MEASUREMENT AND CONTROL TECHNOLOGY - LD DIDACTIC

MEASUREMENT AND 

CONTROL TECHNOLOGY 

CATALOG T8

MEASUREMENT & CONTROL TECHNOLOGY 

Content 

Instrumentation, Control and Automation Technology 

Instrumentation, Control and Automation are terms from the 

Automation field. The aim of this field is to monitor and operate 

technical events and production processes by means of 

automatic-running control systems. Through the use of machine 

controllers human beings are exempted from monotonous control 

and operation tasks. Frequently, technical systems have 

requirements for accuracy, quickness and reliability that can't be 

met by human beings. In many skilled occupations, the rapidly 

spreading Automation technique calls for a sound knowledge of 

sensors and experience in dealing with control circuits. I&C 

Technology from LD Didactic takes this development into 

account. The present complete catalogue T8 Instrumentation, 

Control & Automation introduces our extensive product range 

based on state of the art technology. The equipments, arranged 

by fields of study, contain the material subdivided according to 

fundamentals and industrial applications. As a rule, experiments 

are carried out with modular experiment boards or multimedia 

training courses. 

Print date: 23.08.2011 

LD Didactic 

T 8.3 

Industrial Control 

Technology 

T 8.2 

Basics of 

Control Technology 

T 8.1 

Measurement & 

Sensor Technology 

Page 2 of 94 T 8.2 

T 8


Content 

Training Systems 4 

Technical Data 6 

Measurement and Sensors 11 

Measurement and sensor technology courses impart skills 

necessary to measure the fundamental electrical quantities: 


Current, voltage, frequency, etc. 

As well as knowledge on the function of sensors: 

Strength, temperature, revolutions, pressure etc. 

An important component in the field of measurement 

technology is the present COM3LAB course Sensor 

Technology. 

Basics of Control Technology 27 

This field contains equipment for all skilled occupations 

requiring fundamentals or in-depth knowledge of control 

technology. In the experiments, technical models and 

electronic links with digital operation are used. 

Industrial Control Technology 65 

The field of Industrial Control Technology has been 

completely revised. Apart from an optimised, pneumatic 

instrumentation, the CASSY LAB 2 integration is particularly 

helpful here. 

Equipment sets 86 

Keywords 92 

Symbols and abbreviations used in 

this catalogue: 

Experiment manuals 

contained 

Software contained 

Accessory required 

Battery required 

Compatible to 

COM3LAB 

USB support 

Page 3 of 94 T 8.2 

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Training Systems 

Plug-In System and Training Panels 

The training systems described in this catalogue can be classified 

into three categories: 


STE- Plug-In System electric/electronic 

TPS - Training Panel System 

COM3LAB-Multimedia 

STE Plug-In System Electric /Electronic 

The plug-in system developed by LD DIDACTIC is a proven 

experimental program for electricity and electronics. Electric and 

electronic components are mounted ready to use and protected 

from external mechanical damage by the plug-in elements’ 

transparent casings. The original component is visible through the 

transparent base. 

TPS - Training Panel System 

Training systems based on experiment boards offer many 

advantages in labs and demonstration classes: 

Clear representation 

Block diagrams and schematic symbols according to DIN and 

IEC 

Connections through 19 mm jumpers 

Industrial modules and components for realistic measurement 

results 

Safety sockets and cables 

High compatibility with STE/SIM and COM3LAB training 

systems 

Continuous, thematic extensions. 

Page 4 of 94 T 8.2 

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Training Systems 

COM3LAB-Multimedia 

Theory and practice merged into one package 

COM3LAB is used in the vocational training of electrical 

engineering and electronics. COM3LAB acts as the interface 

between theory and practice. Thus COM3LAB not only conveys 

theoretical aspects of the subject matter, but at the same time 

deepens and consolidates this knowledge by real experiments. 

COM3LAB consists of a Master Unit and various individual 

courses (experiment board + CD-ROM). The Master Unit is the 

basic device through which the software and experiment board 

communicate with each other. More information for the 

COM3LAB components shown in this catalogue can be found 

in the COM3LAB-System-catalogue. 


Page 5 of 94 T 8.2 

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Technical Details 

News from the Control Technology 

The LD training equipment for measurement and control 

technology has been completely redesigned. Newly 

developed and updated electronic devices are based on 

state of the art technology. Modern low-offset and lowdrift 

components deliver precise results. Digital 

components with incremental transducers facilitate the 

adjustment of devices. This allows more time for 

experimenting, as time-consuming calibrations are 

rendered unnecessary. The consistent integration of 

Profi-CASSY and the use of CASSY Lab 2 Software 

simplify the execution and analysis of experiments. 

Complex calibrations on links and controllers, and their 

resulting imprecision are things of the past. All manuals 

in this catalogue are available in electronic form. Simply 

click on the example files and Profi-CASSY automatically 

begins obtaining measurement values. 

Many components have digital controls, making 

parameter adjustments very simple. 


Once adjusted, no unwanted parameter changes 

occur. 

Parameter values are always visible during 

experiments. 

Start-up procedures are self-explanatory. 

Page 6 of 94 T 8.2 

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Components with Incremental Transducers 


Digital Controlled System (734 091) 

Proportional controlled system, time-delayed up to 

2nd order integrating or double-integrating 

Dead time element (734 0891) 

Element with proportional behaviour and adjustable dead 

time (max. 1 s). Ideal for recording frequency response 

curves. 

Two position controller (734 011) 

A classical controller for slow controlled systems, e.g., 

temperature controls. 

2nd Order transfer element (734 0951) 

A 2nd order oscillating system. Frequency and attenuation 

are adjustable. 

Page 7 of 94 T 8.2 

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CASSY-Interfaces and CASSY Lab 2 

The CASSY family consists of various hardware components 

and the dedicated software package CASSY Lab 2. 

CASSY Lab 2 

CASSY Lab 2 is a modern 32-bit software, applicable for Windows XP/Vista/7 with the following 

features: 


Data recording 

Multimeter 

Oscilloscope 

XY-plotter 

FFT-analysis 

Variety of evaluation aids 

Export of measurement data and diagrams. 

Page 8 of 94 T 8.2 

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CASSY-Interfaces and CASSY Lab 2 

524 013 Sensor-CASSY 2 

Sensor-CASSY is a cascadeable interface for data recording. It has 

galvanic separated inputs and automatic sensor box recognition by 

CASSY Lab 2 (plug and play). Sensor-CASSY 2 is the interface with 

enhanced measurement ranges for: 


T 8.1 Measurement Technology 

T 8.3 Industrial Control Technology. 

524 016 Profi-CASSY 

The interface with analogue inputs and outputs for control technology 

applications: 

T 8.2 Control Technology 

T 8.3 Industrial Control Technology 

Profi-CASSY is the interface for specific use in control 

technology and automation. Equipped with USB and PROFIBUS 

interfaces, Profi-CASSY can be connected to a network. With 

two analogue and 16 digital inputs and outputs as well as the 

PROFIBUS interface, it is incredibly versatile. Profi-CASSY is 

ideal for integration in PLC, COM3LAB, mechatronics or 

frequency converters. Profi-CASSY operates under different 

application programs, e.g. WinFACT or CASSY Lab 2 . 

Page 9 of 94 T 8.2 

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T 8 

Page 10 of 94 T 8.2

MEASUREMENT & SENSOR TECHNOLOGY 


T 8.1 Measurement and Sensor 

Technology 

Page 11 of 94 T 8.2 

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T 8.1 Measurement and Sensor Technology 

Content 


T 8.1.3 

COM3LAB-Multimedia: 

Measurement Technology 

T 8.1.2 

Measuring Nonelectrical 

Quantities 

T 8.1.1 

Measuring Electrical 

Quantities 

Page 12 of 94 T 8.2 

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T 8.1 Measurement & Sensor Technology 

Classification 

Instrumentation, Control and Automation is an interdisciplinary 

field very prevalent in modern industrial society. Therefore, 

industry and transport management requires knowledge of 

energy, mass and traffic flows in production and logistics. The 

world is becoming more densely populated and requires 

intelligent processes for controlling and distributing its resources. 

Sensors are indispensable, as they deliver the data required for 

controlling processes. 

T 8.1.1 Measuring Electrical Quantities 

The influence of passive components on current and voltage can 

be demonstrated simply by exchanging plug-in elements (STE). 

With STE, circuits can be modified and tested according to 

personal preference. 

T 8.1.2 Measuring Nonelectrical Quantities 

Force and temperature are well-known examples of nonelectrical 

quantities that should be converted using electric controllers or 

controls for further processing. Training systems in this group 

work mainly with experiment boards (TPS). Industrial sensors are 

used to recognise packaged goods, and the internal structure of 

sensors remains hidden from the user. This is accomplished by 

optimising sensors in each individual application. 

T 8.1.3 COM3LAB-Multimedia: Measurement Technology 

In the condensed version of the LD Multimedia training course, 

principles of measuring elementary electrical and nonelectrical 

quantities are studied. A special COM3LAB course (700 84) is 

dedicated to the important topic of Sensor Technology. This 

course focuses on measurement of nonelectrical quantities. 


Page 13 of 94 T 8.2 

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Experimental set-up with the proven Plug-In System electric/electronic. 


Topics 

� DC and AC measurements, high impedance sources 

� Extending measurement ranges 

� Impedance converter 

� Instrument amplifiers 

� Half wave and instrumentation rectifier 

� F/U and AC converter 

� Peak value measurement 

� Exponential voltage and logarithmic voltage measurement. 

Page 14 of 94 T 8.2 

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Current and voltage are directly available in electrical form and do 

not need to be converted by any sensors from the original 

measurement values. Thus the basics of electrical measurement 

technology belong also to the fundamentals of electrical 

engineering technology. We handle these topics with selected 

components out of our Plug-In systems. 

EQUIPMENT LIST T 8.1.1.1 

Measuring Electrical Quantities 

Quantity Cat.-no Description 


1 727 549N Basic SET T 6.1.11 

1 726 88 AC/DC Stabilizer 

1 524 013S CASSY 2-Starter USB 

1 565 852 Book: Electronic Measuring Device Circuits T 6.1.11 

The complete set of required material is given in the table at the end of this 

catalogue. Or simply ask for an actual offer. 

U A 

V 

10 

5 

0 

0 10 20 

By using Profi-CASSY and CASSY 

Lab 2 Software, electric power or 

energy can be represented as 

instantaneous or mean values. 

Page 15 of 94 T 8.2 

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t / s



Equipment Sets 


T 8.1.2.3 

Temperature Measurement 

T 8.1.2.2 

Recognition of Packaged 

Goods 

T 8.1.2.1 

Force Measurements with 

Strain Gauge 

Page 16 of 94 T 8.2 

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T 8.1.2.1 Force Measurements with Strain Gauge 

Bridge abutments are monitored with strain gauges. Working with 

strain gauges in the lab is a very didactic example of how the 

mechanical quantity, Force, is converted into electrical signals. 

CASSY Lab 2 creates experiments that are particularly suitable 

for demonstration using a projector. 

T 8.1.2.2 Recognition of Packaged Goods 

A practical course based on the use of industrial sensors. 

Sensors are useful for material recognition and, under the correct 

circumstances, are able to detect piece goods on conveyor belts. 

T 8.1.2.3 Temperature Measurement 

Temperature determines the speed of chemical reactions and 

influences basic material properties. Physical quantities, such as 

pressure, concentration, density, pH value, flow rate, etc., depend 

directly on temperature. As a result, temperature is a very 

important status parameter in process engineering. 


Claus Schmidt / pixelio.de 

Martina Braun-Rotmann / pixelio.de 

Dieter Schütz / pixelio.de 

Page 17 of 94 T 8.2 

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Experimental set-up with bending rods and measurement timer 


Topics 

� Conversion of the mechanical quantity force into electrical signals 

� Function and calibration of measurement bridges 

� Measurements per 4-conductor principle. 

Page 18 of 94 T 8.2 

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The measurement of force with a strain gauge is a technique 

used around the world for converting mechanical quantities into 

electrical signals. Its range of application extends from modern 

electronic scales in industry and households right up to load 

controls on building structures and large vehicles. The LD training 

system investigates the conversion of: 


Bending forces 

Tension forces and 

Torsion stresses. 


Force Measurements with Strain Gauge 


1 734 55 Strain Gauge Transducer 

1 734 56 Tensile Test Bar 

1 734 565 Torsion Bar 

1 311 87 Dial Gauge 

1 524 016S2 Profi-CASSY-Starter 2 USB 

1 727 66 DC Bridge Amplifier 

1 315 36 Set of 7 Weights, 0.1 to 2 kg 



F 

N 

50 

40 

30 

20 

10 

0 

0 1000 2000 3000 4000 

Relationship between the loading 

mass m (horizontal axis) and the 

measured weight force F (vertical 

axis). 

Page 19 of 94 T 8.2 

T 8 

m / g





Topics 

� Selection of a suitable sensor according to the material 

characteristics of the sample 

� Alarm circuits with sensors 

� Structure of a sensor chain for recording various 

sample material parameters. 

Page 20 of 94 T 8.2 

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The equipment in this training system includes a large 

selection of real industrial sensors. This allows topics to be 

very closely oriented to practical applications. The hardware 

in this training system is comprehensibly supported with 

extensive teachware and training software. The large 

selection of different material samples makes it possible to 

perform specific correlations between individual sensors and 

real process technology. 


Recognition of Packaged Goods 



1 743 301 Standard Kit Sensors 

1 743 302 Extension Kit Sensors 

1 743 303 Case Test Samples 

The complete set of required material is given in the table at the end of 

this catalogue. Or simply ask for an actual offer. 

A typical industrial sensor with practical 

quick-connect terminals. 

Page 21 of 94 T 8.2 

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Temperature measurement with various temperature probes. 


Topics 

� Characteristic curve of a temperature-controlled system 

� Temperature control using an on-off controller 

� Temperature control using WinFACT 

� On-off controllers with delayed feedback. 

Page 22 of 94 T 8.2 

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Didactic controlled systems with large time constants are difficult 

to monitor and the control process is lengthy. Furthermore, 

measurement technology requires knowledge of how to manage 

industrial measuring probes. For this reason, temperature is 

measured in a special, high-temperature oven (model 734 38) 

reaching approximately 200°C. Its time constant is around 10 min. 

Therefore, a faster system is tested for temperature regulation. 

Experiments with the most important types of temperature 

sensors are performed with our training system: 


Thermo element 

Resistance thermometer (Pt 100) 

Thermistor (NTC). 


Temperature Measurement 


1 734 02 Reference Variable Generator 

1 734 13 Power Amplifier 

1 734 38 Oven Model 20 V, 20 W 

1 734 74 NiCr-Ni Thermoelement 

1 734 75 Thermocouple Connection 

1 734 76 Pt-100 Resistance Probe 

1 734 77 NTC Temperature Probe 

1 727 66 DC Bridge Amplifier 




Foundries must maintain exacting, 

prescribed, temperature profiles for 

the molten mass. 

Page 23 of 94 T 8.2 

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Categories (selection) 

� Electrical Basics 

� Transformers, Rectifier 

� Parameters of the AC current 

� Strength, Pressure, Distance, Speed 

� Temperature, Brightness. 

Page 24 of 94 T 8.2 

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Measurement Technology with COM3LAB 

The COM3LAB courses included in this equipment impart the 

basics laws of electrical engineering as well as measure electrical 

quantities, such as voltage, current, and resistance. COM3LAB 

experiments are performed with circuits that have been previously 

prepared. In each unit, goal-oriented guidance and didactic 

multimedia simultaneously teach the experiment and its 

corresponding theory. In COM3LAB course Sensor Technology 

the measurement of nonelectrical quantities is studied. This 

course is equipped with many important converters, such as: 


Bending beam with strain gauge 

Pt-100, NTC, KTY temperature sensors 

Peltier elements 

Photodiode 

Reed contacts 

Etc. 

EQUIPMENT LIST T 8.1.3 

COM3LAB-Multimedia: Measurement Technology 


1 700 11 COM3LAB Course: DC Technology I 

1 700 12 COM3LAB Course: DC Technology II 

1 700 13 COM3LAB Course: AC Technology I 

1 700 14 COM3LAB Course: AC Technology II 

1 700 84 COM3LAB-Course: Sensor Technology 

1 700 00USB COM3LAB Master Unit (USB) 


catalogue. Or simply ask for an actual offer. You can find complete information 

on COM3LAB products in the COM3LAB System Catalogue or online. 

COM3LAB courses offer a multimedia 

education with practical experiments. 

The experimentation 

circuits are pre-assembled, readyto-use 

function modules that make 

experimentation fast and effective. 

Page 25 of 94 T 8.2 

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T 8 

Page 26 of 94 T 8.2

BASICS OF CONTROL TECHNOLOGY 


T 8.2 Basics of 


Page 27 of 94 T 8.2 

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T 8.2 Basics of Control Technology 

Content 


T 8.2.8 



T 8.2.7 

Stability and Optimization 

T 8.2.6 

Recording of Frequency 

Responses 

T 8.2.5 

Digital Control 

T 8.2.4 

Modules and Transfer 

Elements 

T 8.2.3 

Control of Electronic Lines 

T 8.2.2 

Fuzzy Control 

T 8.2.1 

Control of Technical Lines 

Page 28 of 94 T 8.2 

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T 8.2 Basics of Control Technology 

Content 

T 8.2.1 Control of Technical Lines 

Technical controlled systems provide non-electrical controlled 

quantities, such as level, temperature, flow, listing angle, etc., 

and, consequently, require a sensor system to convert their 

respective controlled quantities into electrical signals. 

Experiments with technical control systems are particularly 

instructional. 

T 8.2.2 Fuzzy Control 

The Fuzzy Control is a rule-based, expert system used to solve 

control problems without complex mathematics. The control 

algorithm is created on a PC and accesses the real controlled 

system through an interface. 

T 8.2.3 Control of Electronic Lines 

Electronic controlled systems require no additional sensors, as 

only electrical signals are present in the control circuit. Because 

electrical signals are easy to measure, experiments with 

electronic control systems are distinguished by conclusive, 

quantifiable results. 

T 8.2.4 Modules and Transfer Elements 

In this course, controller and control systems are comprised of 

basic electronic modules (P, I, D elements) as well as summation 

points. 

T 8.2.5 Digital Control 

In contrast to a hard-wired hardware controller, here the controller 

is implemented either as a block-structured or a mathematical 

model on the computer. Communication with the real environment 

takes place through an interface. 

T 8.2.6 Recording of Frequency Responses 

Control circuits can be tested in the time domain or in the 

frequency domain. While transient responses are mainly 

discussed in the time domain, the Bode diagram, or circle 

diagram, is relevant to the frequency domain. Practical training for 

advanced students testing only electronic control systems as 

measuring objects. 

T 8.2.7 Stability and Optimization 

An optimum control circuit should remain stable when no external 

influences are present. If a disturbance occurs, the control circuit 

should quickly return to its initial status without experiencing great 

deviations from normal operations. The subject can be handled 

using electronic as well as technical control systems. 

T 8.2.8 COM3LAB-Multimedia: Control Technology 

Two condensed COM3LAB courses comprehensively introduce 

experimental control technology. In order to understand electronic 

control circuits, previous knowledge of operational amplifiers and 

sensor technology is required. 


Page 29 of 94 T 8.2 

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T 8.2.1.7 

Listing Control 

T 8.2.1.6 

Speed and Voltage 

Control 

T 8.2.1.5 

Brightness Control 

T 8.2.1.4 

Gas Flow Control 

T 8.2.1.3 

Liquid Level - Measurement 

and Control 

T 8.2.1.2 

Liquid Flow - Measurement 

and Control 

T 8.2.1.1 

Temperature Control 

Page 30 of 94 T 8.2 

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Control of Technical Lines is a focal point in the Fundamentals of 

Control Technology training system. The subsequent subjects are 

of great interest in technical training. 


T 8.2.1.1 Temperature Control 

T 8.2.1.2 Liquid Flow Measurement and Control 

T 8.2.1.3 Liquid Level Measurement and Control 

T 8.2.1.4 Gas Flow Control 

T 8.2.1.5 Brightness Control 

T 8.2.1.6 Speed and Voltage Control 

T 8.2.1.7 Listing Control. 

The speed at which a system responds to status changes is 

determined by its time constants. Moreover, time constants vary 

among technical systems. The following is a rough layout: 

Temperature: very slow 

Fluid flow: slow 

Liquid level: slow 

Speed: fast 

Brightness: very fast 

Page 31 of 94 T 8.2 

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Process visualization (SCADA = Supervisory Control And Data Acquisition). Measurements can be 

professionally displayed using WinFACT and Profi-CASSY. 


Topics 

� Characteristic curve of temperature controlled systems 

� Temperature control with two-point controllers 

� Temperature control using WinFACT 

� On-off controllers with delayed feedback 

� Setup of measurement instruments 

� Calibration of measurement instruments. 

Page 32 of 94 T 8.2 

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Temperature control in residential buildings, vehicles or 

workpieces classically illustrates control in systems with large 

time constants. The LD temperature controlled system, the on-off 

controller, and the PID controller are jointly addressed and can 

also be useful in the Fuzzy control field (T 8.2.2). The internal 

temperature sensor has been previously installed and a cooling 

fan and closable flap valve in the heating channel are used for 

testing disturbance reactions. 


Temperature Control 



1 734 011 Two Position Controller 


1 734 12 Temperature Controlled System 



1 734 482 Software: WinFACT COM3LAB / CASSY-Edition 

1 568 222 Book: Fundamentals of Automatic Control 

Technology II, Vol. 2 



Instead of the oven model 734 38 

from T 8.1.2 Measuring Nonelectrical 

Quantities, the thermally 

quicker Temperature Controlled 

System 734 12 is used here. This 

increases control dynamics and 

decreases measure-ment time. 

Page 33 of 94 T 8.2 

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T 8.2.1.2 Liquid Flow - Measurement and Control 

Level and flow measurement and control can be tested together within fluid controlled systems. 


Topics 

� Step response of flow controlled systems 

� Fluid flow control with the PID Controller 

� Fluid flow control with WinFACT. 

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T 8.2.1.2 Liquid Flow - Measurement and Control 

As is the case in petrochemistry or water management, level and 

flow are integral to motor vehicle technology and fundamental to 

production and logistics within industrial applications. Fluid 

throughput should be recorded, controlled and corrected at every 

stage: from tankers, through refineries, up through the clarification 

plant. 


Liquid Flow - Measurement and Control 




1 734 064 PID Digital Controller 

1 734 262 Liquid Controlled System 



1 564 24EN Book: Control of Technical Lines 



U A 

V 

10 

5 

0 

0 10 20 

The liquid flow is measured with an 

internal sensor. Both absolute and 

relative reading flow meters can be 

created using CASSY Lab 2 

software. 

Red: Flow measured in Closed 

Loop Mode (using integrated 

subordinate control system) 

Black: Open Loop 

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t / s



T 8.2.1.3 Liquid Level - Measurement and Control 

Level measurement in the liquid controlled system tank. The drainage of water from a tank is 

represented for different adjustments of the shut-off valve. A differential pressure sensor with a 

connected immersion pipe is used. 


Topics 

� Level Control with the PID Controller 

� Level Control with WinFACT. 

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T 8.2.1.3 Liquid Level - Measurement and Control 

In addition to pressure measurement, temperature, flow, and the 

acquisition of filling levels in tanks and containers play a key role 

in the chemical industry. Different methods are used to measure 

filling levels. The LD training system uses the following probes: 


Capacitive 

Immersion pipe with differential pressure sensor 

Level switch with float 

EQUIPMENT LIST T 8.2.1.3 – SUPPLEMENTARY TO T 8.2.1.2 

Liquid Level - Measurement and Control 


1 734 81 Differential Pressure Transducer 

1 734 876 Immersion Tube 


The basic experiment can be extended for the dual tank model. 

The probes listed below can also be used in the basic experiment 

OPTION 

Liquid Level Control on a Dual Tank Model 


1 734 264 Additional Reservoir 

1 727 68 C/F-, L/F- and F/U-Converter 

1 734 861 Capacitive Bar-Type Probe 

1 734 881 Level Switch with Float 

1 734 89 Capacitive Level Switch 




w 

V 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

-1 

-2 

-3 

-4 

-5 

-6 

-7 

-8 

-9 

-10 

5 10 15 20 

External sensors are required in 

order to detect the liquid level and 

support a preselected level within 

the control circuit. 

Page 37 of 94 T 8.2 

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t / s 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

-1 

-2 

-3 

-4 

-5 

-6 

-7 

-8 

-9 

-10 

x 

V




Flow Control with blower and windmill type anemometer. 


Topics 

� Step responses of gas flow control systems 

� Gas Flow Control using PID Controllers 

� Gas Flow Control using WinFACT. 

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In classical control circuits, gas flow is measured and maintained 

at the desired value. The anemometer operates using thermal 

cross or thermosensors. Applications for gas flow controls 

include: 


Aeronautics 

Motor vehicles 

Air conditioning. 

The exploitation of wind energy creates a greater demand for 

technology which measures and controls flowing gasses. Varying 

wind speeds should be registered and converted into an optimum 

blade adjustment for the propeller (pitch control). If maximum 

energy production is to be achieved, the nacelle must be turned 

into the wind at all times. 


Gas Flow Control 


1 666 630 Blower 

1 666 632 Windmill Type Anemometer 






(): recommended 



U A 

V 

10 

5 

0 

0 10 20 

The static characteristic curve 

of a thermal anemometer is 

represented in the experiment. 

The air flow rate is measured. 

Bigmama / pixelio.de 

Page 39 of 94 T 8.2 

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t / s





Topics 

� Step responses of light controlled systems 

� Brightness Control with PID Controller 

� Brightness Control with WinFACT. 

Page 40 of 94 T 8.2 

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Brightness control is a practical example of how fast systems are 

controlled. Control circuits responding to changes in brightness 

can be found within biological systems, sports halls, hospitals, 

cameras, etc. Experiments operate using newly developed 

controlled systems with extremely short time constants. 

Responses to starting point changes and disturbance reactions 

are tested. 


Brightness Control 





1 734 311 Light Controlled System 







Light controlled system 

734 311 contains effective light 

source, interfering light source and 

light sensor. New electronic system 

with superbright LED. 

Page 41 of 94 T 8.2 

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T 8.2.1 Technical Systems 



Topics 

� Step response of a machine set 

� Speed control with PID Controller and WinFACT 

� Voltage control 

� Recording the load characteristics 

� Reference and disturbance behaviour of speed control 

� Time profile of reference control with CASSY. 

Page 42 of 94 T 8.2 

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T 8.2.1 Technical Systems 


The set of machines 10 W is a technical controlled system for 

experiments on speed and voltage control. It consists of an 

electrical drive including digital speed sensing, a generator 

machine and an electronic load. Using the adjustable load, real 

generator operation can be investigated. The machine set makes it 

possible to measure the load characteristic of the generator and 

the dynamic behaviour of systems of higher order. A 

microprocessor controlled power module supplies the drive 

machine. Thus no external power amplifier is required. The set of 

machines comes with 7-segment displays for the measurement of 

speed and torque. 


Speed and Voltage Control 





1 734 111 Set of Machines 10 W 






n* 

rpm 

3000 

2000 

1000 

0 

0 10 20 30 40 50 60 

Optimum speed control 

Black: Reference 

Red: Controlled variable 

U A1 

V 

Page 43 of 94 T 8.2 

7 

6,5 

6 

5,5 

5 

4,5 

4 

3,5 

3 

2,5 

2 

1,5 

1 

t1 = 0,101 s, t2 = 0,703 s T1=0.40, T2=0.10 

3 3,5 4 4,5 

Dynamic behaviour of the machine 

set 

T 8 

t / s 

t / s 

7 

6,5 

6 

5,5 

5 

4,5 

4 

3,5 

3 

2,5 

2 

1,5 

1 

U X 

V



T 8.2.1.7 Listing Control 


Topics 

� Position control using PID controllers 

� Position control using WinFACT. 

Page 44 of 94 T 8.2 

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T 8.2.1.7 Listing Control 

Listing, or heeling, is the term given to the rolling movement of 

ships in waves or during the loading procedure. Listing occurs 

particularly when a heavy freight train mounts a ferry. When rail 

vehicles mount a ferry, there should be no rail kinks at the 

interface between ferry and feeder. Such control problems – all of 

which pertain to attitude stabilisation – can be investigated using 

listing controls. The system can be similarly operated using the 

real PID Digital Controller (734 064) or with a software controller 

based on WinFACT. 


Listing Control 




1 734 300 Listing Controlled System 







Listing controllers ensure a 

balanced course tracking. 

Page 45 of 94 T 8.2 

T 8


Software 

WinFACT 

WinFACT is an industry-oriented software used to analyze, 

synthesize, and simulate conventional control systems as well as 

to manage FUZZY and neuro systems. In addition, WinFACT is 

used for process visualisation (SCADA). The software has a 

modular structure and allows real control circuits to be modelled. 

In the adjacent image depicting speed control of an electric 

machine, the simulated WinFACT control circuit works with a PID 

controller (red lines). Parallel to the simulated control circuit, there 

is a second, identically parameterised PID controller with Profi- 

CASSY as the interface. The actual machine set is connected to 

the Profi-CASSY (blue lines). The controlled quantities of actual 

and simulated controlled systems are plotted and printed together 

with the reference quantity (black lines). 

Other technical or electronic control systems from this catalogue 

can also be modelled with the help of WinFACT. The better the 

real process is understood, the closer will be the correspondence 

between simulated and real results. 

The LD Didactic scope of supply contains the following software 

packages for experimental control technology: 

SOFTWARE PACKAGES 

WinFACT 

Cat.no Description Contents 

734 482 WinFACT COM3LAB / CASSY-Edition BORIS 10 Blocks, time period 

734 492 WinFACT7 LD Licence BORIS 100 Blocks, time period 

Fuzzy, Optimization 


0 2 4 6 8 10 12 14 16 18 20 

t -> 

Page 46 of 94 T 8.2 

y-> 

10 

8 

6 

4 

2 

0 

-2 

-4 

-6 

-8 

-10 

-12 

T 8 

GENERATOR 

MOTOR 

Drive 

When the model for the control 

system is built correctly, the real 

experiment and the simulation 

produce the same control 

quantity curve (speed). In 

addition, for optimum control 

adjustment, deviation from the 

desired speed (blue curve) 

should be as low as possible in 

both cases.


Software 

WinFACT / CASSY Lab 2 

The COM3LAB/CASSY-Edition is a reduced, single-user license. 

It must be purchased separately for each workstation. Control 

circuits with a maximum of 10 block elements can be built using 

the COM3LAB/CASSY-Edition. Fuzzy and Optimisation are not 

included. The extensive package, WinFACT LD-Licence, allows 

concurrent use in up to 10 workstations. Apart from measurement, 

simulation, and representation in time domain, this licence 

contains a Fuzzy-Shell for building rule-based control circuits and 

optimisation modules. The LD Driver for COM3LAB and CASSY 

as well as the experimentation examples for WinFACT are 

included exclusively in both software packages. 

CASSY Lab 2 

CASSY Lab 2 is the operating and analysis software for interfaces 

of the CASSY family. With the aid of CASSY Lab 2, Profi-CASSY, 

which is commonly used in control technology, becomes a 

universal measurement and control instrument. The following 

functions can be implemented using CASSY Lab 2: 


Activation and control of Profi-CASSY analogue outputs 

Generation of transient, pulse, or ramp signals 

Recording measured signals in time domains 

Step response analysis 

Export and further processing of measured values using 

external software. 

SOFTWARE PACKAGE 

CASSY Lab 2 

Cat.-no Description Contents 

524 220 CASSY Lab 2 Improved development of the 

successful CASSY Lab 2 

software for recording and 

evaluating measurement data 

acquired using the CASSY family, 

with comprehensive integrated 

help functionality and many 

operable experiment examples 

Software. 

Note: The software CASSY Lab 2 is included in the Starter Package. Example: in 

524 016S2 Profi-CASSY-Starter 2 USB already included in the scope of supply. 

U Y 

V 

Page 47 of 94 T 8.2 

10 

5 

0 

-5 

-10 

A 

B 

C 

1 

D 

E 

2 

0 50 100 

Follow-up control with CASSY 

Lab 2 speed control at set of 

machines 10 W. 

F 

T 8 

G 

t / s



Air conditioners using Fuzzy control. Controlled systems can be heated electrically using halogen 

lamps and cooled by fans. 


Topics 

� Conceptual Fuzzy controller design 

� Definition of Fuzzy Sets 

� Establishing linguistic rules 

� Linear and non-linear Fuzzy controllers 

� Fuzzy heating and climate control 

� Speed control using Fuzzy 

� Expert systems. 

Page 48 of 94 T 8.2 

T 8



Rule-based control algorithms 

Fuzzy describes a formula for controlling technical systems 

using almost no mathematics. The control strategy is defined 

in layman’s terms. Fuzzy control is particularly useful for 

systems with many controlled quantities and can be used with 

a variety of everyday devices, ranging from washing machines 

to digital cameras. Three examples are presented in this 

practical training: 


Heating and climate 

Speed Control 

Position control 

P-Fuzzy and PI-Fuzzy controllers are built for linear and nonlinear 

controllers. 


Fuzzy Control 

Quantity Cat.-no. Description 


1 734 111 Set of Machines 10 W 

1 734 12 Temperature Control System 


1 734 300 Listing Controlled System 




1 734 492 Software: WinFACT7 LD Licence (English) 



y -> 

9 

8 

7 

6 

5 

4 

3 

2 

1 

0 

0 10 20 30 40 50 60 70 

t -> 

Page 49 of 94 T 8.2 

T 8 

Reference Value 

Input from process 

FC 

Curves for controlled quantity, control 

quantity, and reference quantity in a 

speed control system.



Fuzzy Applications 


Listing Controlled System Set of machines 10 W Temperature Control System 

Fuzzy is also used in automotive engineering. After speed 

changes, Drive by Wire technology transmits the desires of the 

driver to a Fuzzy controller. 

Two-point control with Fuzzy 

12 

x 

10 

8 

6 

4 

2 

Teilexperiment 1 

0 

0 50 100 150 200 250 300 

t 

Page 50 of 94 T 8.2 

T 8 

Regelgröße 

Stellgröße



Inside a Fuzzy controller 


StaTemp 

DynTemp 

1 

0 

1 

1.2 

1.0 

0.8 

0.6 

0.4 

0.2 

0.0 

DynTemp 

Schwerpunkt 

MAX-MIN 

Boiler 

Boiler 

-1 -1 

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 

1 

StaticTemp 

VerySmall 

Small 

Medium 

Big 

VeryBig 

Boiler 

The Fuzzy PI controller with 

Profi-CASSY interface is built 

using the BORIS WinFACT 

module. 

Structure of the PI-Fuzzy 

controller: 

The input variables are the 

Fuzzy Sets StaTemp and 

DynTemp. Boiler is the output 

variable. 

3D characteristic field of the 

Fuzzy climate control. Input and 

output quantities are plotted on 

the axes. 

The linguistic output variable, 

Boiler, contains the following 

Fuzzy Sets: 

VerySmall 

Small 

Medium 

Big 

VeryBig 

Page 51 of 94 T 8.2 

T 8



Basic Set 


Topics 

� Continuous, discontinuous and quasi-continuous control 

� Recording and analysing step responses 

� Feedback within transmission systems 

� Output quantities of an open-loop control 

� Control systems with start time and dead time 

� Testing responses to set point changes and disturbance reactions. 

Page 52 of 94 T 8.2 

T 8



Basic Set 

The equipment allows experiments ranging from fundamental to 

university levels. Classic transfer elements of control technology 

are examined in the time domain. Digital controls for controller 

parameters along with time constants allow simple, user-friendly 

and precise device operation. Both continued and discontinued 

controller versions are available. The CASSY Interface allows 

computer assisted control and analysis. For university 

applications, additional simulation using WinFACT is 

recommended. 


Control of Electronic Lines 



1 734 011 Two Position Controller 



1 734 0891 Dead Time Element 

2 734 091 Digital Controlled System 

1 734 0951 2nd Order Transfer Element 



1 564 19EN Book: Control of Electronic Lines 



The front panels show the standard 

international block diagrams. 

Page 53 of 94 T 8.2 

T 8


T 8.2.4 Modules and Transfer Elements 

Supplementary Set 

PI controller built from discrete function blocks 


Topics 

� Manual adjustment of system parameters Kp, Ki, Kd 

� Measurement scales for instruments 

� Recording and analysing step responses 

� Modular PI and PID controller assembly 

� Quasi-continuous control of a 2nd order system. 

Page 54 of 94 T 8.2 

T 8


T 8.2.4 Modules and Transfer elements 

Supplementary Set 

With this supplementary course, controller or control systems are 

comprised of basic electronic modules (P, I, D elements) as well 

as summation points. This offers greater flexibility in experiment 

design. Many experiments within Electronic controlled systems 

T 8.2.3 can be reproduced in detail using the modules. There are 

also additional interesting experiments, such as quasi-continuous 

control of 2nd order systems. Here, the discontinuous controller 

adopts a quasi-continuous controller response using feedbacks. 

EQUIPMENT LIST T 8.2.4 – SUPPLEMENTARY TO T 8.2.3 

Modules and Transfer Elements 



1 734 03 P Controller 

1 734 04 Integral-Action Element 

1 734 05 Derivative-Action Element 

1 734 07 Summing point, 2 Inputs 

1 734 08 Summing point, 5 Inputs 



U A 

V 

10 

5 

0 

0 10 20 

Step responses of different transfer 

elements and controlled systems 

are recorded with CASSY Lab 2. 

Page 55 of 94 T 8.2 

T 8 

t / s




Topics 

� Digital controller using Sample & Hold 

� Digital controller using WinFACT 

� Digital controller using CASSY Lab 2. 

Page 56 of 94 T 8.2 

T 8



In contrast to electronic analogue controllers, digital 

controllers require programming. This can take place in a 

block-oriented way using WinFACT, or in the form of 

mathematical relationships using CASSY Lab 2. In both 

cases one has the advantage of adapting controller 

structure and parameters to the requirements of each 

individual process. Sampling control and digital software 

controllers are tested. Electronic control systems are used 

as controlled systems . 


Digital Control 



1 734 41 Sample and Hold Element 


1 734 08 Summing Point, 5 Inputs 




1 564 22EN Book: Digital Control 



Controller: software 

Controlled system: electronic hardware 

Page 57 of 94 T 8.2 

T 8



Frequency responses in form of Bode diagrams and circle diagrams can be recorded with CASSY 

Lab 2 as well as with WinFACT. The experiment procedure is the same in both cases. 


Topics 

� Measurement of Bode diagrams 

� Measurement of circle diagrams 

� Determining a system’s order 

� Simulation of technical control circuits. 

Page 58 of 94 T 8.2 

T 8



The measurements show the Nyquist plot and Bode diagram of 

a PT2 element, both plotted using CASSY Lab 2. The PT2 

element consists of two PT1 elements connected in series. 

CASSY Lab 2 provides graphing tools to analyse amplitude 

response curves. It is possible, among other things, to 

determine the slope of the curve. For PT2 elements, this 

measuring function results in an attenuation increase of 40 dB 

per decade of frequency. 


Recording of Frequency Responses 








1 564 20EN Book: Recording of Frequency Responses 



ATF 

1 

0,1 

0,1 1 10 

Page 59 of 94 T 8.2 

T 8 

f / Hz


T 8.2.7 Stability and Optimisation 


Topics 

� Controller settings for a controlled system with dead time 

� Stability testing of a 3rd order control system 

� Simulation of technical lines 

� Stability tests with Nyquist plots 

� Criteria for system optimisation 

� Controller optimisation according to integral criteria 

� Controller optimisation according to adjustment rules. 

Page 60 of 94 T 8.2 

T 8


T 8.2.7 Stability and Optimisation 

Stability testing and control circuit optimisation are among the 

most important tasks of control technology. Their results 

determine the usability of the planned application’s control. 

This equipment allows experiments for numerical optimisation of 

system parameters with the help of evolution strategies. 

Computer assisted optimisation is tested according to selectable 

quality criteria (e.g. ITAE, ISE, etc.). 


Stability and Optimisation 



1 734 04 Integral-Action Element 


1 734 08 Summing Point, 5 Inputs 





1 734 492 Software: WinFACT LD Licence 

1 564 21EN Book: Stability and Optimisation 



x 

V 

10 

0 

-10 

0 10 20 30 40 50 

Stability test of an electronically 

simulated gas flow control. The 

integral controlled system is 

governed by a PI controller. Depending 

on the selected control 

parameter, the closed loop control 

becomes unstable. 

Page 61 of 94 T 8.2 

T 8 

t / s 

10 

0 

-10 

x 

V


T 8.2.8 COM3LAB - Multimedia: Control Technology 


Topics (selection) 

� Analysis of controlled systems and controllers 

� Controlled systems with or without compensation using high-order 

systems 

� Analogue / digital control 

� Quality criteria and adjustment rules 

� Temperature, Speed and Intensity Control 

� Systems with dead time using cascade control 

� Frequency response curves using Fuzzy control. 

Page 62 of 94 T 8.2 

T 8


T 8.2.8 COM3LAB - Multimedia: Control Technology 

COM3LAB courses Control Technology I/II are multimedia 

courses with complete introductions to practical theory. 

Experiments are carried out in electronic as well as technical 

control systems (light, speed and temperature controlled 

systems). Analogue controllers and digital controllers are 

available. In course II, additional experiments are integrated 

for Nyquist plots, non-linear control and Fuzzy control. They 

are ideal courses for further understanding of the control 

technology world. 

The subject can be prepared and completed through the 

COM3LAB courses Operational Amplifier (700 81) and Sensor 

Technology (700 84). 


COM3LAB-Multimedia: Control Technology 



1 700 81 COM3LAB Course: Operational Amplifier 

1 700 82 COM3LAB Course: Control Technology I 

1 700 83 COM3LAB Course: Control Technology II 

1 700 84 COM3LAB Course: Sensor Technology 

1 700 00USB COM3LAB Master Unit 



U A 

V 

10 

5 

0 

0 10 20 

Step responses of different transfer 

elements and controlled systems are 

registered with a special transientresponse 

plotter. 

COM3LAB: organized lab, experimenttation 

almost without preparation. 

Page 63 of 94 T 8.2 

T 8 

t / s



T 8 

Page 64 of 94 T 8.2

INDUSTRIAL PROCESS CONTROL 


T 8.3 Industrial Process Control 

T 8.3 

Page 65 of 94 T 8.2



In the field of industrial control technology using commercial 

components, LD offers a variety of systems with practical features: 


Compact assembly, also suitable for small labs. 

Use of commercial components for training with real 

industrial devices. 

Computer analysis for a complete reporting. 

Compressed air is an easy-to-handle energy source used for 

training purposes. This is why the industrial control technology from 

LD works partially with pneumatic components. Pneumatic control 

technology can be supplementally connected to an industrial 

controller, e.g. a PLC. In addition, the subject area contains courses 

pertaining to industrial compact controllers as well as the control of 

industrial driving machines. 

Instrumentation in the industrial 

control technology can take 

place on an electric, pneumatic 

or hydraulic basis. Processrelated 

or security-related 

reasons, e.g. due to explosion 

hazard, make it necessary the 

use of pneumatic devices in 

many production branches. 

T 8.3 

Page 66 of 94 T 8.2



Pressure measurement with CASSY 

Pneumatic devices include: 


controller 

servo units 

measuring transducer 

Sensor-CASSY and two pressure sensors S are used to measure 

pressure. Analysis and reporting take place using the CASSY Lab 2 

software. 

Pneumatic components work in the standard pressure range from 

0.2 bar to 1.0 bar with Live Zero Technology, widespread in 

industrial applications. This process corresponds with 0.2 bar = 0% 

and 1.0 bar = 100%. The auxiliary power supply has a standard 

value of 1.4 bar, equivalent to the voltage supply in electronic 

devices. A pressure energy line exists with 2 bar (E1) as the 

process energy flow. 

Relationship between absolute 

and relative pressure using Live 

Zero. 

The pneumatic valves of the following devices are provided with electronic controls for Sensor- 

CASSY, allowing simple experiment procedures. Thanks to this system, pressure jumps or load 

variations can be easily and precisely controlled by the computer. 

Process control with CASSY 

T 8.3 

Page 67 of 94 T 8.2





T 8.3.8 


Electro-Pneumatics 

T 8.3.7 

Heating Control 

T 8.3.6 

Control of an Industrial 

Machine 300 W 

T 8.3.5 

Control with Compact 

Controllers 

T 8.3.4 

Process with Industrial 

Control 

T 8.3.3 

Extended Pneumatic 

Systems 

T 8.3.2 

Pneumatic Controllers 

T 8.3.1 

Basics Pneumatic Control 

T 8.3 

Page 68 of 94 T 8.2




T 8.3.1 Basics Pneumatic Control 

Basic equipment for industrial pneumatic control technology: 

operation of the air supply station, pressure adjustments, as well as 

handling compressed-air hoses, compressors and other basic, 

fundamental components. 

T 8.3.2 Pneumatic Controllers 

In addition to the complete control stations, controllers are also 

used as individual components and master control stations. 

Characteristics and curve families of different control blocks and 

master control stations are studied. 

T 8.3.3 Extended Pneumatic Systems 

This supplement to the basic T 8.3.1 Basic Pneumatic Control 

Technology course supports experiments for high-order pneumatic 

systems. 

T 8.3.4 Process with Industrial Control 

This supplement to the basic T 8.3.1 Basic Pneumatic Control 

Technology equipment connects the controller to real industrial 

processes. The requirements for the industrial controller (PLC) are 

addressed in this project. 

T 8.3.5 Control with compact Controllers 

The core of this equipment is the Siemens industrial controller 

SIPART DR 19. The controller is configured for real technical / 

electronic controlled systems as well as for virtual controlled 

systems. 

T 8.3.6 Control of an Industrial Machine 300 W 

Speed control using an industrial machine as a model. 

T 8.3.7 Heating Control 

Model construction of a bivalent heating system for a building with 

real hot water circuits and thermal solar panels. 

T 8.3.8 COM3LAB-Multimedia: Pneumatics / Electro Pneumatics 

These basic pneumatics and electro pneumatics courses impart 

knowledge about relay circuits and pneumatic valve control. 


T 8.3 

Page 69 of 94 T 8.2



Computer assisted experimentation in a pressure-controlled system 


Topics 

� Setup procedure for the control station 

� Venting and draining pneumatic devices 

� Setting the direction of action and operating the manual-automatic switch 

� Adjusting the operating point 

� Recording pressure jumps and curve families 

� Response to set point changes and disturbance reactions 

T 8.3 

Page 70 of 94 T 8.2



Control system with air 

Two air supply stations provide outputs with 1.4 bar for the 

auxiliary line AUX and 2.0 bar for the process energy. A servo 

valve controls the air flow for the attached pressure controlled 

system (here: buffer storage tank). The valve position is controlled 

using the actuating pressure of the signal line. As the valve is 

closed when control pressure goes up, the direction of action 

should be set to on the controller. 

Training systems for pneumatic control technology are divided 

into one basic course and two follow-up courses. 


Basics Pneumatic Control 



1 744 905 Filter-Air Pressure Supply Combination 

1 744 912 Pressure Step Generator 

1 744 941 Control Valve 

1 744 942 Pressure Control System 

1 744 943 Buffer Accumulator 

1 744 963 P/PI Control Station 

1 524 013SUSB CASSY 2 Starter USB 

2 524 064 Pressure Sensor S, ± 2000 hPa 

1 568 042 Book: Basics Pneumatic Control 



p X 

bar 

p X 

bar 

1 

0,5 

0 

1 

0,5 

0 

0 10 20 

Step response when controlling 

with a PI controller. The relative 

amplification is: XP = 100 %. 

0 10 20 

Step response when controlling 

with a PI controller. Relative 

amplification: XP = 5 %. 

T 8.3 

Page 71 of 94 T 8.2 

t / s 

t / s 

1 

0 

1 

0,5 

0 

0,5 

p W 

bar 

p W 

bar



Experiments using various pressure controllers 


Topics 

� Experiments on transfer elements 

� Curve families of P, PD and PI elements 

� Recording step responses 

� Closed control circuit with delay element. 

T 8.3 

Page 72 of 94 T 8.2



In the chemical industry, applications exist which require higher 

demands on security, speed, or force adjustment, i.e., during 

tunnel construction, on drilling platforms, or in areas with high risk 

of explosion. These applications depend on non-electrical control 

systems with pneumatic or hydraulic instrumentation. Pneumatic 

instrumentation has the advantage of a readily available energy 

source (compressed air) for training purposes. That is why 

experiments that utilise pneumatic devices in teaching activities 

are easier to implement than, for example, hydraulic experiments. 

In order to supply pneumatic components, one can rely on one’s 

own private compressed air installation. If necessary, the 

experiments can also be easily carried out using a compressor. 


Pneumatic Controllers 





1 744 913 3/2-Way Valve 

1 744 951 Time Delay Element, Two-Fold 

1 744 961 PID Controller 

1 744 962 Supply Line Station 


1 744 965 PD Control Station 



1 568 162 Book: Pneumatic Controllers 



p y 

% 

100 

50 

0 

0 50 100 

Curve family of a P controller for 

different relative amplifications 

XP/%. 

T 8.3 

Page 73 of 94 T 8.2 

p x / %



Experiment setup for measuring step responses on 2nd order delay elements 


Topics 

� Step responses of delay networks 

� Testing high-order controlled systems 

� Response to set point changes and disturbance reactions of pneumatic 

controlled systems 

� Using P and PI controllers in control circuits. 

T 8.3 

Page 74 of 94 T 8.2



Similar to electric control technology, high-order pneumatic 

systems are implemented here by the series connection of delay 

elements. Two preset pressures are switched within the controlled 

system with an electromagnetic 3/2 way valve through a 

pneumatic pressure jump transducer. Command of the pressure 

jump transducer and system pressure analysis are carried out 

using Sensor-CASSY and CASSY Lab 2. 

Also in pneumatic control circuits, step responses supply 

important information about the dynamic and stationary system 

behaviour. CASSY instruments clearly show the standard signal 

0% to 100% with life-zero scaling. 

Experiments on pneumatic control technology teach necessary 

skills for handling flexible tubes, couplings, water separators, etc. 


Extended Pneumatic Systems 





1 744 941 Control Valve 

1 744 942 Pressure Control System 

1 744 951 Time Delay Element, Two-Fold 

1 744 952 Isolation Amplifier 




1 566 152 Book: Systems Extended Pneumatic Systems 



p y 

% 

100 

50 

0 

Differenz: t = 28,62 s, py = 0,0 % 

Differenz: t = 3,37 s, py = 0,0 % 

0 50 100 

Step response and analysis for a 

2nd order pneumatic system. 

T 8.3 

Page 75 of 94 T 8.2 

t / s



The pneumatic process improves pressure control using industrial pneumatic components, e.g., by 

integrating a PLC controller. 


Topics 

� Preparing compressed air systems and cleaning water separators 

� Assembly and start-up procedures of pneumatic systems 

� PLC Programming 

� Linking PLC and pneumatic processes 

T 8.3 

Page 76 of 94 T 8.2



This equipment works with real industrial components from the 

field: 


Pneumatic control technology 

PLC. 

A novelty in practice-oriented training. 

EQUIPMENT LIST T 8.3.4 – Supplementary Set to T 8.3.1 

Process with Industrial Control 


1 730 4011 LOGO! (24 V-Version with Transistor Outputs) 

1 564 23EN Book: PLC Pneumatic Control and Industrial 

Compact Controller 



Industrial controller in the form of 

the Siemens LOGO! 

T 8.3 

Page 77 of 94 T 8.2


T 8.3.5 Control with Compact Controller 

The SIPART Compact Controller works within an electronic controlled system. 


Topics 

� Setup procedure for the SIPART DR19 control station 

� Integrating controllers in different control circuits. 

T 8.3 

Page 78 of 94 T 8.2


T 8.3.5 Control with Compact Controller 

Controllers for industrial applications should be robust and 

versatile in use. As a rule, their settings are rarely modified and 

carry out their functions over long periods of time. However, the 

requirements of didactic controllers that are used for training are 

entirely different. The settings of these controllers are frequently 

modified and usually work for a short time within the same 

processes. 


Control with Compact Controller 



1 734 431 Compact Controller 


1 734 19 Gain and Offset Adjust 

1 734 262 Liquid Controlled System 

1 734 81 Differential Pressure Transducer 

1 734 876 Immersion Tube 

1 524 016S2 Profi-CASSY-Starter 

1 564 23EN Book: PLC Pneumatic Control and Industrial 

Compact Controller 



The Compact Controller 734 431 

contains the Siemens Industrial 

Controller Module SIPART DR 19. 

T 8.3 

Page 79 of 94 T 8.2


T 8.3.6 Control of Industrial Machine 300 W 


Topics 

� Use of manual-automatic switches 

� Preliminary manual adjustment of control circuits 

� Speed control 

� Recording step responses 

� Dimensioning controllers 

T 8.3 

Page 80 of 94 T 8.2


T 8.3.6 Control of Industrial Machine 300 W 

This equipment works with an industrial machine in motoroperation. 

In the experiment one is trained to handle the mains 

voltage. 


Controlling a 300 W Industrial Machine 





1 734 16 Manual/Automatic Switch 

1 734 19 Gain and Offset Adjust 

1 734 22 Actuator 115...230V/1KW 

1 731 91 Shunt Wound Machine 0.3 

1 731 09 Tachogenerator 0.1/0.3 

1 524 016S2 Profi-CASSY-Starter 

1 568 062 Book: Applied Process Control System I 



T 8.3 

Page 81 of 94 T 8.2



Training systems used to control heating and water service in buildings. 


Topics 

� Security of electric resources 

� Carrying out electric connections in the basement boiler room 

� Measuring power 

� Equipotential bonding 

� Regenerative energy sources 

� Measuring heating characteristic curves 

� Adjusting heating controllers. 

T 8.3 

Page 82 of 94 T 8.2



Using heating circulation pumps and real water circuits. 

Radiators with Peltier elements can be actively heated up and 

cooled down, producing actual temperature measurements in 

time-lapse analyses. Heating buildings using solar-assisted 

technology to heat service water. 


Training profiles: 

Plant mechanic for sanitary, heating, and air conditioning 

systems 

Electronic technician for automation technology 

Industrial electrician specialising in devices and systems. 


Heating Control 


1 734 800 Heater Control 



Circulation pump for heating circuit. 

Radiator with temperature selector 

Bypass with flow meter 

T 8.3 

Page 83 of 94 T 8.2


T 8.3.8 COM3LAB-Multimedia: Electro Pneumatics 

Space-saving multimedia training systems can also be used as alternatives to extensive test stands 

and experiment boards. Combining the COM3LAB Electro Pneumatics Course and the Pneumatics 

Board results in an improved experiment setup, with low space requirement while still advancing 

further into pneumatics. 


Topics 

� Fundamentals of Pneumatics / Electro pneumatics 

� Pneumatic and electric circuit diagrams 

� Master control with single-acting cylinder 

� Master control with double-acting cylinder 

� L network controller 

� Basic circuits with AND/OR operations 

� Basic network with electric self-holding circuits 

� Path-dependent controller 

� Time-dependent and pressure-dependent controllers, pull-in and dropout 

delayed 

� Sequence controllers. 

T 8.3 

Page 84 of 94 T 8.2


T 8.3.8 COM3LAB-Multimedia: Electro Pneumatics 

The COM3LAB course Electro Pneumatics imparts basic 

knowledge of pneumatics and electro pneumatics. The operation 

principles of pneumatic and electric circuits are graphically 

presented with the help didactical standard exercises. The 

COM3LAB Board is combined with an Industrial Valve 

Technology Board, or a COM3LAB Pneumatic Board, for 

experimentation. The course contains the following components: 


Relay, 4 change-over contacts 

Timing relay (pull-in and drop-out delayed) 

P/E converter 

Pressure sensor 0 - 10 bar 

Operation and observation elements 

24 V voltage supply. 

The COM3LAB course Pneumatics Board (700 351) is a 

supplement to the COM3LAB Electro Pneumatics Course. The 

Pneumatics Board is directly connected to the COM3LAB Electro 

Pneumatics Course, which monitors the status of components 

through the cylinder’s integrated displacement sensor. 

Components: 

Single-acting cylinder, spring recoverable with capacitive limit 

switch 

Double-acting cylinder with displacement sensor and cylinder 

switch 

Throttle check valves 

5/2 way valves electrically operated, spring recoverable 

5/2 way valves electrically operated, pulse valve 

Central closing valve for pressure supply 

Displacement sensor for the double-acting cylinder. 


COM3LAB-Multimedia: Electro Pneumatics 


1 700 00 USB Master Unit 

1 700 35 COM3LAB Course: Electro Pneumatics 

1 700 351 COM3LAB Course: Pneumatics Board 

1 Compressor 



U A 

V 

10 

5 

0 

0 10 20 

T 8.3 

Page 85 of 94 T 8.2 

t / s


Equipment Sets T 8.1 

Cat.-no. Description 8.1.1.1 

311 87 Dial Gauge 1 

700 11 C3L-Course: DC Technology I 1 

700 12 C3L-Course: DC Technology II 1 

700 13 C3L- Course: AC Technology I 1 

700 14 C3L- Course: AC Technology II 1 

700 84 C3L- Course: Sensor Techno. 1 

727 41 Measurement Value Indicator (1) (1) 

727 549N Basic Set T 6.1.11 

727 66 DC Bridge Amplifier 1 1 

734 02 Reference Variable Generator 1 

734 13 Power Amplifier 1 

743 301 Standard Kit Sensors 1 

734 302 Extension Kit Sensors 1 

734 303 Case Test Samples 1 

734 304 Teachware Sensoric 1 

734 38 Oven Model 20 V, 20 W 1 

734 55 Strain Gauge Transducer 1 

734 56 Tensile Test Bar 1 

734 565 Torsion Bar 1 

734 74 NiCr-Ni Thermoelement 1 

734 75 Thermocouple Connection 1 

734 76 Pt-100 Resistance Probe. 1 

734 77 NTC Temperature Probe 1 

(): Recommended 


8.1.2.1 

8.1.2.2 

8.1.2.3 

8.1.3 

T 8.2 

Page 86 of 94 T 8.2





Accessories 

315 36 Set of 7 Weights, 0.1 to 2 kg 1 

500 98 6 Safety Adapter Sockets, black 1 

501 48 Set of 10 Bridging Plugs 2 

501 511 Set of 10 Bridging Plugs 2 3 

501 512 Set of 10 Bridging Plugs with 

Tap 

8.1.2.1 

8.1.2.2 

1 1 

501 532 Set of 30 Connecting Leads 1 1 1 

524 013SUSB CASSY 2 Starter USB 1 1 1 

562 793NA Power Supply 6 - 24 V 1 

577 32 Resistor 100 , 2 W 3 

577 38 Resistor 330 , 2 W 3 

577 60 Resistor 22 , 0.5 W 1 

577 64 Resistor 47 , 0.5 W 1 

577 657 Resistor 68 , 0.5 W 1 

577 68 Resistor 100 , 0.5 W 1 

577 71 Resistor 220 , 0.5 W 1 

577 97 Resistance Decade 1 

664 121 Beaker 1 

700 00USB Master Unit 1 

700 00CBTDE COM3LAB Software German 1 

726 09 Panel Frame T 130 1 1 

726 50 Plug-In Board 997 x 300 1 

726 86 Stab. Power Supply 15 V / 3 A 1 1 

726 88 AC/DC Stabilizer 1 

726 961 Function Generator 200 kHz 1 

Literature 

565 851 Electronic Meas.Device Circuits 1 

568 271 Force Meas. with Strain Gauge 1 

568 301 Temperature Measurement 1 

8.1.2.3 

8.1.3 

T 8.2 

Page 87 of 94 T 8.2




666 630 Blower 1 

666 633 Thermal Anemometer 1 

666 632 Windmill Type Anemometer 1 


8.2.1.2 

8.2.1.3 

700 81 C3L: Operational amplifier 1 

700 82 C3L: Control Technology I 1 

700 83 C3L: Control Technology II 1 

700 84 C3L: Sensor Technology 1 

734 011 Two-Position Controller 1 1 

734 02 Reference Variable Generator 1 1 1 1 1 1 1 1 1 

734 03 P Controller 1 

734 04 I Element 1 1 

734 05 D Element 1 

734 064 PID Digital Controller 1 1 1 1 1 1 1 1 1 1 

734 07 Summing Point, 2 Inputs 1 

734 08 Summing Point, 5 Inputs 1 1 1 

734 0891 Dead Time Element 1 1 1 

734 091 Digital Controlled System 2 1 2 2 

734 0951 2nd Order Transfer Element 1 1 1 

734 111 Set of Machines 10 W 1 1 

734 12 Temperature Controlled System 1 1 

734 13 Power Amplifier 2 2 

734 262 Liquid Controlled System 1 1 

734 264 Additional Reservoir (1) 

734 300 Listing Controlled System 1 1 

734 311 Light Controlled System 1 

734 41 Sample and Hold Element 1 

734 481 WinFACT C3L / CASSY Edition (1) (1) (1) (1) (1) (1) (1) (1) 1 1 (1) 

734 491 WinFACT LD Licence 1 1 

734 81 Diff. Pressure Transducer 1 

734 861 Capacitive Bar-Type Probe (1) 

734 876 Immersion Tube 1 

734 881 Level Switch with Float (1) 

734 89 Capacitive Level Switch (1) 

(): recommended 

8.2.1.4 

8.2.1.5 

8.2.1.6 

8.2.1.7 

8.2.2 

8.2.3 

T 8.2 

Page 88 of 94 T 8.2 

8.2.4 

8.2.5 

8.2.6 

8.2.7 

8.2.8





Accessories 

510 48 Pair of Magnets 1 1 

8.2.1.2 

8.2.1.3 

501 511 10 Bridging Plugs, black 2 2 2 2 1 1 2 3 3 3 3 3 3 

501 512 10 Bridging Plugs with Tap 1 1 1 1 1 1 1 1 1 1 1 1 1 

501 532 30 Connection Leads, 1 mm² 1 1 1 1 1 1 1 1 1 1 1 1 1 

524 016S2 Profi-CASSY-Starter 2 USB 1 1 1 1 1 1 1 1 1 1 1 1 1 

700 00CBTEN C3L-Software English 1 

700 00USB C3L Master Unit (USB) 1 

726 09 Panel Frame, T130, Two Levels 1 1 1 1 1 1 1 1 1 1 1 1 1 

726 86 Stab. Power Supply +/-15V/3 A 1 1 1 1 1 1 1 1 1 1 1 1 1 

Literature 

564 19EN Control of Electronic Systems 1 1 

564 20EN Measurement of Frequency 

Responses 

564 21EN Stability & Optimisation 1 

564 22EN Digital Controllers 1 

564 24EN Control of Technical Systems 1 1 1 1 1 1 1 

568 222 Fundamentals of Automatic 

Control Technology II, Vol. 2 

568 232 Fundamentals of Automatic 

Control Technology II, Vol. 1 

568 342 Flow Measuring of Gases 1 

8.2.1.4 

8.2.1.5 

8.2.1.6 

1 1 1 1 1 1 1 1 1 

8.2.1.7 

8.2.2 

8.2.3 

1 1 

T 8.2 

Page 89 of 94 T 8.2 

8.2.4 

8.2.5 

8.2.6 

1 

8.2.7 

8.2.8



Cat.-no. Description 8.3.1 

700 35 C3L: Electro Pneumatics 1 

700 351 C3L: Pneumatics Board 1 

730 4031 LOGO! 1 

731 91 Shunt Wound Machine 0.3 1 

734 02 Reference Variable Generator 1 

734 064 PID Digital Controller 1 

734 091 Digital Controlled System 1 

734 16 Manual / Automatic Switch 1 

734 19 Gain and Offset Adjust 1 1 

734 22 Actuator 115...230 V / 1 KW 1 

734 262 Liquid Controlled System 1 

734 81 Diff.l Pressure Transducer 1 

734 800 Heater Control 1 

734 876 Immersion Tube 1 

734 431 Compact Controller 1 

744 912 Pressure Step Controller 1 1 1 

744 913 3/2 Way Valve 1 

744 941 Servo Valve 1 1 

744942 Pressure Control System 1 1 

744 943 Buffer Accumulator 1 

744 951 Time Delay Element, two Fold 1 1 

744 952 Isolation Amplifier 1 

744 961 PID Controller 1 

744 962 Supply Line Station 1 

744 963 P/PI Control Station 1 1 1 

744 965 PD Control Station 1 


8.3.2 

8.3.3 

8.3.4 

8.3.5 

8.3.6 

8.3.7 

8.3.8 

T 8.2 

Page 90 of 94 T 8.2



Cat.-no. Description 8.3.1 


Accessories 

524 016S2USB CASSY 2 Starter USB 1 1 1 1 1 

524 064 Pressure sensor S, 2000 hPa 2 2 2 

531 583 Multimeter METRAport 40S 3 

700 00USB Master Unit 1 

700 00CBTEN COM3LAB Software English 1 

725 25 Panel Frame VT150, 3 Levels 1 1 1 

726 09 Panel Frame T130, 2 Levels 1 1 

726 86 Power Supply 15V / 3A 1 1 

731 09 Tachogenerator 0.1/0.3 1 

731 06 Coupling 0.1/0.3 1 

731 08 Coupling Guard 0.1/0.3 1 

731 07 Shaft End Guard 0.1/0.3 2 

744 900 Compressor Type V01-10 1 1 1 1 

744 902 Compressor Connection Hosing 1 1 1 1 

744 905 Filter / Pressure Supply Comb. 1 1 1 

744 906 Pneumatic Hose Couplers 1 1 1 

500 59 Set of 10 Safety Bridging Plugs 1 

500 611 Safety Conn. Lead, 25 cm, red 6 

500 611 Safety Conn. Lead, 25 cm, red 6 

500 612 Safety Conn. Lead, 25 cm, blue 6 

500 641 Safety Conn. Lead, 1 m, red 6 

500 6421 Safety Conn. Lead, 1 m, blue 6 

501 511 10 Bridging Plugs, black 1 1 1 3 2 

501 512 10 Bridging Plugs with Tap 1 1 

501 532 30 Connection Leads, 1 mm² 1 1 

Literature 

568 042 Fund. of Pneumatic Control 1 

568 162 Pneumatic Controller 1 

568 152 Extended Pneumatic Systems 1 

564 23EN Process with Industrial Control 1 1 

568 062 Applied Control Technology 1 

83.2 

83.3 

83.4 

8.3.5 

83.6 

83.7 

8.3.8 

T 8.2 

Page 91 of 94 T 8.2


Keywords 

2 

2nd order system, 8 

3 

3D characteristic field, 52 

A 

Amplitude response, 60 

Anemometer, 40 

Attenuation, 60 

Automation, 3 

Auxiliary power supply, 68 

B 

Block diagrams, 54 

Bode diagram, 59 

Buffer storage tank, 72 

C 

Circle diagram, 59 

Closed loop mode, 36 

Compact controllers, industrial, 67 

Compressor, 70 

Control algorithms, 50 

Control system parameter, manual adjustment, 55 

Control systems with dead time, 53 

Control systems with start time, 53 

Control technology, industrial, 67 

Control technology, multimedia course, 64 

Control, continuous, 53 

Control, discontinuous, 53 

Control, quasi-continuous, 53 

Controlled systems, 58 

Controller parameters, 54 

Controller, digital, 57 

Curve families, 73 

Cylinder, double-acting, 85 

D 

Delay network, 75 

Differential pressure sensor, 37 

Direction of action, 71 

Displaying processes, 33 

Disturbance reaction, 34, 42, 71 

E 

Electro pneumatics, 85, 86 

Energy sources, regenerative, 83 

Equipotential bonding, 83 

Evolution strategy, 62 


T 8.2 

Page 92 of 94 T 8.2


F 

Feedback, 53 

Flow, 35 

Fluid controlled systems, 35 

Follow-up control, 48 

Frequency response, 59 

Fuzzy control, 49, 50 

Fuzzy set, 52 

H 

Heating characteristic curve, 83 

Heating circulation pump, 84 

Heating controller, 83 

Heating of buildings, 84 

Heating of service water, 84 

I 

Immersion pipe, 37 

Incremental transducer, 7 

Industrial valve technology, 86 

Integral criteria, 61 

ITAE, 62 

L 

Level, 35 

Light controlled systems, 41 

Linguistic output variable, 52 

Linguistic rules, 49 

Live Zero, 68 

M 

Master control, 85 

Master control station, 70 

Measuring instrument, scale, 55 

Multimedia, 26 

O 

On-off controllers with delayed feedback, 23 

Open loop mode, 36 

Open-loop control, 53 

Optimisation, numerical, 62 

P 

Parameter, 7 

Peltier elements, 84 

PLC controller, 77 

Plotter, 47 

Pneumatics, 85 

Position control, 45 

Pressure jumps, 68 

Pressure sensor, 86 

Process control, 68 


T 8.2 

Page 93 of 94 T 8.2


Process visualisation, 47 

PROFIBUS interfaces, 10 

Profi-CASSY, 10, 47 

Programming, block oriented, 58 

Programming, with mathematical relationships, 58 

PT1 element, 60 

PT2 element, 60 

Q 

Quality criteria, 62 

R 

Response speed, 32 

Response to setpoint changes, 42, 71 

S 

Sample & Hold, 57 

Sampling element, 57 

SCADA, 33 

Sequence controllers, 85 

Servo valve, 72 

Signal line, 72 

Simulation, 54 

Simulation of technical control circuits, 59 

SIPART DR 19, 70 

Slope, 60 

Software controllers, 58 

Step response, 35, 53 

Summation points, 56 

System optimisation, 61 

System order, determination, 59 

T 

Temperature sensor, 34 

Thermal cross, 40 

Thermosensor, 40 

Throttle check valves, 86 

Time constants, 32, 54 

Transfer elements, classic, 54 

V 

Valve, pneumatic, 68 

W 

Water separator, 77 

WinFACT, 47 


T 8.2 

Page 94 of 94 T 8.2

LD DIDACTIC GMbH 

Leyboldstraße 1 

D- 50354 Hürth 

Tel.: +49(0)2233- 604-0 

Fax: +49(0)2233- 604-222 

E-Mail: info@ld-didactic.de 

www.ld-didactic.com 

www.LD-DIDACTIC.COM 

1345002- T8 Measurement and Control Technology– 22.12

MEASUREMENT AND CONTROL TECHNOLOGY - LD DIDACTIC

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