30884-02
30884-00
30884-02
30884-00
32621-01
33336-01
32621-02
33336-02
32621-00
33336-00
32621-01
33336-01
32621-02
33336-02
32621-00
33336-00
75941-21
75941-31
75941-22
75941-32
75941-20
75941-30
75941-21
75941-31
75941-22
75941-32
75941-20
75941-30
75942-21
75942-31
75942-22
75942-32
75942-20
75942-30
75942-21
75942-31
75942-22
75942-32
75942-20
75942-30
75943-21
75943-31
75943-22
75943-32
75943-20
75943-30
75943-21
75943-31
75943-21
75943-31
75943-20
75943-30
75944-21
75944-31
75944-22
75944-32
75944-20
75944-30
75944-21
75944-31
75944-22
75944-32
75944-20
75944-30
31446-00
N/A
N/A
N/A
N/A
N/A
31446-00
N/A
N/A
N/A
N/A
N/A
31446-00
N/A
75947-20
75947-30
N/A
N/A
N/A
N/A
75947-20
75947-30
N/A
N/A
N/A
N/A
75947-20
75947-30
75948-20
75948-30
N/A
N/A
N/A
N/A
75948-20
75948-30
N/A
N/A
N/A
N/A
75948-20
75948-30
6059 Fundamentals of Fluid Power
Student Manual Vol. 1
Instructor Guide Vol. 1
Pre-Test Student
Pre-Test Answer Key
Post-Test Student
Post-Test Answer Key
Text Book
Student Manual Vol. 2
Instructor Guide Vol. 2
Pre-Test Student
Pre-Test Answer Key
Post-Test Student
Post-Test Answer Key
3521 Process Control Trainer
Student Manual
3522 Temperature/Flow Process
Student Manual
3674 Process Control Simulator (LV-PROSIM)
Student Manual
30884-00
6090 Process Control Training System
Student Manuals:
Process Control Fundamentals
Using LVPROSIM Software
Pressure, Flow and Level
Process Control
Temperature Process Control
3501-MO
Heat Exchanger Station
Student Manual
Instructor Guide
3508-MO
75944-20
75944-30
Mobile Multi-Process Station
Student Manual
Instructor Guide
3507-MO
75943-20
75943-30
Mobile Temperature Process Station
Student Manual
Instructor Guide
3505-MO
75942-20
75942-30
Mobile Level Process Station
Student Manual
Instructor Guide
3504-MO
75941-20
75941-30
Mobile Flow Process Station
Student Manual
Instructor Guide
3503-MO
32621-00
33336-00
Mobile Pressure Process Station
Student Manual
Instructor Guide
3502-MO
30884-00
Analytic Process Station
Student Manual
Instructor Guide
65
COURSEWARE ORDERING INFORMATION
MANUFACTURING/MECHATRONICS
COURSEWARE ORDERING INFORMATION
120 V - 60 HZ
MODEL DESCRIPTION
3550-MO
ENGLISH
220 V - 50 HZ
240 V - 50 HZ
FRENCH
SPANISH
ENGLISH
FRENCH
SPANISH
ENGLISH
76015-21
76015-31
76015-22
76015-32
76015-20
76015-30
76015-21
76015-31
76015-22
76015-32
76015-20
76015-30
N/A
N/A
N/A
N/A
N/A
N/A
TBE
34431-00
34431-10
N/A
N/A
N/A
N/A
N/A
N/A
TBE
34431-00
34431-10
TBE
34431-00
34431-10
N/A
N/A
N/A
N/A
N/A
N/A
TBE
34431-00
34431-10
N/A
N/A
N/A
N/A
N/A
N/A
TBE
34431-00
34431-10
34175-E0
34175-00
34175-10
N/A
N/A
N/A
N/A
34175-E0
34175-00
34175-10
N/A
N/A
N/A
N/A
36188-E0
N/A
36188-E2
36188-E0
N/A
36188-E2
36188-E0
36189-E0
N/A
36189-E2
36189-E0
N/A
36189-E2
36189-E0
36188-E0
36784-E0
N/A
N/A
36188-E2
36784-E2
36188-E0
36784-E0
N/A
N/A
36188-E2
36784-E2
36188-E0
36784-E0
36189-E0
36783-E0
N/A
N/A
36189-E2
36783-E2
36189-E0
36783-E0
N/A
N/A
36189-E2
36783-E2
36189-E0
36783-E0
36017-00
32381-00
N/A
36017-02
32381-02
36017-00
32381-00
N/A
N/A
N/A
36017-02
32381-02
36017-00
32381-00
36017-10
N/A
36017-12
36017-10
N/A
36017-12
36017-10
32381-10
N/A
32381-12
32381-10
N/A
N/A
32381-10
30811-00
N/A
30811-02
30811-00
N/A
30811-02
30811-00
30812-00
N/A
N/A
30812-00
N/A
N/A
30812-00
30813-00
N/A
30813-02
30813-00
N/A
30813-02
30813-00
Instrumentation and Calibration Station
Student Manual
Instructor Guide
76015-20
76015-30
Model 5100-20 Teach Pendant Controlled Robot
User Manual
Student Manual
Instructor Guide
TBE
34431-00
34431-10
Model 5150-10 Computer-Controlled Robot
User Manual
Student Manual
Instructor Guide
Model 5250 Servo Robot
User Manual
Student Manual
Instructor Guide
34175-E0
34175-00
34175-10
5300 CNC Lathe
User Guide: CNC Lathe Software
5400 CNC Mill
User Guide: CNC Mill Software
5500 CNC Lathe
User Guide: CNC Lathe Software
Quick-Start Guide: Familiarization
with the CNC Lathe
5600 CNC Mill
User Guide: CNC Mill Software
Quick-Start Guide: Familiarization
with the CNC Mill
3240 PLC Training System
Student Basic Principles
Student Programming
Software & Applications
Instructor’s Guide Basic
Principles
Instructor’s Guide Programming
Software and Applications
3341 Exploring Sensors
Student Manual
3342 Exploring Mechanisms
Student Manual
3343 Exploring Electricity
Student Manual
66
MANUFACTURING TECHNOLOGY
Other Product Literature Available from Lab-Volt:
Military Training Systems
Brochure
Computer-Based Electronics Training
System (FACET®) Product Guide
Lab-Volt Product
Catalog on CD-ROM
State-of-the-art training systems for military
applications in
telecommunications,
radar,
electronic warfare,
electronics, fluid power,
and electric power
technologies. 12-page
color brochure.
Forty-eight-page catalog of
Lab-Volt training systems
in Fundamental
Electronics; Analog, Digital
and Fiber Optic
Communications;
Semiconductors,
Transistors, Thyristors, FET
and Amplifiers.
Descriptions and
demonstrations of
Lab-Volt training
systems and
software. Includes
FACET ®, EMS, and
other awardwinning training
systems.
Electric Power/Controls
Product Guide
Industrial Maintenance Brochure
Forty-four page catalog
of Lab-Volt’s vast
offering of training
modules in Electromechanical systems,
PLCs, Power
Electronics, and
corresponding CBT and
simulation software
programs.
Twelve-page color
brochure showcasing
Lab-Volt’s comprehensive industrial training
sytems, including
industrial pumps,
mechanical systems,
industrial wiring, rigging, and more.
Graymark Information
Technology Brochure
Tech-World®: Applications in
Information Technology Brochure
Twelve-page, four-color
brochure describes this
multimedia curriculum
that prepares students
for certifications, entrylevel employment,
advanced education and
careers in Information
Technology or any other
IT-dependent industry.
Tech-Design® Foundations in
Information Technology (FIT)
Fluid Power Brochure
Eight-page brochure of
Graymark’s quality IT
training products,
including PC familiarization, troubleshooting
and repair; cable
installation; monitor and
printer repair; GPS technology; and network
technology programs.
Twelve page 4-color
brochure featuring
Lab-Volt’s premier line
of Fluid Power training
systems, including the
Hydraulics and
Phenuatics Modular
Training System.
TechWorld®: Manufacturing
Brochure
Tech-World®: Manufacturing
Demo CD
Tech-Design® Technology
Education Catalog
Seventy-four-page
catalog with detailed
descriptions of
43 Tech-Design
modules and course objectives, including
skills-at-a-glance charts
showing competencies
associated with each
module.
Twelve-page color
brochure describes this
multimedia and handson curriculum for engineering and manufacturing; presents competencies students
achieve and related
career opportunities.
Sixteen-page color
brochure features this
modular, competencybased curriculum for
information technology
(IT), which provides
skills development and
career exploration in the
four IT career Cluster
Concentrations.
4 Easy Ways to Order Additional Product Literature:
✔ Send e-mail to:
us@labvolt.com (USA)
ca@labvolt.com (Canada)
✔ Call us at 1-800-LAB-VOLT (USA AND CANADA)
or 1-732-938-2000 (outside of the USA and Canada)
Highly graphical CD
demonstrates this preengineering/manufacturing curriculum that
provides realistic,
hands-on training with
industry-standard
equipment and
advanced software.
Please complete the following:
Name _______________________________________________________
Institution ___________________________________________________
Address _____________________________________________________
Address 2 _____________________________________________________
✔ Visit our website at www.labvolt.com
City ________________________________ State __________________
✔ Circle the requested items above and fax it: 1-732-774-8573
Country _____________________________ Postal Code ____________
67
NOTES
68
FLUID POWER
MANUFACTURING/MECHATRONICS TECHNOLOGY
z
z
z
z
z
z
REFRIGERATION, AIR CONDITIONING & HEATING
EXPLORING TECHNOLOGY
INSTRUMENTATION & PROCESS CONTROL
COMPUTER-BASED ELECTRONICS TRAINING SYSTEM
ELECTRIC POWER/CONTROLS
DIGITAL MICROPROCESSOR & COMPUTER
ELECTRICITY & ELECTRONICS
TELECOMMUNICATIONS
WORLD LEADER IN TECHNICAL TRAINING SYSTEMS
95016-00 REV. D
ELECTRICAL & MECHANICAL SYSTEMS
FLUID POWER
INSTRUMENTATION & PROCESS CONTROL
WEB-BASED INDUSTRIAL TRAINING
AUTOMATION & ROBOTICS
EXPLORING TECHNOLOGY
M A N U FA C T U R I N G / M E C H AT R O N I C S T E C H N O L O G Y
AUTOMATION & ROBOTICS
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