Lesson 1 - Introduction to Controls


Process dynamics; Current, position, and time proportioning; Controller modes, actions, terminology, and options; Loop accuracy

Learning Objectives:
– Describe the kinds of controllers most often used in industrial applications.
– Discuss six important problems of process dynamics that controllers must overcome.
– Compare the actions of current proportioning, position proportioning, and time proportioning.
– Name four kinds of controller alarms.
– Discuss the importance of safety in control loops.

Lesson 2 - Controller Operations


Automatic/manual control; Range and span; Direct-, reverse-acting, on/off, and proportional controllers; Current, time, and position-proportioning control; Control strategies

Learning Objectives:
– Explain why automatic/manual control is necessary.
– Explain how on/off controllers work and discuss the difference between on/off and proportional controllers.
– Describe a basic controller tuning process.
– Describe current-, time-, and position-proportioning controllers and name possible uses for each.
– Explain how split control works.

Lesson 3 - Controller Modes and Tuning


Proportional mode; Offset; Integral mode (reset); Derivative mode (rate); Single, two, and three mode controllers; Loop tuning; Step-change response

Learning Objectives:
– Describe the effect of the proportional, integral, and derivative modes on a controller's response to process changes.
– Discuss proper uses for the proportional, integral, and derivative modes.
– Explain how the proportional, integral, and derivative modes affect the tuning of a controller.
– Describe the procedure for tuning a controller by the step-change response method.

Lesson 4 - Special Controller Applications and Options


Cascade, feedforward, ratio, and auctioneering control; Hardware options; Remote setpoint; Auxiliary outputs; Indicators; Limits and alarms

Learning Objectives:
– Compare cascade, feedforward, ratio, and auctioneering control strategies.
– Describe three optional features used with auto/manual controllers.
– Discuss the use of remote setpoint, auxiliary outputs, and several kinds of indicators as hardware options for controllers.
– Explain how input signal conditioning, anti-reset windup, adaptive gain, error-squared calculation, and setpoint/output ramp and clamp affect controller operation.
– Discuss the use of limit and alarm options available for controllers.

Lesson 5 - Maintaining Controller Systems


Preventing problems; Electrical noise and suppression; Regulating power; Electrical coupling; Temperature variation; Troubleshooting

Learning Objectives:
– Describe five ways of suppressing electrical noise.
– Discuss the effects of an inadequate power supply and explain how to regulate it.
– Describe ways to avoid the harmful effects of electrical coupling.
– Explain how temperature variations affect controllers.
– Describe the kinds of equipment and proper connections needed to test controllers.
– Discuss elements of effective controller maintenance and troubleshooting.