Engineering tools
Automation and instrumentation tools
Calculators for the control panel and the plant floor: scaling 4–20 mA and 0–10 V signals into engineering units and PLC counts, sizing pump motors from flow and head, PID tuning from a step test, PT100 resistance and wiring errors, and tank volume from level.
These are the calculations we do while commissioning control systems: turning a loop current into a pressure the operator can read, checking that a transmitter and a PLC channel are ranged the same way, and putting the right motor behind a pump. Each tool states its formula and where the numbers come from.
4–20 mA signal scaling calculator
Convert a 4–20 mA, 0–20 mA or 0–10 V signal into percent of span, engineering units and a PLC raw count, and back again, with the NAMUR NE 43 fault bands and the voltage the loop current produces across the receiver's sense resistor.
Open tool →Pump power and motor sizing calculator
Work out hydraulic and shaft power from flow, head and fluid density, pick the next standard IEC motor rating with a margin, and see the electrical input, line current, motor loading and the specific energy in kWh per cubic metre that decides the electricity bill.
Open tool →PID tuning calculator (step test and ultimate gain)
Turn an open-loop step test (process gain, time constant, dead time) or a closed-loop ultimate test (Ku, Pu) into P, PI or PID settings by the Ziegler–Nichols and SIMC rules, in gain and times or proportional band and repeats per minute, with the parallel-form Ki and Kd.
Open tool →PT100 and PT1000 resistance–temperature calculator
Convert a PT100 or PT1000 temperature to resistance and back with the IEC 60751 Callendar–Van Dusen equation, see the sensitivity and tolerance class at that temperature, and find out how much a 2-, 3- or 4-wire connection with real lead resistance adds to the reading.
Open tool →Tank volume and level calculator
Turn a measured level into litres for a horizontal cylinder, a vertical cylinder or a rectangular tank: capacity, volume and mass at the level, the 4–20 mA the transmitter gives, the error a linear PLC scaling makes on a horizontal tank, and a strapping table to load into the PLC.
Open tool →Signals and drives, not just arithmetic
Most commissioning faults we are called to are not broken hardware; they are a transmitter ranged 0–16 bar feeding a PLC block scaled 0–10 bar, or a pump motor chosen from the pump's nameplate rather than its duty point. The tools here make those numbers explicit so they can be checked against the drawings before power is applied. For the reasoning behind each one, read the paired automation guides.