EQUIPMENT 1: FLOPPER NOZZLE

INTRODUCTION

The flopper nozzle system mainly consists of a current to pressure converter. The pneumatic
signal is used to actuate pneumatic controllers, control valves, and other pneumatic
positioners particularly used in chemical and petrochemical industries where there is a fire
risk and hence electric motor cannot be used.

THEORY OF OPERATION

The pickup system consists of coil situated in the air gap of the permanent magnet. The
converter consists of nozzle, restructure and the baffle plate on beam which is mounted on
beam pivot. The converter serves to convert the force on the coil (produced by 4-20mA input
signal) in to movement of the baffle plate, which closes nozzle and so increases the pressure
in connecting pipe. The pneumatic relay consists of diaphragm valve seat and needle and
capillary tube.

The increased pressure in connecting tube causes the diaphragm to move down closing the
port below it. This results in a pressure build up on the top surface of the double membrane
which is connected to the valve needle. The valve is opened till the pressure equilibrium, on
both sides of the double membrane is restored. When the valve opens to restore equilibrium,
the supply air flows directly to the outlet, with a pressure proportional to the valve opening.

- +
P Pi

x
apper
F
Air Supply Ps
d
d

4
Fixed Restriction to
20mA
Nozzle

Current carrying coil

UNIT DESCRIPTION

The unit converts a standardized (0 - 20) mA or (4 - 20) mA in to a pneumatic output of (0.1 -

1)bar (0.2 - 1Kg/sqcm (or) 3 - 15 psi). The large output volume ensures quick response from
attached pneumatic elements. The relationship between input current and output pressure is
linear. The converter is robustly built for long term reliability and gives sustained accuracy.
An integral bracket is used for surface mounting of the converter. Pneumatic connections are
1/4" NTP internally threaded. Electrical connections are to a terminal block via a cable entry
compression gland. Span and zero adjustments are made by means of screw adjusters.

WORKING PROCEDURE OF THE UNIT

The unit has two modes of operation. One is Mechanical nozzle arrangement and the other
one is Electrical nozzle arrangement.

In the Mechanical nozzle arrangement mode of operation, the user has no need to give power
supply to the unit. He just will have to rotate the screw gauge connected to the flopper nozzle.
The variable point of the screw gauge will in turn be responsible for the movement of the
flopper to close the nozzle. The output will be shown in the gauge G3 in terms of pressure
output.

In the Electrical nozzle arrangement, the POT below the gauge is varied from (4 - 20) mA
range to obtain a differential value of pressure from (3-15) psi as output. The variable current
reading can be seen in the DPM and the variable pressure is indicated in the G2.

PRINCIPLE

Generally, Flopper-Nozzle method is used for current to Pressure conversion. When the
flopper moves to the left about its pivot less air will leak out and a large pressure will be
developed between the fixed restriction and nozzle. Regulated air supply enters through
restriction and comes out through the nozzle. In front of the nozzle, a flopper is fixed on a
pilot. So that the flopper is placed to move freely to and fro. One end of the flopper is placed
near the nozzle and other end is placed near the current carrying coil. This operating coil
energized by current flowing through it. As the current in the coil is increased, one of the
flopper moves towards the coil and hence the other end moves towards the nozzle.
Where
P0 = Back pressure, Psi
X = Distance between nozzle and flopper, mm

TECHNICAL SPECIFICATION ABOUT ELECTRICAL NOZZLE ARRANGEMENT

Input : (4-20) mA

Output Pressure : 3-15Psi.

Linearity : <1% of span.

Repeatability : <0.5% of span.

Hysteresis : <1% of span.

Air Supply : 30Psi

Maximum. Operating Temperature : (0-

50) °C. Pressure Connection : 1/4" NPT.

FRONTPANEL DIAGRAM

FLAPPER NOZZLE SYSTEM

AMMET
ELECTRICAL NOZZLE

CUR
m

VARI

FI
G G

PO A P H

I
H

TO
O MECHANICAL NOZZLE ARRANGEMENT

Vi Microsystems
APPLICATION

The Electrical signal converter is used as a linking component between electric or electronic
and pneumatic systems. It converts standard electric signals 0-20mA or 4-20mA, respectively
into the standard pneumatic signal 0.2 - 1.0 bar (3 - 15 psi/0.2 - 1.0 kg/cm) 2.
Due to its innovative construction principle based on a fixed coil and a low - mass (100mg)
moving permanent magnet, the Electrical signal converter is highly resistant to shocks and
vibrations.

PRINCIPLE OF OPERATION

The input current flows through the coil there by magnetizing the soft-iron yoke. The flux
lines of this system being exposed at the gap apply a force proportional to the input signal on
the permanent magnet which is made from a highly coercive metal.

The small magnet together with the flapper forms the moving parts, controlling the air
pressure at the nozzle which is proportional to the magnetic force. The air flowing from the
nozzle forms a restoring force balanced by the force applied to the magnet.

The nozzle is supplied with air through a throttle. And back pressure through power amplifier
gives proportional output. The described units are properly matched. Hence, a linear
correspondence of electric input and pneumatic output signals is achieved.

The direction of action of the converter is determined by the coil polarization.

Zero adjustment is made by twisting the tensioning band, on which the flapper is mounted.

Span adjustment is performed using the potentiometer connected with a resistor in parallel to
the coil.
EXPERIMENTAL SECTION

EXPERIMENT -
1 AIM
To study the characteristics of Flopper nozzle system using Mechanical Nozzle Arrangement.

REQUIREMENTS

1. VFNS-01 Unit.
2. Screw Gauge.
4. Different Nozzles.
3 Air compressor.

PROCEDURE

1. Switch ON the compressor.

2. Set the Air compressor output pressure to 20psi.
3. To set the valve positions HV1 fully closed, HV2 fully open.
4. Now vary the screw gauge slowly to vary the position of the flopper.
5. Note down the output of the pressure gauge (G3) reading and screw gauge readings.
NOTE

The screw gauge should be varied as slowly as possible to obtain the readings and also
ensure that the screw gauge is not rotated after the gauge has reached 20psi output pressure.

TABULATION

S. No Screw Gauge Output pressure (in

Reading Psi) (G3)
(µm)
RESULT

Thus the characteristics of Flopper nozzle system using Mechanical Nozzle Arrangement
was verified.
EXPERIMENT -

2 AIM

To study the characteristics of Flopper nozzle system using Electrical Nozzle Arrangement.

REQUIREMENTS

1. VFNS-01 Unit.
2. Current source
3 Electrical Nozzle Arrangement
4 Air compressor.

PROCEDURE

1. Switch ON the compressor.

2. Set the Air compressor output pressure (G1) to 20psi.
3. Switch ON the unit. Then the variable/fixed switch is in variable mode.

4. To set the valve position HV1 fully open, HV2 fully closed.

5. Vary the variable pot in terms of (4 - 20) mA as indicated and note down the
corresponding gauge pressure (G2).
6. To set the current source POT meter in maximum position and to set the
variable/fixed switch is in variable and fixed position for various flopper nozzle
arrangement.
TABULATION

S. No Current Signal mA Outlet pressure

Psi
(G2)

RESULT

Thus the characteristics of Flopper nozzle system using Electrical Nozzle Arrangement were
verified.
EQUIPMENT 2: PRESSURE MEASUREMENT TRAINER KIT

INTRODUCTION

Measurement of pressure has high importance in the field of science and technology.
Pressure measurement can be done by using a variety of transmitter. Use of strain gauge for
such a purpose can be studied using this trainer. This pressure measurement trainer (ITB-16-
CE) is designed to measure the pressure of the cylinder by using a diaphragm as a primary
transducer and strain gauge as a secondary transducer.

TECHNICAL SPECIFICATION

(i) Pressure Cell

Material : Stainless steel

Sensor : Diaphragm with strain gauge

Young's modulus : 2 x 1011 kg /m2

Type : Flange Mounting

Strain gauge : Wire wound resistance

Capacity : Vacuum 1200kg /cm2

Gauge Factor : 1.9 to 2.3

Bridge Resistance : 350 M +/- 1 M

Safety overload : 150 % of rated capacity

Max. Overload : 200 % of rated capacity

Operating Temperature : 10˚C - 55˚C

Accuracy : 0.5 % of full scale division

Linearity : 0.5 % of full scale division

Connection : Four core shielded cable

(ii) LED display

Size : 50 × 20 mm

Type : Common anode.

Display : 3.5 Digit

Segment : Seven Segment

Colour : Green

(iii) Power supply

Input : 230 V AC / 50 Hz

Outputs : +5 V / 1 A
-5 V /500 mA
+12 V / 500 mA
-12 V / 500 mA

ITB-16-CE unit

Working Temperature : 15°C to 50° C

Accuracy : 1.5 % of full scale division

Linearity : 1.875 % of full scale division

Size : 370 × 280 × 90 mm

Material : Mild Steel.

Pressure Cell setup

Size : 350mm × 350mm

Tank size : 110 × 300mm

Pump capacity : 150 Psi

Tank Capacity : 180 Psi

Gauge range : (0 - 100) Psig

FRONT PANEL DIAGRAM
FRONT PANEL DESCRIPTION
Power ON/OFF : It is used to switch ON/OFF the unit.

Transmitter Interface : Pressure Cell interfaced into the ITB-16-CE

Trainer kit through this interface.

Test Point (T1) : For measuring the pressure Cell input voltage.
Test point (T2) and (T3) : For measuring the Cell output current (V) across
T2 and T3

Zero adjustment POT : For zero Calibration.

T4 : For measuring the current to voltage converter

output voltage (mV).

Seven Segment 3.5 digit display : For displaying the pressure Cell output in terms of
Psi (Pound per square inch)
THEORY

Pressure Measurement

The term “pressure” refers to the force per unit area exerted by a fluid on a containing wall.

Principle of strain Gauges

If a metal conductor is stretched of compressed, its resistance changes on account of both

length and diameter of conductor change. Also there is a change in the value of resistivity of
the conductor when it is strained and this property is called piezo - resistive effect. Therefore,
resistance strain gauges are also known as piezo-resistive gauges. The strain gauges are used
for measurement of strain and associated stress in experimental stress analysis. Secondly,
many other detectors and transducers, notably the load cells, torque meters, diaphragm type
pressure gauges, temperature sensors, accelerometers and flow meters, employstrain gauges
as secondary transducers. Strain gauges may be attached to any elastic member on which
there exists a suitable plane area to accommodate them. This arrangement may then be used
to measure pressure applied to deform or deflect the member, provided that the resultant
strain is large enough to produce detectible outputs. Here diaphragm is used as the primary
transducer.

BASICS OF PRESSURE MEASUREMENT

Since pressure can be easily transduced to force by allowing it to act on a known area, the
basic methods of measuring force and pressure are essentially the same, except for the high
vacuum region where a variety of special methods not directly related to force measurement
are necessary.

Types of Pressure Measurement Devices:

In industrial applications the pressure is usually measured by means of indicating gauges or

recorders. These instruments may be mechanical, electro-mechanical, electrical or electronic
in operation.

i) Mechanical Instruments:

These instruments may be classified into two groups. The first group include those
instruments in which the pressure measurement is made by balancing an unknown force with
a known force. Instruments using this principle include manometers and ring and belt type of
gauges. The second group includes those instruments which employ the balancing of
unknown force through a force produced on a known area due to stress in an elastic member.
This group employs quantitative deformation of an elastic member for measurement of
pressure. The elastic members used are Bourdon tubes, bellows and diaphragms.
ii) Electro-Mechanical Instruments:

These instruments usually employ a mechanical means for detecting the pressure and electrical
means for indicating or recording the detected pressure.

iii) Electronic Instruments:

Electronic pressure measuring instruments normally depend on some physical change that can
be detected and indicated or recorded electronically.

Interfacing and Calibration Procedure

1. The pressure cell’s 9 pin. 'D' type male connector is interfaced to '9' pin 'D'
type female connector, fixed on the ITB-16-CE module.

2. First, fully open the tank air release valve and nullify the display by using zero
adjustment POT.

3. Apply the pressure of 50 Psig to the cylinder and adjust the gain POT to
display 50 Psig in the ITB-16-CE. The voltage across T5 and GND should be
2.5V.

4. After this initial calibration, the unit should not be disturbed until the
completion of the experiment.

SAFETY PRECAUTION

1. During offset adjustment, the pressure inside the cylinder should be 0 psig.

2. During the gain adjustment, the pressure should be 50 Psig and also voltage
across the T5 and GND should be 2.5V.

3. The cylinder should not be disturbed during the experiment.

4. Release the air from the cylinder, after completion of the experiment
otherwise wire wound strain gauge will damage.

5. If you are getting an unsatisfactory reading, then vary the zero and span POT
minimum to maximum.

6. Maximum pressure should not exceed 100 Psig.

7. Once calibrated, the setting should not be disturbed till the end of this
experiment.
 EXPERIMENTAL SECTION
AIM:

To study the characteristics of the pressure cell with respect to bridge voltage.

APPARATUS REQUIRED

i. ITB-16-CE Trainer kit

ii. Multimeter (mV)

iii. Pressure cell setup.

iv. Power chord

PROCEDURE

1. Install the pressure cell setup and interface the 9 pin D connector with ITB-16-
CEkit.

2. Connect the multimeter (in millivolt mode) across T2 and T3 for bridge
voltagemeasurement.

3. Switch "ON" the module

4. Initially, Open the air release valve and exhaust the tank inlet air nullify the
bridge voltage by using zero adjustment POT.

5. Now, close the opened air release valve. By pressing the pump piston, the
pumpsucks the air from atmosphere and supply it to the cylinder.
 Then, the pressurewill be developed in the cylinder and now measure the bridge
voltage (mV) across T2 and T3.

6. Gradually increase the pressure by pressing the pump piston and note down
thebridge voltage (mA) for corresponding gauge pressure.

7. Tabulate the readings and plot a graph between gauge pressure and bridge
voltage(mV).

8. Plot a graph between applied pressures versus bridge voltage (mV).

TABULAR COLUMN

Applied Gauge Bridge

pressure (PSI) pressu voltage
re Psi (mV)
MODEL GRAPH

RESULT

Thus the characteristics between pressure applied to the pressure sensor and the bridge
voltagewas studied and graph was plotted.
EQUIPMENT 3: CONTROL VALVE

INTRODUCTORY INFORMATION ABOUT CONTROL VALVE

A control valve is the usual mechanism for adjusting the input of the process
control system. It is used to control flow of fluid viz. air, water, gas, steam, coolant
water, vacuum, contaminated or viscous fluid, mild acids, alkalies non injurious to
body, stem, seating and gland packing.

The two types of control valves are

A. Single seat valve.

B. Double seat valve.

With a single seat valve, the valve position depends on both the unbalanced force
on the plug from the pressure drop across the valve and the force produced by the
motor. The effect of valve pressure drop can be minimized by using either a more
powerful motor or a valve positioner.

The advantages of using double seats are that the pressure drop forces on the plugs
are almost cancel, and also the flow capacity is up to 30 percent greater than for
single seat valve of same size.

Our control valve is a single seated control valve as the valve with two seats cannot
be tightly closed and cannot be used where positive shut off is essential.
TECHNICAL SPECIFICATION

PNEUMATIC CONTROL VALVE

Make : RK Valve
Type : Single seated globe
Flow Rate : 1000LPH (Max).
Trim Mat. : SS316
Characteristics : Equal %/ Linear/Quick Opening
Body Mat : CS Body
Spring Range : (0.2 - 1) Kg / cm
Medium : Water / Air.
Valve Action : Air to open. End
Conn. : 3/4" Flanged.

ROTAMETER

Source : TELELIN
Range : (100-1000) LPH
Type : Variable area Body
material : glass
Float material : SS 316 Tube
material : glass
End conn. : 3/4" Flanged.

PUMP

Source : Kirloskar/Equivalent
Model : PEARL
Speed : 2700 RPM
Voltage : 220/230 Volts AC
 Discharge : 1500(L.P.H.)
Motor rating : 0.5HP
Pipe size : 3/4"/1" PRESSURE

REGULATOR WITH GAUGE

Source : PLACKA Instruments & Controls/ABB.

Maximum input : 18kg / cm2 Output :
(0.2 - 1) kg / cm2 Special
Features : Regulator/Filter. End
connection : 1/4" BSP (F) Thread

PRESSURE GAUGE

Make : Waaree/manometer
Range : (0 - 30) Psi
Body material : SS
Size : 4”
Mounting : Bottom
End connection : 1/4" BSP Back connection

RESERVOIR TANK

Source : Self
Capacity : 15 liters
Body : MS with fiber coating.

VCVT - 03A UNIT

Size : 700 × 600 (Approx.) mm

Body Materials : Mild steel with powder coating.
POSITIONER

Supply : 20 psi constant

Instrument : (3-15) psi
Output : (3-15) psi
Action : Direct
Stem travel : (0 - 13) mm
FRONT PANEL DIAGRAM
FRONT PANEL DESCRIPTION

Power ON/OFF switch : Switch ON/OFF the unit. Pump

ON : Switch ON/OFF the pump. Pump

Indicator : To indicate the pump power. HV1

: Bypass hand valve.

HV2 : Inlet regulating valve for quick opening valve.

HV3 : Inlet regulating valve for equal percentage valve.

HV4 : Inlet regulating valve for linear valve.

HV5 : Pressure supplying valve for quick opening valve.

HV6 : Pressure supplying valve for equal percentage valve.

HV7 : Pressure supplying valve for linear valve.

HV8 : Vent valve.

G1 : To measure the pressure drop across the control valve

G2 : To measure the actuator pressure.

G3 : To measure the supply pressure for positioner.

CV1 : Quick opening control valve.

CV2 : linear control valve.

CV3 : Equal percentage control valve.

COMPONENTS OF CONTROL VALVE

CONTROL VALVE (ACTION AIR TO OPEN)

CONTROL VALVE CUT SECTION VIEW
CONTROL VALVE AND ITS COMPONENTS

Valve is essentially a variable orifice. Control valve is a valve with a pneumatic,

hydraulic, electric (a position dictated by primarily to throttle energy in a fluid
system and not for shutoff purpose. excluding solenoids) or other externally
powered actuator that automatically, fully or partially opens or closes the valve.
Depending upon the valve plug design, the control valves can be classified as quick
opening, linear and equal percent type.

The control valve consists of two major components

A. Actuator.

B. Valve.

The actuator is made of the following components

1. Flexible diaphragm.
2. Spring (usually) and spring tension element (range location element).
3. Plate, Stem and locknut.
4. Housing.
 EXPERIMENTAL SECTION
EXPERIMENT -1 AIM

To study the characteristics of quick opening (ON/OFF) control

valve. APPARATUS REQUIRED

* VCVT-03A

PROCEDURE

* Before conducting the experiment, make sure that availability of water in

reservoir tank. Fill clean and soft water in the reservoir.

* Connect air supply pipe to the regulator. Confirm there is no loose connection.

* Hand valve settings for ON/OFF control valve characteristics study; HV2 (the
regulating valve, which is provided at the inlet of control valve) and HV5 should
be fully open. Regulating valves of other control valves should be fully closed.

* Initially, set the output pressure of air regulator to 15 Psi by varying the knob.
The quick opening valve is fully open.

* Keep partially open the vent valve (HV8), when air regulator lifts to its
maximum range.
* Switch on the unit.

* Set the maximum flow in the rotameter by adjusting the bypass valve (HV1) and
inlet regulating valve (HV2).
* Maintain the pressure drop across the control valve in pressure gauge (G1) (e.g.
1/1.5/2 Psi) remains constant by varying the hand valve (HV2). Note the
pressure dropacross the valve at fully open (G1).

* Never disturb the hand valve (HV2), once it is adjusted for particular opening.

* Observe flow and inlet pressure variations. Note down the air regulator pressure
(G2), rotameter flow, and stem position in control valve.

* Decrease the pressure in air regulator to 12 Psi, at same time, pressure across
the control valve slightly increases, adjust hand valve (HV1) to maintain
predefined pressure in G1.

* Note the flow in rotameter and stem position in control valve, air regulator
pressure.

* Slowly decrease/increase the air pressure regulator for achieving different stem
positions till the valve is fully closed/open.

* Tabulate the rotameter flow, air regulator pressure and stem position.

* Plot the graph between rotameter flows in the y-axis and stem position in

x- axis.
TABULATION

Pressure drop across control valve (Îp)=

Actuator pressure Stem position Rotameter flow
(Psi) (%) (LPH)

* Calculate the control valve co-efficient from the table,

CONTROL VALVE CO-EFFICIENT

The number of US gallons of water/min that flow through a fully open valve with a
∆p of 1psi.

Where,

Q = flow rate in GPM (1 GPM=227.1247LPH) G =

specific gravity of water (=1)

∆p = pressure drop across the control valve in Psi

Determine the control valve gain,

MODEL GRAPH

RESULT

Thus, the characteristic of quick opening (ON/OFF) valve was studied.

EXPERIMENT-2 AIM

To study the characteristics of equal percentage control

valve. APPARATUS REQUIRED

* VCVT-03A

PROCEDURE

* Before conducting the experiment, make sure that availability of water in

reservoir tank. Fill clean and soft water in the reservoir.

* Connect air supply pipe to regulator. Confirm there is no loose connection.

* Hand valve settings for equal percentage control valve characteristics study;
HV3 (the regulating valve, which is provided at the inlet of control valve) and
HV6 should be fully open. Regulating valves of other control valves should be
fully closed.

* Initially, set the output pressure of air regulator to 15 Psi by varying the knob.
The equal percentage valve is fully open.

* Keep partially open the vent valve (HV8), when air regulator lifts to its
maximum range.

* Switch on the unit.

* Set the maximum flow in the rotameter by adjusting the bypass valve (HV1) and
inlet regulating valve (HV3).
* Maintain the pressure drop across the control valve in pressure gauge (G1)(e.g.
1/1.5/2 Psi) remains constant varying the hand valve (HV3). Note the pressure
drop across the valve at fully open (G1).

* Never disturb the hand valve (HV3), once it is adjusted for particular opening.

* Observe flow and inlet pressure variations. Note down the air regulator pressure
(G2), rotameter flow, and stem position in control valve.

* Decrease the pressure in air regulator to 12 Psi, at same time, pressure across
the control valve slightly increases, adjust bypass valve (HV1) to maintain
predefined pressure in G1.

* Note the flow in rotameter and stem position in control valve, air regulator
pressure.

* Slowly decrease/increase the air pressure regulator for achieving different stem
positions till the valve is fully closed/open.

* Tabulate the rotameter flow, air regulator pressure and stem position.

* Plot the graph between rotameter flow in the y-axis and stem position in x-axis.
TABULATION

Pressure drop across control valve (∆p)=

Actuator pressure Stem position Rotameter flow (LPH)
(Psi) (%)

* Calculate the control valve co-efficient from the table,

CONTROL VALVE CO-EFFICIENT

The number of US gallons of water/min that flow through a fully open valve with a p of 1psi.

Where,

Q = flow rate in GPM (1 GPM=227.1247LPH) G

= specific gravity of water (=1)
p =pressure drop across the control valve in Psi
Determine the control valve gain,
MODEL GRAPH

RESULT

Thus, the characteristics of equal opening valve was studied.

EXPERIMENT-3 AIM

To study the characteristics of linear control valve without

positioner. APPARATUS REQUIRED

VCVT-03A

PROCEDURE

* Before conducting the experiment, make sure that availability of water in

reservoir tank. Fill clean and soft water in the reservoir.
* Connect air supply pipe to regulator. Confirm there is no loose connection.

* Control valve positioner should be in “bypass” mode

* Hand valve settings for linear control valve characteristics study HV4 (the
regulating valve, which is provided at the inlet of control valve) and HV7 should
be fully open. Regulating valves of other control valves should be fully closed.

* Initially, set the output pressure of air regulator to 15 Psi by varying the knob.
The linear valve is fully open.

* Keep partially open the vent valve (HV8), when air regulator lifts to its
maximum range.

* Switch on the unit.

* Set the maximum flow in the rotameter by adjusting the bypass valve (HV1) and
inlet regulating valve (HV4).
* Maintain the pressure drop across the control valve in pressure gauge (G1)(e.g.
1/1.5/2 Psi) remains constant varying the bypass valve (HV4). Note the pressure
drop across the valve at fully open (G1).

* Never disturb the hand valve (HV4), once it is adjusted for particular opening.

* Observe flow and inlet pressure variations. Note down the air regulator pressure
(G2), rotameter flow, and stem position in control valve.

* Decrease the pressure in air regulator to 12 Psi, at same time, pressure across
the control valve slightly increases, adjust bypass valve (HV1) to maintain
predefined pressure in G1.

* Note the flow in rotameter and stem position in control valve, air regulator
pressure.

* Slowly decrease/increase the air pressure regulator for achieving different stem
positions till the valve is fully closed/open.

* Tabulate the rotameter flow, air regulator pressure and stem position.

* Plot the graph between rotameter flows in the y-axis and stem position in x-
axis.
TABULATION

Pressure drop across control valve (∆p)=

Actuator pressure Stem position Rotameter flow (LPH)
(Psi) (%)

* Calculate the control valve co-efficient from the table,

CONTROL VALVE CO-EFFICIENT

The number of US gallons of water/min that flow through a fully open valve with a
∆p of 1psi.

Where,

Q= flow rate in GPM (1 GPM=227.1247LPH)

G=specific gravity of water (=1)
∆p=pressure drop across the control valve in Psi
Determine the control valve gain,

MODEL GRAPH

RESULT

Thus, the characteristics of linear valve without positioner was studied.

EXPERIMENT-4 AIM

To study the characteristics of linear control valve with

positioner. APPARATUS REQUIRED

VCVT-03A

PROCEDURE

* Before conducting the experiment, make sure that availability of water in

reservoir tank. Fill clean and soft water in the reservoir.

* Connect air supply pipe to regulator. Confirm there is no loose connection.

* Initially, set the output pressure of air regulator (G3) to 20 Psi by varying the
knob.

* Control valve positioner should be in “auto” mode

* Hand valve settings for linear control valve characteristics study; HV4 (the
regulatingvalve, which is provided at the inlet of control valve) and HV7 should
be fully open.Regulating valves of other control valves should be fully closed.

* Set the output pressure of air pressure to 15 Psi by varying the knob. The linear
valve is fully open.

* Keep partially open the vent valve (HV8), when air regulator lifts to its
maximum range.

* Switch on the unit.

* Set the maximum flow in the rotameter by adjusting the bypass valve (HV1) and
inlet regulating valve (HV4).

* Maintain the pressure drop across the control valve in pressure gauge (G1)(e.g.
1/1.5/2 Psi) remains constant varying the hand valve (HV4). Note the pressure
drop across the valve at fully open (G1).

* Never disturb the hand valve (HV4), once it is adjusted for particular opening.

* Observe flow and inlet pressure variations. Note down the air regulator pressure
(G2), rotameter flow, and stem position in control valve.

* Decrease the pressure in air regulator to 12 Psi, at same time, pressure across
the control valve slightly increases, adjust bypass valve (HV1) to maintain
predefined pressure in G1.

* Note the flow in rotameter and stem position in control valve, air regulator
pressure.

* Slowly decrease/increase the air pressure regulator for achieving different stem
positions till the valve is fully closed/open.

* Tabulate the rotameter flow, air regulator pressure and stem position.

* Plot the graph between rotameter flows in the y-axis and stem position in x-
axis.
TABULATION

Pressure drop across control valve (∆p) =

Actuator pressure Stem position Rotameter flow (LPH)
(Psi) (%)

* Calculate the control valve co-efficient from the table,

CONTROL VALVE CO-EFFICIENT

The number of US gallons of water/min that flow through a fully open valve with a
∆p of 1psi.

Where,

Q = flow rate in GPM (1 GPM=227.1247LPH) G

= specific gravity of water (=1)
Îp = pressure drop across the control valve in Psi
Determine the control valve gain,

MODEL GRAPH

RESULT

Thus, the characteristics of linear valve with positioned valve were studied.
EQUIPMENT 4: MULTIPROCESS CONTROL SYSTEM
INTRODUCTION

Process control is now becomes a major branch in the field of instrumentation. It is being adopted and
practiced by various industries, automation areas etc. VMPA - 64 is a multi process station which
simulates the idea of process control. By this unit, we can analyses processes like flow, level, pressure,
temperature etc. It also helps us in understanding the concept of transducers, controllers, final control
elements etc.

TECHNICAL SPECIFICATION OF COMPONENTS DPT

* Source - Rosemount
* Built-in-Sensor - Piezo-electric with μC based
* Input - (0-6500) mm H20
* Output - (4-20) mA at 24V DC / 2wire system.

Orifice Plate

* Material - SS - 316
* Diameter - 3.5 mm (4 mm)
* Up-stream distance - 25 ×D
* Downstream distance - 5 ×D

Rotameter

* Make - Tele line

* Range - 50 to 500 LPH
* End connection - 1/4" BSP (F) Thread
* Body material - Acrylic
* Float material - SS - 316

Air Regulator

* Source - Placka Instruments

* Input range - (0 - 10.6) Kg / cm2
* Output range - (0 - 2.1) Kg / cm2
 * Special feature - Air regulator cum filter

Electro-pneumatic converter
* Pneumatic Input air - 20 psi constant
* Current input - (4-20) mA / 24V DC
* Pneumatic output - (3-15) psi Signal

Pneumatic Control Valve

* Source - RK valve Ltd

* Type - Globe valve
* Flow rate - (500/1000) LPH
* Trim mat - SS - 316
* Characteristics - Equal %
* Spring range - (0-2.1) Kg/cm
* Valve action - Air to open
* End connection - 1/2" Screwed
* Medium - Water/air
* Body material - CS Body.
Pump

* Source - Cintu/Tullu
* Voltage - 230 VAC/ DC,
50Hz
* Discharge - 800 LPH

Pressure Transmitter

* Make - Keller Instruments

* Type - Piezo electric
* Range - (0 - 5) bar
* Supply - 24V DC @ 100mA

Pressure gauge

* Make - Shreeji Ltd.

* Range - (0-30) psi
* Mounting - Panel
* Diameter - 2"
* Type - Bourdon tube
Level Transmitter

* Make - Swithzer Instruments

* Type - Capacitive
* Range - (0 - 300) mm
* Measuring Range - (0 - 250) mm
* Supply - 24V DC @100mA

RTD Sensor

* Type - Pt -100.
* Length - 60 mm.
* Tube material - SS 316.
RTD Transmitter

* Source - Vi Microsystems Pvt. Ltd.,

* Type - Pt 100 (3 wire).
* Temp Range - (0-100°C).
* Supply - 24V DC.
* Output - (4-20) mA DC.

Process Tank with heater

* Make - Vi Microsystems Pvt. Ltd.,

* Height - 400mm
* Diameter - 250mm
* Body material - SS-316
* Stirrer supply - 5V DC
* Heater supply - 230V AC/50Hz
* Heater power - 3kW
SCR Unit

* Source - Vi Microsystems Pvt. Ltd.,

* Input - 230V AC.
* Control Input - (0-5) V/ (4-20) mA.
* Output - (0 - 230) V AC.
* Current rating - 20 Amps maximum.
PICTORIAL VIEW
 BLOCK DIAGRAM OF PRESSURE PROCESS

Com Data Acquisition Pressure

 BLOCK DIAG RAM POR LEVEL

Com Data Acquisition Level Pressure

 BLOCK DIAGRAM OF TEMPERATURE PROCESS

Microcont Temperature Temperature

230 AC
(0-220)V Water in
Error (0 (4- (0
DAC Process V
to I .built Beater

RTD
Trans

‹ ' (4-
I
to V
DESCRIPTION

VMPA-64 is a multi-process station by which several processes like Flow, Level, Pressure, and
Temperature can be controlled and studied. Here PC acts as error detector and controller. Set point is
given manually to the computer. It gets process variable from the process and accordingly it generates
error. According to the error, controller output is developed which again feedback to the process for
controlling. Water in the reservoir tank is pumped directly through overhead tank (for temperature, level,
flow process) using pump.

Flow Control System: A Differential Pressure Transmitter is used to measure the flow of the fluid
through orifice plate. Pump discharges the water from reservoir tank and give it to control valve.
Computer acts as an error detector and controller. According to the error signal, that it develops a control
signal. Here Current to pressure convertor acts as actuator this control signal is given to I/P Converter
that operates the control valve. It controls the flow of the fluid in pipeline by varying stem position of the
control valve. By pass line is provided to avoid the pump overloading. Data Acquisition card (Data
Acquisition System) having ADC and DAC, section so that it acts an effective link between the process
plant and the controller. Flow through orifice is sensed and transmitted (4-20) mA to the controller by a
differential pressure transmitter (DPT). Accordingly, controller produces error and generates an output
which again feedback to the process. This controlled output is given to Pneumatic Control valve (Final
Control Element). According to controller output, control valve opens or closes and thus a controlled
flow is allowed into the process.

Pressure Control System: Pressure is developed in the pressure tank. The pressure is sensed and
transmitted by a piezo-resistive pressure transmitter and given to the controller. Based on this, a
controller output is generated. This is fed to Pneumatic control valve through Current to Pressure (I to P)
convertor by which opening and closing gets controlled by which the pressure is adjusted. This controls
pressure in the tank.

Level Control System: Level is developed in the head level of process tank using height of the fluid in
it. This bottom level is sensed and transmitted by a level transmitter and it is given to the controller.
Based on the controller, output is generated. According to the controller output, control valve open or
closed and this level of the process are controlled.

Temperature Control System: Temperature of the fluid flow near to the outlet of the heater is
controlled here. RTD is used as sensor and is transmitted by a temperature transmitter to the controller.
Accordingly a controlled output is generated and is given to thyristor power driver circuit. Here
Controller output is converted to (0-5) V here which is fed to gate of thyristor. Accordingly the firing
angle varies which in turn controls the supply delivered to heater and thus temperature gets controlled.
Since all are closed loop operations, the cycle is continuously taking place until process settled. Data
acquisition card or digital controller has inbuilt ADC and DAC so that is acts as an effective link
between process and controller.
FRONT PANEL DIAGRAM
FRONT PANEL DESCRIPTION

Power ON/OFF - To switch ON/OFF the unit.

Heater ON/OFF - To switch ON/OFF the heater.
Pump speed - To Vary the speed of the pump.
Stirrer - To switch ON/OFF the stirrer.
E1, E2 - Output terminals of the thyristor power controller.
T1 - Supply (+24V) terminal of temperature transmitter.
T2 - Output (4 - 20) mA terminal of temperature transmitter.
L1 - Supply (+24V) terminal of level transmitter.
L2 - Output terminal (4 - 20) mA of level transmitter
F1 - Supply (+24V) terminal of differential pressure transmitter (DPT) F2
- Output terminal (4-20) mA of differential pressure transmitter (DPT)
P1 - Supply (+24) V terminals of pressure transmitter output.
P2 - Output terminals (4 - 20) mA of pressure transmitter output.
(B1 - B2) - Input (4 - 20) mA terminals of I/P converter output
Input 1 - In built +24V positive terminals.
Input 2 - Channel 1 ADC input terminals
Output 1, Output 2- Controller output terminals.
I1, I2 - (4 - 20) mA current output.

G1 - To indicate the input pressure (from compressor)

G2 - To indicate output pressure of the air regulator (FR2)
G3 - To indicate the output of air regulator (FR1)
G4 - To indicate the output of I/P converter.
G5 - To indicate the pressure output of the pressure tank.
REQUIREMENTS FOR COMMISSIONING

● Filtered constant air supply (20psi) from compressor Air regulator input should be more than 25
Psi. Air regulator output (G3) should be always maintained as 20 Psi.
● Pump should neither be dry nor be loaded under working condition.

● Always use clean water to avoid impurities accumulation.

● Ensure the hand valve settings are correct before doing the experiments.

● Patching should be correct and tight.

● Supply and load disturbance can be given by using variable speed knob, bypass hand valve,
Outlet of process tank, rotameter inlet etc., for appropriate processes.
● Overhead tank should have always enough amount of water during process.

● Never switch ON the heater without sufficient water.

Make sure that rotameter is set at some minimum flow rate say (30 or 40 Lph) withoutany
oscillations.
● Switch OFF the heater, after finishing the experiment.

● Never switch ON the unit during the low voltage, high voltage or fluctuating voltage.
Otherwise, transmitter may be damaged.
● Single phase 5A Electrical supply with proper earthing is neutral with earth voltage less than
10V/AC (5A socket – 5 Numbers).

● Distilled (or) clean water.

● System operating system windows Xp, windows 7 with USB port facility.

● To drain the storage tank water weekly once.

● Don’t run the pump dry and low voltage condition.

● To release drain valve in the compressor weekly once

▲ For transmitter safety, never switch on the unit low, fluctuating

voltage.
INTERFACING DIAGRAM
PATCHING DIAGRAM (FLOW)
EXPERIMENTAL SECTION
EXPERIMENT - 1

AIM

To study the performance of PID controller on flow process

APPARATUS REQUIRED

1. VMPA - 64 Unit.
2. Data Acquisition card with cable.
3. PC with Process Control software.
4. Patch chords.

PROCEDURE
* Ensure the availability of Air & Water.

* Interface the PC with process and Data Acquisition System.

*. Patch terminals through Patch chords as per connection patching diagram.

* Maintain Gauge (G2) pressure at 20 Psi by using air regulator knob.

*. Ensure the hand valve settings are correct.

HAND VALVE SETTINGS

HV1, HV4, HV7 - Fully Open
HV2, HV5, HV6, HV8, HV9 - Fully Close
* Switch ON VMPA - 64 unit and the Data Acquisition System with PC.

* Invoke “Process Control” Software.

i. In PC select “Start Menu All Programs Process Control”

The following window will be appeared,

 ii. Select the “file>>Start” menu. The menu will be shown below,

The port setting window will open Select the COM port number, Baud rate (38400) and keep the
remaining boxes as it is and click OK button
 1

The Port opened successfully window will appear. Then click OK button.

To select the appropriate control and set the parameters like Setpoint,KP,KI & KD values
* Switch ON the pump and vary the speed control knob.

* Enter the parameters and observe the responses.

* Switch OFF the pump.

* Save the response and conclude the behavior of Flow process.

* Load the file and analysis the graph

RESULT

Thus, the performance of PID controller on flow process was studied.

Note:
Supply cum load disturbances can be given through speed regulator knob, bypass valve and rotameter
EXPERIMENT - 2

AIM

To study the characteristics of the Current to pressure converter and control valve.

APPARATUS REQUIRED

1. VMPA - 64 Unit.
2. Data Acquisition card with cable.
3. PC with Process Control software.
4. Patch chords.
PROCEDURE
* Ensure the availability of Air.

* Interface the PC with process and Data Acquisition System.

*. Patch terminals through Patch chords as per connection patching diagram.

* Maintain Gauge (G2) pressure at 20 Psi by using air regulator knob.

*. Ensure the hand valve settings are correct.

HAND VALVE SETTINGS

HV1, HV4, HV7 - Fully Open
HV2, HV5, HV6, HV8, HV9 - Fully Close

* Position the Hand valve HV1 in partially open position.

* Switch ON VMPA - 64 unit and the Data Acquisition System with PC.

* Invoke “Process Control” Software.

i. In PC select “Start Menu All Programs Process Control”

The following window will be appeared,

*. Select “control >> manual mode”. Enter the controller power in the dialog box. Select
 “manual mode” and enter a controller output of 100%.

* Connect multi meter (in current 20 mA mode) to the CO test points.

* Gradually vary the controller output from 0 to 100% and note down the current reading
and pressure reading (G4) and stem movement (%).

* Tabulate the readings and draw the graph between current in mA Vs pressure in Psi.

* Similarly, draw the graph between pressure (G4) (Psi) Vs stem movement (%).

* Conclude the behavior of Current to Pressure Converter and Control Valve.

TABULATION
Controller Current Pressure Output Stem
Output Input (G3) Psi movem
(%) (mA) ent (%)

RESULT

Thus, the characteristic of the current to pressure converter and control valve was studied.
EXPERIMENT – 3

AIM

To study the characteristics of the Flow transmitter.

APPARATUS REQUIRED

1. VMPA - 64 Unit.
2. Data Acquisition card with cable.
3. PC with Process control software.
4. Patch chords.

PROCEDURE

* Ensure the availability of Air & Water.

*. Interface the Data Acquisition card with process and PC.

*. Make the connections as per connection diagram - 3.

*. Maintain Gauge (G3) pressure at 20 Psi by using air regulator knob.

*. Ensure the hand valve settings are correct.

HAND VALVE SETTINGS

HV1, HV4, HV7 - Fully Open

HV2, HV5, HV6, HV8, HV9 - Fully Close

*. Switch ON VMPA - 64 unit and Data Acquisition card with PC.

*. Invoke the Process control software.

*. Select “Flow/control >> manual mode” and enter a controller output of 100%.

* Connect multimeter (in current 200 mA mode) to the PV test points.

* Select “manual mode” and enter a controller output of 100%.

* Gradually increase the flow (say in steps of 50 LPH) by varying the pump speed, and note down
the current readings.

*. Switch ON the pump. Vary pump speed regulator to run pump at desired speed.

*. Note down the DPT output for 50 LPH rise in flow by adjusting HV5.

*. Switch OFF the Pump.

*. Draw the graph between flow Vs output current and conclude the behaviour of the DPT.

TABULATION

Flow Flow Transmitter Current Output

(LPH) (mA)

RESULT

Thus, the characteristic of the Flow transmitter was studied

PATCHING DIAGRAM (PRESSURE)
EXPERIMENT - 4

AIM

To study the performance of PID controller on pressure process

APPARATUS REQUIRED

1. VMPA - 64 Unit.
2. Data Acquisition card (VDAS-01) with cable.
3. PC with Process Control software.
4. Patch chords.

PROCEDURE

* Ensure the availability of Air.

* Interface the PC with process and Data Acquisition System.

*. Patch terminals through Patch chords as per connection patching diagram.

* Maintain Gauge (G2) pressure at 20 Psi by using air regulator knob.

*. Ensure the hand valve settings are correct.

HAND VALVE SETTINGS

HV2, HV5, - Fully Open
HV1, HV4, HV7, HV9 - Fully Close
HV3 - partially open

* Switch ON VMPA - 64 unit and the Data Acquisition System with PC.

* Invoke “Process Control” Software.

i. In PC select “Start Menu All Programs Process Control”

The following window will be appeared,

,

ii. Select the “file>>Start” menu. The menu will be shown below,

The port setting window will open Select the COM port number, Baud rate (38400) and keep the
remaining boxes as it is and click OK button
 3

The Port opened successfully window will appear. Then click OK button.

To select the appropriate control and set the parameters like Setpoint, KP, KI & KD values
* Switch ON the pump and vary the speed control knob.

* Enter the parameters and observe the responses.

* Switch OFF the pump.

* Save the response and conclude the behavior of Pressure process.

* Load the file and analysis the graph

RESULT

Thus, the performance of PID controller on pressure process was studied.

Note:
Supply cum load disturbances can be given through inlet Hand valve opening and relief valve.

Air regulator (FR2) pressure should more than 75 psi.

EXPERIMENT - 5

AIM

To study the characteristics of the Pressure transmitter.

APPARATUS REQUIRED

1. VMPA - 64 Unit.
2. Data Acquisition card with cable.
3. PC with Process control software.
4. Patch chords.

PROCEDURE

*. Ensure the availability of Air & Water.

* Interface the Data Acquisition card with process and PC.

*. Make the connections as per connection diagram - 2.

*. Maintain Gauge (G3) pressure at 20 Psi by using air regulator knob.

*. Ensure the hand valve settings are correct.

HAND VALVE SETTINGS

HV2, HV5, - Fully Open
HV1, HV4, HV7, HV9 - Fully Close
HV3 - partially open
*. Switch ON VMPA - 64 unit and Data Acquisition card with PC.

*. Invoke the “Process control” software.

*. Select “Pressure/control >> manual mode” and enter a controller output of 100%.

*. Note down the current readings for various pressure readings.

*. Draw the graph between Pressure Vs output current and conclude the behavior of the Pressure
 transmitter.

TABULATION

Gauge Pressure Pressure Transmitter Current Output

(Psi) (mA)

RESULT

Thus the characteristics of the Pressure transmitter were studied.

PATCHING DIAGRAM (LEVEL)
EXPERIMENT - 6

AIM

To study the performance of PID controller on Level process

APPARATUS REQUIRED

1. VMPA - 64 Unit.
2. Data Acquisition card (VDAS-01) with cable.
3. PC with Process Control software.
4. Patch chords.
PROCEDURE

* Ensure the availability of Air & Water.

* Interface the PC with process and Data Acquisition System.

*. Patch terminals through Patch chords as per connection patching diagram.

* Maintain Gauge (G2) pressure at 20 Psi by using air regulator knob.

*. Ensure the hand valve settings are correct.

HAND VALVE SETTINGS

HV1, HV4 - Fully Open

HV2, HV5, HV6, HV8, HV9 - Fully Close
HV7 - partially open
* Position the Hand valve HV1 in position.

* Switch ON VMPA - 64 unit and the Data Acquisition System with PC.

* Invoke “Process Control” Software.

i. In PC select “Start Menu All Programs Process Control”

The following window will be appeared

,
 ii. Select the “file>>Start” menu. The menu will be shown below,

The port setting window will open Select the COM port number, Baud rate (38400) and keep the
remaining boxes as it is and click OK button
 4

The Port opened successfully window will appear. Then click OK button.

To select the appropriate control and set the parameters like Setpoint,KP,KI & KD values
* Switch ON the pump and vary the speed control knob.

* Enter the parameters and observe the responses.

* Switch OFF the pump.

* Save the response and conclude the behavior of Level process.

* Load the file and analysis the graph

RESULT
Thus, the performance of PID controller on level process was studied.

Note:
Supply cum load disturbances can be given through speed regulator knob, bypass valve and rotameter
PATCHING DIAGRAM (TEMPERATURE)
EXPERIMENT - 7

AIM

To study the performance of PID controller on temperature process

APPARATUS REQUIRED

1. VMPA - 64 Unit.
2. Data Acquisition card with cable.
3. PC with Process Control software.
4. Patch chords.
PROCEDURE

* Ensure the availability of Air & Water.

* Interface the PC with process and Data Acquisition System.

*. Patch terminals through Patch chords as per connection patching diagram.

* Maintain Gauge (G2) pressure at 20 Psi by using air regulator knob.

*. Ensure the hand valve settings are correct.

HAND VALVE SETTINGS

HV1, HV4 - Fully Open
HV2, HV5, HV7, HV8, HV9 - Fully Close
HV6 - partially open
* Switch ON VMPA - 64 unit and the Data Acquisition System with PC.

* Invoke “Process Control” Software.

i. In PC select “Start Menu All Programs Process Control”

The following window will be appeared

,
 5

ii. Select the “file>>Start” menu. The menu will be shown below,

The port setting window will open Select the COM port number, Baud rate (38400) and keep the
remaining boxes as it is and click OK button
 6

The Port opened successfully window will appear. Then click OK button.

To select the appropriate control and set the parameters like Setpoint,KP,KI & KD values
* Switch ON the pump and vary the speed control knob.

*. Set the rotameter at some minimum flow rate (say 40 LPH).

*. Switch ON the heater.

* Enter the parameters and observe the responses.

* Switch OFF the pump.

*. Switch OFF the heater.

* Save the response and conclude the behavior of Temperature process.

* Load the file and analysis the graph

RESULT
Thus, the performance of PID controller on temperature process was studied.

Note:
Supply cum load disturbances can be given through speed regulator knob, bypass valve and rotameter
EXPERIMENT - 8

AIM

To study the characteristics of the Temperature transmitter.

APPARATUS REQUIRED

1. VMPA - 64 Unit.
2. Data Acquisition card with cable.
3. PC with Process control software.
4. Patch chords.

PROCEDURE

*. Ensure the availability of Water.

*. Interface the Data Acquisition card with process and PC.
*. Make the connections as per connection diagram - 4.
*. Ensure the hand valve settings are correct.
HAND VALVE SETTINGS
HV1, HV4 - Fully Open
HV2, HV5, HV7, HV8, HV9 - Fully Close
HV6 - partially open
*. Switch ON VMPA - 64 unit and Data Acquisition card with PC.

*. Invoke the Process control software.

*. Select “Temperature/control >> manual mode” and enter a controller output of 100%.

*. Switch ON the pump. Vary pump speed regulator to run pump at desired speed.

*. Set the rotameter at some minimum flow rate (say 40 LPH).

*. Switch ON the heater after the Flow of water.

*. Note down the current readings for different temperature (read from the computer).
*. Switch OFF the heater.
*. Switch OFF the Pump.
*. Draw the graph between Temperature Vs output current.

TABULATION

Temperature Temperature Transmitter Current Output (mA)

(°C)

RESULT

Thus the characteristics of the Temperature transmitter were studied.

TROUBLESHOOTING
Components Cau Rectificati
se on
Flow Unable to get current To Check the +24V DC supply to the
Transmitter variation & current output DPT. To check orifice plate.
(DPT) To check loop
cable. To check
the wiring.
Pressure Unable to get current To Check the +24V DC supply to the
Transmitter (PT) variation & current output PT. To check tank pressure.
To check loop
cable. To check
the wiring.
Level Unable to get current To Check the +24V DC supply to the
Transmitter variation & current output LT. To check Level in Tank.
(LT) To check loop
cable. To check
the wiring.
Temperat Unable to get current To Check the +24V DC supply to the
ure variation & current output TT. To check the Temperature.
Transmitt To check loop
er (TT) cable. To check
the wiring.
Data Unable to communicate To check the port settings.
with system
Acquisition System
Current to Unabl t g pressur To check the analog current
Pressure e o e e output. To check the supply
Converter variati t pressure.
on
Control Valve Unable to get To check the valve
proper opening. To calibrate the
Calibration. valve.
Rotameter. Rust problem To maintain the clean water.
Pump Leakage problem Check the carbon
brush. To replace the
oil seal.
Air Filter Regulator Unabl t g pressur To check the compressor
e o e e output. To check the pressure
variati t gauge.
on
Thyristor power Unable to get power variation To check supply voltage.
driver
EQUIPMENT 5:
JOGGING
INTRODUCTION

When running motor comes to shutdown due to jamming, to overcome this problem
Jogging method is used. Because, we have 3 phase supply to motor, for this high voltage, we
can’t able to rectify this type of jamming problems. Due to continuous supply is applied and
may be its cause’s damages while motor is in running condition. By using the Jogging
method, we supply little amount of voltage by using push button, the motor turns in the
condition of forward and reverse direction due to the pulse applied. The push button details
are given below.

DESCRIPTION

The Run-Stop-Jog Switch provides a momentary jog speed, which can be used to index a
machine into position. The switch contains three (3) positions:

1. “Run” – The switch is placed in this position when the control output is to be set using
the Main Speed Potentiometer.

2. “Jog” – Used to provide a low speed output. This position is spring loaded so the
switch must be held. The jog speed can be changed using the JOG trim pot located on
the PC board.

3. “Stop” – Used as a resting position when the Jog function is used. The motor will stop
when in this position.

FEATURES OF VPAT-15A

● Jogging control circuit can be created with all the three phases.

● Both manually and PLC based operation is possible.

FRONT PANEL VIEW
FRONT PANEL DESCRIPTION

R - Push button for reverse mode operation.

F - Push button for forward mode

operation MCB - Switch ON 3φ output to motor.

STOP - To stop the motor during manual operation.

MOTOR SPECIFICATIONS

Make = Siemens

H.P = 0.5 HP

Kw = 0.37Kw

RPM = 1370 rpm

Cos φ = 0.78.

Voltage = 220 volt 3φ supply

maximum
Current = 1 amp maximum

Frequenc = 50Hz.
y
EXPERIMENTAL
SECTION EXP NO:1

AIM

To study the Jogging control circuit using manual operation.

APPRATUS REQUIRED

1. Patch chords

2. VPAT-15A (Jogging control circuit module)

3. 0.5 HP 3φ induction motor.

CONNECTION PROCEDURE

1. Connect the 3φ(R, Y, B) input to 3φ AC input (R, Y, B) connection respectively in

VPAT-15A.

2. Connect the 3φ induction motor to the connectors to 3φ AC output (R, Y, B) in

VPAT-15A.

3. Before switch ON make the all switches at OFF position.

4. Keep the MCB at off position.

EXPERIMENTAL PROCEDURE

1. Switch on the MCB.

2. Use the Run-Jog switch for selecting the mode operation like normal mode or
jogging mode.

3. Press the forward button, so that motor starts running at forward direction.

4. Now press stop switch, so the contact gets open and motor stops.

5. Again press the reverse button, so that the motor starts running at reverse direction.
RESULT

Thus the jogging control circuit using manual operation has been studied.
 EXP: NO:

2 AIM

To study the Jogging control circuit with PLC mode operation.

APPRATUS REQUIRED

1. Patch chords

2. VPAT-15A (Jogging control circuit module)

3. 0.5 HP 3φ induction motor

4. PLC trainer kit

5. PLC INTERFACE BOX.

6. TIA PORTAL V16 SOFTWARE

7. Ethernet cable

8. Personal computer.

BLOCK DIAGRAM OF PLC WITH INTERFACE JOGGING

PLC JOG
COMPUTER PLC INTERFACE GING
BOX CONTR
OL
CIRCUI

MOTO
R
 WIRING CONNECTION FOR JOGGING MODE

Forw 9 1
PLC INTERFACE

R
Reve

F N
Com 1 2

R Y B R Y B
Q Q
3- PHASE
3-PHASE OUTPUT

24v dc -
PLC
CONNECTION PROCEDURE

1. Connect the PLC outputs Q1, Q2 to the PLC interface box forward and reverse
connectors respectively.

2. Connect the PLC INTERFACE BOX output 440volts connectors to the inputs of Y
and B phases.

3. Connect the PLC INTERFACE BOX output forward connectors to the 9 pin and 10
pin connectors in VPAT-15A.

4. Connect the PLC INTERFACE BOX output reverse connectors to the 19 pin and 20
pin connectors in VPAT-15A.

EXPERIMENTAL PROCEDURE

1. Write the PLC ladder program.

2. To download the PLC program and execute the program.

3. Switch on the MCB.

4. In PLC kit I1, I2, I3 represents the forward, stop and reverse switches respectively.
RESULT

Thus the Jogging control circuit with PLC mode operation has been studied.
 EQUIPMENT 6: ELECTRO HYDRAULIC CONTROL
Pneumatics in review

Pneumatics has long since played an important role as a technology in the performance
of mechanical work. It is also used in the development of automatic solutions. In the majority
of applications compressed air is used for one or more of the following functions:

* To determine the status of the processor.

* Information processing (processors).

* Switching of actuators by means of final control elements.

* Carrying out work (actuators).

To be able to control machinery and installations necessitates the construction of a

generally complex logic interconnection of statuses and switching conditions. This occurs as a
result of the interaction of partly pneumatic systems. The technological progress made in
material, design and production process has further improved the quality and diversity of
Pneumatic components and thereby contributed to their widely spread use in automation. The
pneumatic cylinder has a significant role as a linear drive unit, due to its

* Relatively low cost.

* Ease of installation.

* Simple and robust construction and

* Ready availability in various sizes and stroke lengths.

General characteristics of pneumatic cylinder

* Diameter 2.5 to 320mm

* Stroke lengths 1 to 2000mm

* Available forces 2 to 45000 N at 6 bar

* Piston speed 0.1 to 1.5 m/s

Industrial application of pneumatic system

⮚ General methods of material handling:

 Positioning and Orienting

 Clamping and Shifting

 Branching of material flow

⮚ General applications:

 Packaging

 Filling

 Metering

 Locking

▪ Driving of axes

 Door or chute control

 Transfer of materials

 Turning and inverting of parts

 ▪ Sorting of parts

 Stacking of components

 Stamping and embossing of components

 Advantages of compressed air

PROGRAM
EXPERIMENT: 1
PLC PROGRAM:
EXPERIMENT – 1

PLC CONTROL OF SINGLE ACTING CYLINDER USING AND LOGIC

AIM

To simulate the single acting cylinder using PLC ladder diagram

APPARATUS REQUIRED

Compressor, FRL, air tube, single acting cylinder, PLC, LOGO software,3/2 single
solenoid valve.

PROCEDURE

1. Open the LOGO software in desktop.

2. Draw the ladder diagram.
3. Provide +24V and -24V from PLC trainer to electro pneumatic trainer with PLC
panel. Output of the PLC (Q1) is direct connect to input of 3/2 single solenoid
coil.
4. Download and Run the PLC.
5. Connect the pneumatic circuit connection as per the connection diagram.
6. Check the all circuit in panel and Ladder diagram.
7. Run the PLC. When two input(I1 & I2) is high, output(Q1) is high.

TRUTH TABLE

Inp
ut Output Q1
I1 I2
OFF OFF OFF
ON OFF OFF
OFF ON OFF
ON ON ON

RESULT

Thus the actuation of single acting cylinder with AND Gate was done.
EXPERIMENT 2:
PLC PROGRAM:
EXPERIMENT – 2

ACTUATION OF SINGLE ACTING CYLINDER WITH OR GATE USING PLC

AIM
To simulate the single acting cylinder using OR Gate logic

APPARATUS REQUIRED

Compressor, FRL, Air tube, LOGO software, 3/2 single solenoid valve, PLC, single
acting cylinder.

PROCEDURE

1. Open the LOGO software in desktop.

2. Draw the ladder diagram.
3. Provide +24V and -24V from PLC trainer to electro pneumatic trainer with PLC
panel. Output of the PLC (Q1) is direct connect to input of 3/2 single solenoid
coil.
4. Download and Run the PLC.
5. Connect the pneumatic circuit connection as per the connection diagram.
6. Check the all circuit in panel and Ladder diagram.
7. Run the PLC. When anyone of the input(I1 or I2) is high, output(Q1) is high.

TRUTH TABLE

Inp
ut Output 1Q
1i 2i
OFF OFF OFF
ON OFF ON
OFF ON ON
ON ON ON

RESULT

Thus the actuation of single acting cylinder with OR Gate was done using PLC.
EXPERIMENT: 3
PLC PROGRAM:
EXPERIMENT – 3
ACTUATION OF SINGLE ACTING CYLINDER WITH OFF DELAY TIMER
USING PLC

AIM
To simulate the single acting cylinder with off delay timer using PLC

APPARATUS REQUIRED

Compressor, FRL, air tube, 3/2 single solenoid valve, PLC, single acting cylinder,
than LOGO software.

PROCEDURE

1. Open the LOGO software in desktop.

2. Draw the ladder diagram.
3. Provide +24V and -24V from PLC trainer to electro pneumatic trainer with PLC
panel. Output of the PLC (Q1) is direct connect to input of 3/2 single solenoid
coil.
4. Download and Run the PLC.
5. Connect the pneumatic circuit connection as per the connection diagram.
6. Check the all circuit in panel and Ladder diagram.
7. Run the PLC. Use input1 (Trg), input2(Reset) and output 1. Initially keep first
Switch ON condition then switch OFF (1).Output (1) goes low after the delay time
(say 5 secs).

RESULT

Thus the actuation of single acting cylinder with OFF Delay timer was done using PLC.
EXPERIMENT: 4
PLC PROGRAM:
EXPERIMENT – 4

SIMULATE THE SINGLE ACTING CYLINDER WITH ON DELAY TIMER

USING PLC

AIM
To simulate the single acting cylinder with ON delay timer using PLC.

APPARATUS REQUIRED

Compressor, FRL, air tube, 3/2 single solenoid valve, PLC, single acting cylinder
and LOGO software.

PROCEDURE
1. Open the LOGO software in desktop.
2. Draw the ladder diagram.
3. Provide +24V and -24V from PLC trainer to electro pneumatic trainer with PLC
panel. Output of the PLC (Q1) is direct connect to input of 3/2 single solenoid
coil.
4. Download and Run the PLC.
5. Connect the pneumatic circuit connection as per the connection diagram.
6. Check the all circuit in panel and Ladder diagram.
7. Run the PLC. Use input1 (Trg) and output 1. Initially keep first Switch ON then
Output (1) goes high after the delay time (say 5 secs).

RESULT

Thus the single acting cylinder is actuated with timer using PLC.
EXPERIMENT: 5
PLC PROGRAM:
EXPERIMENT -5

CONTROL OF DOUBLE ACTING CYLINDER WITH UP/DOWN COUNTER

USING PLC

AIM
To simulate the double acting cylinder with UP/DOWN COUNTER using PLC

APPARATUS REQUIRED

Compressor, FRL, air tube, 5/2 single solenoid valve, PLC, Double acting cylinder,
LOGO software.

PROCEDURE

1. Open the LOGO software in desktop.

2. Draw the ladder diagram.
3. Provide +24V and -24V from PLC trainer to electro pneumatic trainer with PLC
panel. Output of the PLC (Q1) is direct connect to input of 5/2 single solenoid
coil.
4. Download and Run the PLC.
5. Connect the pneumatic circuit connection as per the connection diagram.
6. Check the all circuit in panel and Ladder diagram.
7. Run the PLC. Follow the below procedure.
Once Switch ON & OFF Input 2(for Reset).
Switch ON & OFF Input 1 For 5 Times.(as mentioned in count
value) After 5 Counts Output 1 Goes High.
Then Switch ON & OFF Input 2(Reset).

RESULT

Thus the double acting cylinder is actuated with up counter using PLC.
EXPERIMENT: 6
PLC PROGRAM:
EXPERIMENT – 6

AUTOMATIC ACTUATION OF DOUBLE ACTING CYLINDER USING PLC

AIM
To simulate the automatic sequence of double acting cylinder using PLC.

APPARATUS REQUIRED

Compressor, FRL, Air tube, 5/2 double solenoid valve, PLC, Double acting cylinder,
LOGO software and Flow control valve.

PROCEDURE

1. Open the LOGO software in desktop.

2. Draw the ladder diagram.
3. Provide +24V and -24V from PLC trainer to electro pneumatic trainer with PLC
panel. Output of the PLC (Q1, Q2) is direct connect to input of 5/2 double
solenoid coil. Connect magnetic reed switch feedback to I1(low limit) & I2(high
limit). Use I3 for start/stop of the cycle.
4. Download and Run the PLC.
5. Connect the pneumatic circuit connection as per the connection diagram.
6. Check the all circuit in panel and Ladder diagram.
7. Run the PLC. Now switch ON the I3 for starting the cycle. For stopping switch
OFF the I3.

RESULT

The ladder diagram for the automatic running of double acting cylinder is drawn and executed.
EXPERIMENT: 7
PLC PROGRAM
EXPERIMENT – 8

PLC CONTROL OF SEQUENCING CIRCUIT USING PLC LADDER

DIAGRAM AIM

To design a circuit for the sequence A+B+A-B- USING PLC

APPARATUS REQUIRED

Compressor, FRL, Air tube, 5/2 single solenoid valve, PLC, double acting cylinder, mini
actuate cylinder, versa pro software.

PROCEDURE

1. Open the LOGO software in desktop.

2. Draw the ladder diagram.
3. Provide +24V and -24V from PLC trainer to electro pneumatic trainer with PLC
panel. Output of the PLC (Q1, Q2,Q3,Q4) is direct connect to input of 5/2 double
solenoid coils. Use I1 for start/stop of the cycle.
4. Download and Run the PLC.
5. Connect the pneumatic circuit connection as per the connection diagram.
6. Check the all circuit in panel and Ladder diagram.
7. Run the PLC. Now switch ON the I1 for starting the cycle. For stopping switch
OFF the I1.
8. Run the PLC. Observe the working of double acting cylinder is automatic
reciprocating using the circuit A+B+A-B-.

RESULT

The ladder diagram for the automatic running of double acting cylinders is using this circuit
(A+B+A-B-) is drawn and executed.
EQUIPMENT 7: PLC BASED LIFT CONTROL SYSTEM

INTRODUCTION

The “Lift control system” is one of the applications of PLC. PLC’s are solid state device in
built by Micro controller and Relay. The PLC operates by the software’s the ladder logics
functions. The PLC interface with the PC via RS 232 cables and the lift control system get
the inputs, outputs from PLC.

LIFT
P PLC CONT
ROL

WORKING PRINCIPLE

There are three floors and each floor has one requesting switch. Whenever the switch is
pressed the lift comes to that floor and remains in that floor for the given particular time
period.

STEPPER MOTOR

The stepper motor in the trainer kit produces the required rotating motion to the bottle
platform. The stepper motor windings Coil 1, Coil 2, Coil 3, Coil 4 can be cylindrically
excited with the DC current to run the motor in clockwise direction. By reversing the phase
sequences Coil 1, Coil 4, Coil 3, Coil 2. The 4 coils of the stepper motor are arranged in a
fashion to rotate in steps.
The steps angle for rotation of stepper motor is governed by number of stator and rotors.

Step Angle = 360 / NS×NR

The Material platform stepper motor axis connected together exhibit

synchronism. The stepper motor operates in a two modes of operation as it is

given.
i. Single step operation

For a single step operation energized each coil step by step for that consider the below given
table at the time of moving the first decimal data (1) Coil 1 is energized, then coil 2 for
second decimal data and so on. This process repeated again and again to achieve the
required job.

Coil Coil Coil Coil Decimal

1 2 3 4 Value
1 0 0 0 1
0 1 0 0 2
0 0 1 0 4
0 0 0 1 8

Double Step Operation

Double step operation energized 2 coils simultaneously and repeat same for step by step at
that time of moving the first decimal data (3) Coil 1 & 2 are energized. Then coil 2 & 3 for
second decimal data (6) and so on.

Coil Coil Coil Coil Decimal

1 2 3 4 Value
1 1 0 0 3
0 1 1 0 6
0 0 1 1 12
1 0 0 1 9
Wiring for Stepper Motor:

Bl -
ue
Coil 1
Re -
d
Coil 2
Green -

Coil 3
Orange -

Coil 4

Specificatio
ns

Torque -

2Kg
Voltage - 12V

Inductive Sensor

This inductive sensor is used to monitor the lift position, when it senses the output of the
sensor will be given to the PLC input.

Specifications

Voltage - 230V
Current - 100mA.
 B
L
O
C
LIFT CONTROL SYSTEM K

D
I
I/P
PULSE

FLOO REQU
R EST
P SENS SWITC

I/P STEPPER STEP

PULSE MOTOR PER
DRIVER

UNIT 1 UNIT
2
LIFT FRONT PANEL DIAGRAM

LIFT CONTROL SYSTEM (VPAT-

FLO

24 REQUEST

+
FLOOR

I
N
FLO

R
REQUEST
R
S
FLOOR
F
S

FLO
OU

C
REQUEST
C
O
FLOOR
C
O
Program Description

I1, I2, I3 - Requestion switch.

I4, I5, I6 - Sensor Inputs

Q2, Q3, Q4, Q5 - Output for stepper motor.

I1, I2, I3 are the requestion switches I4, I5, I6 are the sensor placed in each floor. The other
coils used in the program are the set coil, reset coil, Positive transition coil, and negative
transition coil are in memory location.

The timer functions are used to produce the required time

delay. Bit sequence function is used to drive the stepper motor.

Whenever the requirement switch I1, is pressed the set coil M1 is energized and bit
sequence outputs are enabled then the stepper motor rotates.

When the motor reaches the respective floor, the switch I4 gets closed and energizes both
positive transition coil & negative transition coil.

The positive transition coil energize one more set coil, which is used to enable the

timer. This timer is used to give time delay for the lift in each floor.

The negative transition coil which was energized is used to reset the

requestion. The above functions are repeated in each floor.

Conditions For rotation Of Motor

Consider the lift is in ground floor, when the requestion is given from first floor or second
floor the motor has to move forward.

If the lift is in top floor then it has to move in the reverse direction.

If the lift is in middle floor then according to the requestion, lift will move in forward or
reverse direction.
WIRING DIAGRAM
LADDER DIAGRAM
RESULT

Thus the LIFT CONTROL SYSTEM was studied successfully by using Ladder Logicprogram.
EQUIPMENT 8: S7 1200 SIEMENS PLC
TRAINER INTRODUCTION

The S7-1200 controller provides the flexibility and power to control a wide variety of
devices in support of your automation needs. The compact design, flexible configuration, and
powerful instruction set combine to make S7-1200 a perfect solution for controlling a wide
variety of applications.

The CPU combines a microprocessor, an integrated power supply, input and output
circuits, built-in PROFINET, high-speed motion control I/O, and on-board analog inputs in a
compact housing to create a powerful controller. After you download your program, the CPU
contains the logic required to monitor and control the devices in your application. The CPU
monitors the inputs and changes the outputs according to the logic of your user program,
which can include Boolean logic, counting, timing, complex math operations, and
communications with other intelligent devices.

To communicate with a programming device, the CPU provides a built-in PROFINET

port. With the PROFINET network, the CPU can communicate with HMI panels or another
CPU. To provide security for your application, every S7-1200 CPU provides password
protection that allows you to configure access to the CPU functions.
 PLC controller used to this project is S7-1200 1214C AC/DC/RLY with version 3.0
and MLFB number is 6ES7 214-1BE31-OXBO.

DETAILS:

● Digital inputs in the controller is14 and Voltage is 24

● Digital output in the controller is 10 and Voltage is 24

● Back plane is available to connect extra I/O modulus and communication modules

● Analog input in the controller is two

● Input power supply to the controller is 120/240 VAC

● Three communication modules and eight I/O expansion modules can be used

● Modbus communication board, analog output board and analog input board can be used

PLC LANGUAGES
The function of all programming languages is to allow the user to communicate with
the programmable controller (PC) via a programming device. They all convey to the system,
by means of instructions, a basic control plan. Ladder diagrams, function blocks, and the
sequential function chart are the most common types of languages encountered in
programmable controller system design. Ladder diagrams form the basic PC languages, while
function blocks and the sequential function charting are categorized as high-level languages.

The basic programmable controller languages consist of a set of instructions that will
perform the most common type of control functions like relay replacement, timing, counting,
sequencing, and logic. High level languages are used for analog control, data manipulation,
reporting, and other functions that are not possible with the basic instruction sets.

The language used in a PC dictates the range of applications in which the controller
can be applied. Depending on the size and capabilities of the controller, one or more
languages may be used. Here are some typical combinations of the languages;
1. Ladder diagram (LAD).
2. Function blocks diagram (FBD).
WORKING PROCEDURE:

Select TIA portal 16.0 and double click on it as shown in the red color mark in the below

image Double click on create new project as shown in the below image
.

Select the project name ''1'' and select the location path to save project ''2'' then click create
''3'' as shown in the below image

1
2

3
Double click on device and network as show in the image

Click add new device as shown in the red color mark

Click Controller ''1'' and ''2'' SIMATIC S7 1200 as shown in the below image

1
2

Click on CPU ''1'' and ''2'' CPU 1214C DC/DC/DC then select the required ''3'' MLFB
number and click add ''4''.
The below image shows the PLC controller configuration image and just follow the
below procedure to communication

Double click on the RJ 45 symbol in the controller ''1'' ,now properties of the controller
will be open and Ethernet configuration also open if it is not opened just click on the
Ethernet address and change IP address as require''2'' as shown in the below image.

2
Analog module selection:

● Double click the module block (1) given below the diagram

● And also got the catalog in right side column and click the signal boards folder(2).

● After select the signal boards folder(2) go to click AQ(3) and select the
module folder(4)and module(5)simultaneously.

2
1
3
4
5
Now the Analog Module was created inside the PLC module in shown below the diagram.

Now save the program settings to enter the (CTRL+S) function. Then go to compile
operation to click the Red color mark in below diagram.
Then go to downloading the program settings for click the online tab(1) and also select the
download to device option(2).
1

Another one option for download the program goes to click download icon nearer to the
compile icon (or) Enter the following shortcut key for CTRL+L.
Then automatically open the Extended to download device window and do the
following procedure simultaneously.

● Select the PN/IE into the Type of the PG/PC Interface(1).

● And also select the PG/PC Interface(2).

● Then select the show all compatible devices(3).

● Finally click the Start Search option(4).

1
2

4
Then go to select target device window and select the plc device(1). And then click the load
Button(2).

If you are using first time of downloading the program in plc in contains following
procedures. In Software synchronization before loading to a device window in open and
then click the
Continue without synchronization option is shown below the Figure.
Then goes to load preview window to click the load option is marked in Red color block.
And also goes to Load Results window tick the start all and click the Finish option in
given figure.

Programming Method in PLC:

Click PLC-1 in the project tree ''1'' then click program block ''2'' and click main OB1
''3'' as shown in the below image

1
2
3
Now the below image shows (Object Block1) OB1 is created.

Now select the network as shown in the below image ''1'' and just double click on
normally open ''2'' as shown in the below image

1
Below image shows normally open is added

Select the ''1'' in below image and add the output coil in network. Then double click on the
both NO contact and output coil to enter their addresses simultaneously(2).

NOTES:

In Digital input starts from I0.0

In Digital output starts from Q0.0

 1

Right Click the PLC_1 in Project tree then Go to "Download to device"[1] option and the
Hardware and Software (only changes)[2].

1 2
If you are first time to download the program in plc it shows the below window then click the
Continue without synchronization option

Load preview window will open, select "Load" option.

In load results windows, select "start all" option and then select "finish" option.

For make an online process goes to click the Monitoring on/off icon is shown below the image.
Then below the image shows the online mode of the PLC
 EXPERIMENT NO: 1

AIM:

To study about the AND_GATE operation using SIEMENS S7-1200 PLC via
TIA Portal Software.

APPARATUS REQUIRED:

● PLC Trainer kit

● Personal Computer Installed with TIA Portal Software

● Ethernet cable

● Patch chords

OPERATIONS:

❖ In AND_GATE operation is used to make the multiple operation of 2 inputs.

Now using A&B are 2 inputs and C is the output.

❖ Now generating the following formula to create the AND_GATE operation is

given below.
A.B = C
TRUTH TABLE & SYMBOL OF
AND_GATE:

A
C
B

Notes:

0 - LOW ; 1 - HIGH
 Programming Method in PLC:

Click PLC-1 in the project tree ''1'' then click program block ''2'' and click
main OB1 ''3'' as shown in the below image

2 3

Now the below image shows (Object Block1) OB1 is created.

A B C

0 0 0
0 1 0
1 0 0
1 1 1
Now write an AND_GATE operation for make a 2 inputs like A and B .It is created by using
two normally open contacts. And their addresses are A (I0.0) and B (I0.1).

And the only one output can be used in this program that is C and their address is

(Q0.0). The given below image can be shows the AND_GATE operation program.
Then save the program to press (CTRL+S) function it will be saved.

After saved the program go to online mode to click GO Online icon directly.

After click the online mode goes to select the Monitoring ON/OFF Icon.
 Finally the two inputs [(I0.0), (I0.1)] are goes to HIGH the output

[Q0.0] will goes to HIGH.It can be represented in Green color

indications in below the Figure.

RESULT:

Thus the S7-1200 PLC based AND_GATE operation was studied

and createdsuccessfully through TIA portal.
EQUIPMENT NO: 9
INTRODUCTION
LABTECH Transducer Trainer is specially designed to study the characteristics and
working principles of various transducers like Strain Gauge, Load Cell, LVDT, Thermocouple
and RTD. Signal conditioning blocks are provided to measure the parameters of corresponding
Transducer. Digital Panel Meter is provided to display the Strain, Load (g), Displacement (mm)
and Temp (°C).

TECHNICAL SPECIFICATION:

Input Power 230V AC, 50Hz

DC Source +5V, -5V, +12v, -12V
AC Source Sine Wave 1Khz, 1V
Room AD590
Temperature
Thermometer Material Glass
Range (0-150) °C
Output 3 1/2 digit display
Transducer 1 Power Supply +/- 5 VDc, 500 Ma
Strain Gauge Capacity 1Kg
Connection Through four core cable
Signal conditioning IC 741
Transducer 2 Power Supply +/- 5 VDc, 500 mA
Load Cell Capacity 1Kg
Connection Through four core cable
Signal conditioning IC 741
Transducer 3 Primary Input 1Khz, 1V
LVDT range
±10mm
Micro meter scale 0-25 mm (Industrial standard)
Signal conditioning IC TL084
Transducer 4 Power Supply +/- 12 VDc, 500 mA
Thermocouple Capacity 200 °C
Connection Through four core Sheilded cable
Signal conditioning IC 741
Transducer 5 Power Supply +/- 12 VDc, 500 mA
RTD Capacity 200 °C
Connection Through four core Sheilded cable
Signal conditioning IC 741
1
FEATURES:

● The built in DC power supply of ±5V and ±12V (With maximum current output of

500mA) are provided.

● Built in sine wave signal generator.

● The user adjustable Zero and Span adjustment pots are provided.

● Output can compatible to connect with DAS.

● LVDT Sensor has to be fixed on the separate JIG arrangement.

● The measured parameters are displayed in the Digital Panel Meter, which is provided in

the front panel.

● Heat source (sterlizer) has to be supplied (100°C) can be supplied.

● Each block in this Trainer is terminated on the front panel separately.

● All interconnected through the internal patching; therefore we can understand the concept

better.

● The entire measuring unit is covered with fine wooden box.

● Inter connection cords and technical reference manuals are provided

2
 MODULE DESCRIPTION:

1. AC & DC Source

2. Transducers

3. Instrumentation Amplifier – Strain & Load

4. Converter & Instrumentation Amplifier – LVDT

5. Room Temperature measurement

6. DAQ System

7. Digital Panel Meter (DPM)

Mains:

Ac power supply is an internally connected to ON/OFF switch through the fuse and the
switch is mounted on the front panel of the Trainer. Input power supply use power to all
electronic devices inside the circuitry.

AC & DC Source:

3
 Sine Wave Generator generates the sine wave in the frequency of 1 KHz, 1V (P-P)

amplitude which is used for input of the LVDT. Inbuilt DC Power supply in the range of ±12V, ±5V/

500mA is provided. High stable regulated power supply is used for better performance.

Converter & Instrumentation Amplifier – LVDT

Converter unit gets the input from secondary winding of LVDT. It converts the AC to the
corresponding DC voltage. The output is depends on the core position of LVDT. Here the converter
output is Signal conditioned and displayed it in to the Output Indicator (DPM) in terms of mm. This
section also has the facility to user calibratable zero and span adjustments.

4
Instrumentation Amplifier – Strain & Load

Signal conditioner will process the output of transducer and presents a linear DC voltage to the
amplifier. This circuit will also buffer the inputs signal given to the differential amplifier. The
operational amplifier is used as a differential amplifier where the signal gets amplified to required
level. The amplifier gives out the analog output. The amplified output is terminated in the section and
its used for characteristics study of the Transducer and measurement.

Room Temperature measurement:

Room Temperature has to be sensed by AD590 semiconductor Temperature Transducer

and output of the Transducer is in the range of μA/k and this is to be converting to voltage using I/V

converter and this voltage is terminated in this section in terms of Room Temperature.

5
DAQ System

This is inbuilt circuit for signal conditioning unit which gives the output voltage Transducers
(Strain Gauge, Load Cell, LVDT, Thermocouple & RTD) for corresponding Voltage measured in
Multimeter. This voltage can compatible interface with DAQ System.

Digital Panel Meter (DPM):

The output from the amplifier is a linearised analog DC voltage. This analog voltage is
converted into digital output with the help of IC 7107. Then it is displayed through seven
segmented LEDs. When Switch S is in Up Direction, the 3½ digit digital panel meter displays the
Strain and Load (g). When Switch S is in Down Direction, the 3½ digit digital panel meter
displays the Displacement in (mm) and Temp (°c).

6
 Transducer
– 1 Strain
gauge
Strain gauge experiment module is a unique strain gauge experiment instrument. This is a
demonstration set up for measurement of strain exerted on the material. It comprises of a
complete instrument with instrumentation amplifiers, gain amplifiers, power supply with a
cantilever beam mounted on a base weights can be added up to a maximum of 1Kg on the pan,
which is fixed at one end of the cantilever beam.

Four strain elements are pasted in straight position on fixed end of cantilever beam,
while the other end is free to move up and down by suspending weights up to maximum of
1kg.The strain gauge is a resistive element. The resistance of each element is 350 Ohms. All the
strain elements are interconnected in the form of bridge circuit with compensating resistors. The
measuring instrument has built-in power supplies, instrumentation amplifier, gain amplifier. The
final output is terminated on output terminals for measurement of strain.

1.1 EXPERIMENTS:

1. To Characteristics study of Strain sensor.

2. Strain measurement and displayed in digital display.
3. Output can be calibrated to DAS.

1.2 TECHNICAL SPECIFICATION:

Power Supply : +/- 5 VDc, 500

mA Transducer : Strain Gauge
Excitation : 10V Dc
Max.Weight : 1Kg
Strain Range : (0- 250)
Output : 3 1/2 digit display
DAQ System : (0-5)Vdc

7
1.3 THEORY

ELECTRICAL STRAIN GAUGES

The development of strain gauges as followed many different approaches and gauges have
been based on mechanical, optical, electrical and pneumatic principles, when electrical strain
gauges were first introduced the gauge elements was produces by winding grid with very fine
diameter wire. Standard gauge resistance is 120 Ohms and 350 Ohms. But in some
configurations resistance of 600 Ohms and 1000 Ohms are available. The gauge is normally
fabricated by advance, iso-elastic alloys.

Strain gauge are packed with polymide plastic or a very thin brittle, high modules epoxy.
These gauges are bonded on the material at which the strain has to be measured. A ceramic
adhesive is used to maintain the grid configuration and to electrically insulate the grid from the
specimen. Bonding of strain gauge to the specimen is the vital part in the strain measuring
system. A thin layer of adhesive is coated on the cleaned surface of the specimen and pressed
with the thumb. Depending in the adhesive used the specimen is cured at certain temperature for
proper bonding.

STRAIN GAUGE EXPERIMENTAL MODULE

Strain gauge is a passive transducer. This is used to measure the lateral strain exerted on a
given surface. This sensor converts a mechanical displacement in to a change in resistance.
Positioning and quality of bonding the sensor on the surface, larger determines the accuracy. An
optional external wheat stone’s bridge is used to measure bridge imbalance. Which is a measure
of strain A bridge is symmetrical, four – element, circuit that enhances the instrument’s ability to
detect small changes in quiescent voltage drop, allowing magnification of the different signal.
This acquired signal is conditioned and computed to indicate actual strain suffered by the surface.

8
 In the strain gauge experimental module, the sensor is bonded on one end of a long
rectangular stainless steel metal strip of uniform cross section. This end is fixed firmly to a
metallic stand. The other end is freely suspended, similar to a Cantilever. To this free end,
weights ranging from 100 gms to 1000 gms in multiples of 100 gms are added to create strain
(elongation) on the strain gauge strip. A relation between applied stress and measured strain gives
the change in resistance of the gauge, explaining the Principle of strain gauge transducer, This
consists of a built – in power supply, interface electronics, assorted weights. A standard digital
multi-meter in 2V DC range is used to make voltage measurement. This voltage measurement
directly indicated the weights added on the strain gauge.

The strain gauge is an example of a passive transducer that converts a mechanical

displacement into a change of resistance. A strain gauge is a thin, wafer-like device that can be
attached (bonded) to a variety of materials to measure applied strain. Metallic strain gauges are
manufactured from small diameter resistance wire, such as constantan, or etched from thin foil
sheets. The resistance of the wire or metal foil changes with length as the material to which the
gauge is attached undergoes tension or compression. This change in resistance is proportional to
the applied strain and is measured with a specially adapted wheat stone bridge.

The sensitivity of strain gauge is described in terms of characteristics called gauge factor K,
defined as the unit change in resistance per unit change in length l, or

Gauge factor K = [ΔR/R] /

[ΔL/L] Where K =

gauge factor
R = Normal gauge resistance

ΔR = Change gauge resistance

l = Normal specimen length (unstressed condition)

Δl = Change in specimen length

9
 The term Δ1/1 in the denominator of the equation is the strainσ. The equation can be

written as K = [ΔR/R] / σ

Where σ = The strain in the lateral direction.

The resistance change (R) of a conductor with length 1 can be calculated by using the
expression for the resistance of a conductor of uniform cross section:

Length

ρx 1 R = ρ

Area (Π/4) d2

Where ρ = the specific resistance of the conductor

material 1 = Length of the conductor

d = diameter of the conductor

Tension on the conductor causes an increase Δl in its length and a simultaneous decrease Δd

in its diameter.

The resistance of the conductor then changes to

(1+Δ1) 1(1+Δ1/1)

R=ρ =ρ

(Π/4) (d-Δd) 2 (Π/4) d2 (1-2Δd/d)

 The equation may be simplified by using Poisson’s ratio, defined as the ratio of strain in the
lateral direction to strain in the axial direction. Therefore

10
 Δd/d

μ=

Δ1/1

1 (1+Δ1/1)

Rs = ρ X

(Π/4) d2 (1-2μΔ1/1)

Which can be simplified to

Rs = R + (R = R [1+ (1+2μ) Δ1/1)

The increment of resistance (R) as compared to the length l can then be expressed in terms of the
gauge factor K where

ΔR/R

K= = 1+2μ

Δ1/1

Poisson’s ratio for most metals lies in the range of 0.25 to 0.35, and the gauge factor would
then be on the order of 1.5 to 1.7

For strain – gauge applications, a high sensitivity is very desirable. A large gauge factor
means a relatively large resistance change, which can be more easily measured that a small
resistance change. For constantan wire, K is about 2; Whereas Alloy 479 gives a K value of
about 4.

I t is interesting to carry out a simple calculation to find out what effect an applied stress has
on the resistance change of a strain gauge. Hooke’s law gives the relationship between stress and
strain for a linear stress strain curve, in terms of the modulus of elasticity of the material under
tension. Defining stress as the applied force per unit area and strain as the elongation of the
stressed member per unit length, Hooke’s law is written as
S

11
 σ=
E
Where σ = Strain, Δ1/1 (no

units) S = Stress, Kg /
cm 2.
E = Young’s modulus, Kg / cm 2. For steel E = 2.1 X 106

12
EXPERIMENTS:
EX.NO:

1.1 AIM

To study the characteristics of strain gauge by creating strain (elonguvation) on the strain
gauge strip by applying load to the cantilever beam.

APPARTUS REQUIRED:

❖ LABTECH TRANSDUCER TRAINER

❖ Strain transducer assembly

❖ Multimeter

❖ Patch chords

❖ Weight (0-1000)gms

PROCEDURE

1. Give the AC supply to the trainer using power card. It is provided at the backside of the
trainer.
2. Connect the sensor to the trainer as mentioned in patching diagram.
3. Interconnect the circuit as per the patching diagram (Ex.No:1.1)
4. Connect the Multimeter (milli volt) at the output terminals of strain gauge bridge.
5. Do not add weight on the weighing pan.
6. Measure the output voltage of the strain transducer using Volt meter. If the bridge is
balanced the meter will read zero. Otherwise adjust the Zero Adj 1 pot provided in the
strain gauge section till the voltage equal to zero.
7. Without disturbing Zero Adj 1 add the weight 100 gm on the pan.
8. Now the Voltmeter will display the voltage in mV, further slowly add the weights one by
one and observe the characteristics of the sensor.
9. Tabulate the readings in the tabular column.
10. Plot the graph between weight in ‘X’ axis and output voltage in “Y” axis.

13
TABULATION:

Sl. Weig Output

No hts Voltage
(gra (mV)
m)
1 100
. .
. .

10 1000

RESULT:

Thus the characteristic of strain gauge was studied.

14
EX.NO: 1.2

AIM:
Experiment to measure the strain (Elonguvation) on the strain gauge strip by applying load to
the cantilever beam.

APPARTUS REQUIRED:

❖ LABTECH TRANSDUCER TRAINER

❖ Strain transducer assembly

❖ Multimeter

❖ Patch chords

❖ Weight (0-1000)gms

PROCEDURE:
1. Interconnect the strain transducer assembly to the measuring trainer.
2. Connect the power cord of the measuring instrument to a 230V AC power .
3. Do not add weight on the weighing pan.
4. Patch the circuit as per the patching diagram (1.2).
5. Select Switch S to Strain Mode (Up Direction).
6. Keep Span Adj 1 pot in middle position.
7. Switch ON the trainer.
8. Observe the DPM display it will be zero otherwise adjust the Zero Adj 1 pot
provided in Strain Gauge section.
9. Add the 100 gms weight to the pan. Now the DPM shows the corresponding
strain extended on the cantilever beam.
10. Calibrate the DPM reading to 25 strains using Span Adj 1 pot. Now the
trainer is calibrated to read the strain.
11. Increase the load in steps of 100g the strain indicator (DPM) shows the exact strain
value without any change in zero and span pot release the load on the pan.

15
CANTILEVER BEAM TRANSDUCER ASSEMBLY DIMENSIONS

22Cms

B= 2.8 Cms
S s
t
r
a Length L = 22Cms, Breadth B= 2.8 Cms,
i Thickness T= 0.3 Cms Young’s Modulus Y for
n stainless steel = 2.1X106

E SAMPLE CALCULATION:
l
e 6 WL
m Strain is given by the formula = -----------------
e BT2Y
n Weight in Kg.
t

E
g:
1
6 X 0.1X 22
For 100 gram weight the strain is -------------------------------------------- = 24.95 =
25
2.8 X 0.3 X 0.3 X 2.1 X 106
Eg: 2

6 X 1X 22
For 1000 g weight the strain is = -------------------------------------------- = 249.5 = 250
2.8 X 0.3 X 0.3 X 2.1 X 106

16
TABULATION:

Sl. Weig Stra

No hts in
(gra
m)
1 100 25
. . .
. . .

10 1000 250

RESULT:
The strain (Elonguvation) on the strain gauge strip by applying load to the cantilever
beam was measured.

17
EX: NO:
1.3 AIM:
To measure the strain with DAS
APPARTUS REQUIRED:

❖ LABTECH TRANSDUCER TRAINER

❖ Strain transducer assembly

❖ Multi meter

❖ Patch chords

❖ Weight (0-1000)gms

PROCEDURE:
1. Check the connection made and switch on the instrument.
2. Measures the voltage it will be zero otherwise adjust the Zero Adj 1 pot
provided in Strain Gauge section.
3. Add the 100 gm weight to the pan. Now the Voltmeter shows the
corresponding strain extended on the cantilever beam.
4. Calibrate the voltmeter reading to 0.5V strains using Span Adj 1 & 6 pot.
5. Increase the load in steps of 100g the Voltmeter shows the exact strain value
without any change in zero and span pot release the load on the pan.
6. Apply load to the fulcrum arm by adding dead weight in steps of 100g
7. Strain sensor produces the output in voltage proportional to the strain applied
which is displayed in the Volt meter.
8. Observe the output voltage to the corresponding weight applied and tabulate it.

18
TABULATION:

Sl. Weig Output

No hts Voltag
(gra e (V)
m)
1 100 0.5
. . .
. . .

10 1000 5

RESULT:
The given strain sensor characteristics was studied and the corresponding sensor
output voltages were note

19
 Transducer
– 2 Load
Cell
This is a demonstration setup for measurement of weight exerted on the material. It is a complete
instrument having amplification circuit, power supply, pan and stand arrangement. In this
arrangement weight can be measure the maximum of 1KG. The pan is fixed to the stand is
possible to experiment the principle of load cell.

The load cell is a resistive element. All the resistance of each element is interconnected in
the form of a bridge circuit with compensation resistors. The measuring instruments have built in
power supplies, instrumentation amplifier, gain amplifier and DPM (Digital Panel Meter). Load
cells are packed with polyamide plastic or a very thin brittle, high modules epoxy.

2.1. OBJECTIVES

1. To study the characteristics of Load cell

Transducer. 2.To Study of signal conditioning unit.
3. To measure the given load and display it in digitally.
4. Output calibrated with DAS.

2.2 TECHNICAL SPECIFICATION:

Input Power 230V AC, 50Hz

Power Supply +12v, -12V
Sensor capacity Max. 1Kg
Signal conditioning IC 741
Output 3 ½ digit digital Display
Multi meter Digital (Optional)

20
1.3. THEORY
LOAD MEASUREMENT:
Load may be measured in compressive force. Load cell unit resistance changes directly
proportional to the load applied.

LOAD CELL EXPERIMENT MODULE:

A strain gauge – elastic member combination arrangement used for the measurement of
load or weight is called load cell. It utilizes an elastic member as primary transducer and strain
gauge as a secondary transducer. A suitable plane area is placed on the elastic member as a
weight stand. Then, strain gauge is attached to the elastic member. On applying load, the elastic
member will deform or deflect. Since the strain gauge is attached to the elastic member, strain
gauge may elongate or compress due to tension. This varies its length and in turn its resistance
varies. By measuring the variation in the resistance of the strain gauge, the applied load can be
Calculated.

21
 TABULATI

AIM:
To study the characteristics of Load cell Transducer.

APPARTUS REQUIRED:

❖ LABTECH TRANSDUCER TRAINER

❖ Load cell transducer assembly

❖ Multimeter

❖ Patch chords

❖ Weight (0-1000)gms

PEOCEDURE:

1. Give the AC supply to the trainer using power card. It is provided at the backside of the
trainer.
2. Connect the sensor to the trainer as mentioned in patching diagram.
3. Interconnect the circuit as per the patching diagram (Ex.No:2.1)
4. Connect the Multimeter (milli volt) at the output terminals of Load Cell Bridge.
5. Do not add weight on the weighing pan.
6. Measure the output voltage of the Load Cell transducer using Volt meter. If the bridge is
balanced the meter will read zero. Otherwise adjust the Zero Adj 2 pot provided in the
Load Cell section till the voltage equal to zero.
7. Without disturbing Zero Adj 2 add the weight 100 gm on the pan.
8. Now the Voltmeter will display the voltage in mV, further slowly add the weights one by
one and observe the characteristics of the sensor.
9. Tabulate the readings in the tabular column.
10. Plot the graph between weight in ‘X’ axis and output voltage in “Y” axis.

22
 EX.NO:

Sl. Weig Output

No hts Voltage
(gra (mV)
m)
1 100
. .
. .

10 1000

RESULT:

Thus the characteristic of Load ell was studied.

23
 TABULATI

AIM:
To measure the given load and display it in digitally.

APPARATUS REQUIRED:

❖ LABTECH TRANSDUCER TRAINER

❖ Load cell transducer assembly

❖ Multimeter

❖ Patch chords

PROCEDURE:

1. Interconnect the Load Cell transducer assembly to the measuring trainer.

2. Connect the power cord of the measuring instrument to a 230V AC power outlet.
3. Do not add weight on the weighing pan.
4. Patch the circuit as per the patching diagram (2.2).
5. Select Switch S to Load Mode (Up Direction).
6. Keep Span Adj 1 pot in middle position.
7. Switch ON the trainer.
8. Observe the DPM display it will be zero otherwise adjust the Zero Adj 2 pot
provided in Load Cell section.
9. Add the 100 gms weight to the pan. Now the DPM shows the corresponding Load.
10. Calibrate the DPM reading to 100 gm using Span Adj 1 pot. Now the trainer is
calibrated to read the Load.
11. Increase the load in steps of 100g the load indicator (DPM) shows the exact load
value without any change in zero and span pot release the load on the pan. Apply the
unknown load input to the pan the load indicator measures the known load.

24
 EX.NO:

Sl. Applied Load

No Weights (DPM)
(gram) (gram)
1 100 100
. . .
. . .

10 1000 1000

RESULT:

The unknown load was measured by using load cell sensor and the measured value is
displayed in digital panel meter (DPM) in terms of loading.

25
EX: NO:
2.3 AIM:
To measure the Load with DAS
APPARTUS REQUIRED:

❖ LABTECH TRANSDUCER TRAINER

❖ Load Cell transducer assembly

❖ Multi meter

❖ Patch chords

❖ Weight (0-1000)gms

PROCEDURE:
1. Check the connection made and switch on the instrument.
2. Measures the voltage it will be zero otherwise adjust the Zero Adj 2 pot
provided in Load Cell section.
3. Add the 100 gm weight to the pan. Now the Voltmeter shows the
corresponding Load extended on the cantilever beam.
4. Calibrate the voltmeter reading to 0.5V using Span Adj 1 & 6 pot.
5. Increase the load in steps of 100g the Voltmeter shows the exact Load
value without any change in zero and span pot release the load on the pan.
6. Apply load to the fulcrum arm by adding dead weight in steps of 100g.
7. Load Cell sensor produces the output in voltage proportional to the strain
applied which is displayed in the Volt meter.
8. Observe the output voltage to the corresponding weight applied and
tabulate it.

26
TABULATION:

Sl. Weig Output

No hts Voltag
(gra e (V)
m)
1 100 0.5
. . .
. . .

10 1000 5

RESULT:
The given Load Cell characteristic was studied and the corresponding sensor output
voltages were noted.

27
 Transducer – 3
Linear Variable Differential Transformer (LVDT)

OUR LABTECH LVDT Transducer gives the complete knowledge about Displacement
transducer, displacement measurement technique and also it is used to study the characteristics of
the LVDT sensor. For students easy understanding purpose the circuit diagram is printed on the
front panel. The measured displacement value is displayed in the Digital Panel Meter (DPM) in
terms of mm.

3.1. Objective
1. To Study the characteristics of LVDT
2. To measure the linear displacement using LVDT.
3. Outputs can compatible to connect with DAS.

3.2. TECHNICAL SPECIFICATIONS:

Sensor range : ±10mm

Micro meter scale : 0-25 mm (Industrial standard)

Sine signal generator : 1 KHz, (1V P-P)

Output : 3 1/2 digit digital display

28
3.3. THEORY:

LVD TRANSFORMER:
It has the two secondary windings namely SY1, SY2. The LVD transformer gets the
input from sine wave signal generator. The primary and secondary terminals are mounted
separately on the front panel.

The Linear Variable differential transformer consists of a single primary winding P1.
And two secondary winding S1 and S2 wound on a hallow cylindrical former. The secondary
have an equal number of turns but in displacement measurement they are connected in series
opposition so that the EMFS Induced in the coils is opposed each other. The primary winding
is connected to an AC source, whose frequency may range from 50Hz to 20 KHz. A movable
soft Iron core determines the flux linkage between the AC excited primary winding and each
of the two secondary windings. The core made up of nickel–Iron Alloy is slotted
longitudinally to reduce Eddy current losses. The displacement is measured by applied to an
arm attached to the core. The core is in the center or null position, the induced EMF in the
secondary’s are equal and since they oppose each other, the output voltage will be 0 volt.

29
 When an externally applied force moves the core to the left hand position, more
magnetic flux links the left hand coil then the right hand coil. The EMF induced in the left
hand coil, Es1 is therefore larger than the induced EMF of the right hand coil, Es2.

The magnitude of the output voltage is then equal to the difference between the
two secondary voltages and it is in phase with the voltage of the left –hand coil.

Similarly, When the core is forced to move to the right, more flux links the
right- hand coil than the left-hand coil and the resulting output voltage, which is the
difference between Es2 and Es1, is now in phase with the EMF of the right –hand coil.

Thus the LVDT output voltage is a function of the core position. The amount of
a voltage change in either secondary winding is proportional to the amount of movement of
the core. By noting which output is increasing or decreasing, the direction of motion can be
determined. The output ac voltage inverts in phase and the core passes through the central
null position. Further as the core moves from the center, the greater is the difference in value
between Es1 and Es2 and consequently the greater the output voltage. Therefore the
amplitude of the output voltage is a function of the distance the core moves, while the
polarity or phase indicates the direction of the motion.

30
 The amount of output voltage of an LVDT is a linear function of the core displacement within a
limited range of motion.

31
 EX.NO:3.1

AIM:
To study the Characteristics of LVDT Transducer.

APPARATUS REQUIRED:

🞛 LABTECH TRANSDUCER TRAINER

🞛 LVDTJIG Setup
🞛 CRO
🞛 Patch Chords

PROCEDURE:

1. Give the AC power supply to the trainer using power cord.

2. Switch “ON” the trainer and check the Sine wave generator output using CRO.
3. Switch “OFF” the trainer and interface the LVDT sensor to the trainer.
4. Give the connections as per given patching diagram(3.1)
5. Observe sy1& sy2 output voltage using voltmeter (Vac).
6. Adjust the LVDT core position to null i.e. (10mm).
7. Adjust the core position and observe the output voltage. The amplitude of secondary
voltage is depends on the core position.
TABULATION:

Core Position From Secondary Voltage (sy1) Secondary Voltage (sy1)

Transducer
(mm)

20(max
+ve)
.
.
10 (null)
.
.
0(max -
Ve)

32
MODEL GRAPH:

RESULT:

The characteristics of LVDT transducer were studied.

33
 EX.NO.

3.2: AIM:

Experiment to measure the linear displacement using LVDT Transformer.

APPARATUS REQUIRED:

❖ LABTECH TRANSDUCER TRAINER

❖ LVDT Micrometer JIG Arrangement
❖ Patch Cord

PROCEDURE:

1. Patch the circuit as per the circuit diagram (3.2).

2. The LVDT JIG micro meter main scale is calibrated by

0 mm = max +ve
Displacement 10 mm = Null
position
20 mm = max -ve Displacement

3. Select Switch S to Displacement in mm Mode (Down Direction).

4. Now set the LVDT Core position as null i.e. set the micrometer main scale position to
10mm and set the DPM to (000), using Zero Adj 3 pot provided in the converter.
5. Change the micrometer scale arrangement to 5mm and adjust the Span 3 pot until the
DPM shows +05.0mm.
6. Now the LVDT Trainer is calibrated and varies the core position using micrometer scale
arrangement note down the corresponding output voltages, with respect to core
displacement.
7. Plot the graph between Displacements versus Output Voltage.

34
TABULATION:

Core Position From Displacement From Output Voltages (V)

Transducer DPM (mm)
(mm)

20(max -
+ve) 1
0
. .
. .
10 (null) 0
. .
. .
0(max - +
Ve) 1
0

RESULT:

The linear displacement of LVDT transformer was measured, interms of mm, and
the displacement versus output voltage graph were plotted

35
EX: NO:
3.3 AIM:
To measure the Displacement with DAS

APPARTUS REQUIRED:

❖ LABTECH TRANSDUCER TRAINER

❖ LVDT Micrometer JIG Arrangement

❖ Patch Cord

❖ Multi meter

PROCEDURE:
1. Check the connection made and switch on the instrument.
2. Now set the LVDT Core position as null i.e. set the micrometer main scale position to
10mm and set the Voltmeter to (000V), using Zero Adj 3 pot provided in the converter.
8. Change the micrometer scale arrangement to 5mm and adjust the Span 3 & Span Adj 6
pot until the Voltmeter shows +0.5V.
3. Now the LVDT Trainer is calibrated and varies the core position using micrometer scale
arrangement note down the corresponding output voltages, with respect to core
displacement.
4. Observe the output voltage to the corresponding Core position and tabulate it.

TABULATION:

Core Position From Output Voltages (V)

Transducer
(mm)

20(max
+ve)
.
.

0 (null)
.
.

0(max -
Ve)
36
RESULT:

The given LVDT characteristic was studied and the corresponding sensor output
voltages were noted.

37
 Transducer
– 4
Thermocou
ple
Our LABTECH Transducer Trainer is used to measure the temperature of the given
heating source using Thermocouple. Hot junction produced milli volts proportional to
temperature. Which is signal conditioned and digitally displayed in terms of degree celsius.
Room Temperature has to be sensed by AD590 semiconductor Temperature Transducer

and output of the Transducer is in the range of μA/k and this is to be converting to voltage using

I/V converter and this voltage is terminated in this section in terms of Room Temperature. The
cold junction of Thermocouple should be maintained in zero level and the measured Temperature
only the increasable output of this section because of this reason, user adjustable zero and span
adjustments are provided in this section. In this section, the raw output of Thermocouple sensor
is amplified in small level. The amplified output is terminated in the section and its used for
characteristics study of the sensor and Temperature measurement.

4.1. OBJECTIVE:

1. To study and observe the characteristics of Thermocouple Transducer.

2. To Measure the temperature of the given Heating source using Thermocouple.
3. Output calibrated to standard range to connect with Data Acquisition card.

38
 4.2. TECHNICAL SPECIFICATION:

Room Temperature Sensor AD590

Temperature Sensor Thermocouple
Signal conditioning IC 741
Range 30- 100°C
Output 3 ½ digit digital Display
Hot Source Sterlizer (1000W) with closing cover.
Thermometer Glass Type

4.3 THEORY:

THERMOCOUPLE (PRINCIPLES):

SEEBECK EFFECT:

See beck observed the existence of thermoelectric circuits while studying the electromagnetic
effects of metals. He found that bonding wires of two dissimilar metals together to form a closed
circuit caused an electric current to flow in the circuit whenever a difference in temperature was
imposed between the end junctions.

39
PRACTICAL RULES APPLYING TO THERMOCOUPLES:

A thermocouple current can be sustained in a circuit of a single homogenous material,

however varying in cross section, by the application of heat alone.

The algebraic sum of the thermo electromotive forces in a circuit composed of any number of
dissimilar materials is zero if all of the circuit is at a uniform temperature. This means that a third
homogenous material always can be added to a circuit with no effect on the net EMF of the
circuit so long as its extremities are at the same temperature. Therefore a device for measuring
the thermal EMF may be introduced into a circuit at any point without affecting the resultant
EMF, provided all the junctions added to the circuit are at the same temperature. It also follows
that any junction whose temperature is uniform and which makes a good electrical contact does
not affect the EMF of the thermocouple circuit regardless of the method used in forming the

junction.

If two dissimilar Homogenous metals produce a thermal EMF of E1 when the junctions are at
temperatures T1 and T2, and a thermal EMF of E2 when the junctions are at T2 and T3, the EMF
generated when the junctions are at T1 and T3 will be E1 +E2.

The application of this law permits a thermocouple calibrated for a given reference
temperature to be used with any other reference temperature through the use of a suitable
correction. Another example of this law is that extension wires having the same Thermo-electric
characteristics as those

40
of the Thermocouple wires can be introduced in to the Thermocouple circuit without affecting
the net EMF of the Thermocouple.

AD590:

The AD590 is a two-terminal integrated circuit Temperature Transducer which produces

an output current proportional to absolute Temperature. Several techniques can be used to
compensate for reference junction temperatures that deviate from 0°C. If the reference junction

temperature is maintained in the 0°C-50°C range, a monolithic linear Temperature sensor such as
the AD590 from Analog device can be used.
The AD590 is a calibrated two terminal Temperature sensor requiring only a Dc
voltage supply (+4Vto+30V). Costly Transmitters, filters, lead wire compensation and
linearization circuits and all unnecessary in applying the device.

41
 EX.NO:

AIM: To study the characteristics of Thermocouple Transducer.

APPARATUS REQUIRED:

❖ LABTECH LABTECH TRANSDUCER TRAINER

❖ Thermocouple Transducer.

❖ Heating source with water (sterlizer).

❖ Thermometer

PRECAUTIONS:

1. Sterlizer should be closed position and holes are provided in the top position of the
sterlizer for fixing the Thermocouple sensors.

2. Before doing the experiments, check all the power supplies.

PROCEDURE:
1. Refer Patching Diagram (4.1).
2. Connect the water bath with the AC supply and insert the Thermocouple sensor and
thermometer in to the water bathe.
3. Now increase the temperature of the Thermocouple through water bath to a certain Celsius.
4. On heating, measure the milli volt output at the Thermocouple test points using multi
meter in mv mode for every 10ºC and the corresponding temperature using thermometer.
Tabulate the readings in the tabulation given below.
5. Plot the graph Temperature Vs. Output voltage (mv) and observe the characteristics.

42
TABULATION:

Temperatu Output
re voltage
(mv)
(ºc)
30

40

50

RESULT:
The characteristics of Thermocouple was studied and the graph Temperature vs
Resistance was plotted

43
 EX.NO:

AIM: To calibrate the Thermocouple Transducer.

APPARATUS REQUIRED:

❖ LABTECH LABTECH TRANSDUCER TRAINER

❖ Thermocouple Transducer.

❖ Heating source with water (sterlizer).

❖ Thermometer

PRECAUTIONS:

1. Sterlizer should be closed position and holes are provided in the top position of the
sterlizer for fixing the Thermocouple sensors.

2. Before doing the experiments, check all the power supplies.

PROCEDURE:

1. Connect the Ac power supply to the trainer using 3pin power cord and the power socket is
provided in the backside of Trainer.
2. Switch “ON” the power supply of the trainer using ON/OFF switch and check the DC
power supply using multimeter.
3. Select Switch S to Temp (°C) Mode (Down Direction).
4. Keep Span Adj 4 pot in middle position.
5. Switch On the Trainer.
6. Set the Room Temperature voltage (TR) 0.3V with respect to GND using multimeter by
vary the Zero Adj 6 Pot which is provided in Room Temperature section.
7. Give the connections as per the patching diagram (4.2).
8. Set the Room Temperature as 30.0 °C in DPM by using Zero Adj 4 Pot which is
provided in Thermocouple Section.
44
 9. Connect the AC power supply to the sterlizer using 3pin power cord and then switch
“ON” the sterlizer.
10. Dip the Thermocouple Transducer and Thermometer in to the sterilizer.
11. Then note down the Thermometer reading corresponding increasing Temperature
display in the DPM.

Sl.No Thermometer DPM

. Reading Readin
(°C) g (°C)
3 3
0 0
. .
. .

RESULT:

Thus the Characteristics of Thermocouple transducer was calibrated.

45
 Transducer – 5
Resistance Temperature Detector (RTD)
Our LABTECH Transducer Trainer is used to measure the temperature of the given
heating source using RTD. Room Temperature has to be sensed by AD590 semiconductor

Temperature Transducer and output of the Transducer is in the range of μA/k and this is to be

converting to voltage using I/V converter and this voltage is terminated in this section in terms
of Room Temperature. The cold junction of RTD should be maintained in zero level and the
measured Temperature only the increasable output of this section because of this reason, user
adjustable zero and span adjustments are provided in this section. In this section, the raw output
of RTD sensor is amplified in small level. The amplified output is terminated in the section and
its used for characteristics study of the sensor and Temperature measurement.

5.1. OBJECTIVE:

1. To study and observe the characteristics of RTD Transducer.

2. To Measure the temperature of the given Heating source using RTD.
3. Output calibrated to standard range to connect with Data Acquisition card.

5.2 . TECHNICAL SPECIFICATION:

Room Temperature Sensor AD590
Temperature Sensor RTD-PT100
Signal conditioning IC 741
Output 3 ½ digit digital Display
Hot Source Sterlizer (1000W) with closing cover.
Range (30-100)°C

46
 EX.NO:

AIM: To study the characteristics of RTD Transducer.

APPARATUS REQUIRED:

❖ LABTECH LABTECH TRANSDUCER TRAINER

❖ RTD – PT100 Transducer.

❖ Heating source with water (sterlizer).

❖ Thermometer

PRECAUTIONS:

3. Sterlizer should be closed position and holes are provided in the top position of the
sterlizer for fixing the RTD sensors.

4. Before doing the experiments, check all the power supplies.

PROCEDURE:
1. Refer Patching Diagram (5.1).
2. Measure the resistance value of the RTD using digital multi meter. The value of RTD
shows around 110 ohms.
3. Connect the water bath with the AC supply and insert the RTD sensor and thermometer in
to the water bathe.
4. Now increase the temperature of the RTD through water bath to a certain Celsius.
5. On heating, measure the resistance at the RTD test points using multi meter in ohms
mode for every 10ºC and the corresponding temperature using thermometer. Tabulate the
readings in the tabulation given below.
6. Plot the graph Temperature Vs. Resistance and observe the characteristics.

47
TABULATION:

Temperatu Resistan
re ce
(Ohms
(ºc) )
30 110

40 117

50 121

RESULT:
The characteristics of RTD was studied and the graph Temperature vs Resistance was
plotted

48
 EX.NO:

AIM: To study the calibrate the RTD Transducer.

APPARATUS REQUIRED:

❖ LABTECH LABTECH TRANSDUCER TRAINER

❖ RTD – PT100 Transducer.

❖ Heating source with water (sterlizer).

❖ Thermometer

PRECAUTIONS:

1. Sterlizer should be closed position and holes are provided in the top position of the
sterlizer for fixing the RTD sensors.

2. Before doing the experiments, check all the power supplies.

PROCEDURE:

1. Connect the Ac power supply to the trainer using 3pin power cord and the power socket
is provided in the backside of Trainer.
2. Switch “ON” the power supply of the trainer using ON/OFF switch and check the DC
power supply using multimeter.
3. Select Switch S to Temp(°C) Mode (Down Direction).
4. Keep Span Adj 5 pot in middle position.
5. Switch On the Trainer.
6. Set the Room Temperature voltage (TR) 0.3V with respect to GND using multimeter by
vary the Zero Adj 6 Pot which is provided in Room Temperature section.
7. Give the connections as per the patching diagram (5.2).
8. Set the Room Temperature as 30.0 °C in DPM by using Zero Adj 5 Pot which is
provided in RTD Section.
49
 9. Connect the AC power supply to the sterlizer using 3pin power cord and then switch
“ON” the sterlizer.
10. Dip the RTD Transducer and Thermometer in to the sterilizer.
11. Then note down the Thermometer reading corresponding increasing Temperature
display in the DPM.

Sl.No Thermometer DPM

. Reading Readin
(°C) g (°C)
3 3
0 0
. .
. .

RESULT:

Thus the Characteristics of RTD transducer was calibrated.

50
1 5
52
53
54
55
56
57
58
59
60
61
62
 EQUIPMENT NO: 10 CAPACTIOR TRAINER KIT
EXPIREMENT:
AIM
To find the capacitance value.
APPARTUS REQUIRED:
1) LABTECH Capacitive Transducer Trainer
Power Supply : + / - 12 VDC, 500 mA
Capacitance Range : (42 – 151) μF
Frequency Output : 3 ½ digit display
Output Voltage : 0-5 V
Measureable Range : (100 – 500) Hz
2) Patch chords

Theory:
LABTECH’S TRAINER KIT FOR CAPACITIVE TRANSDUCER TRAINER

CAPACITIVE TRANSDUCER TRAINER

● The trainer consists of a frequency generator that generates a frequency of square wave for
the corresponding capacitance and it is fed to the input of signal conditioning unit.

● The signal conditioning unit comprises of a F to V converter that produces a voltage

corresponding to the input frequency.
 CAPACITOR VAULES:
FREQUENCY(Hz)
CAPACIT
Theoretical
OR (μF) Practical Value
Value
C1=151
μF
C2=125
μF
C3=115
μF
C4=106
μF

C5=95μ
F
C6=90μ
F
C7=79μ
F
C8=58μ
F
C9=47μ
F
C10=42
μF

BLOCK DIAGRAM:
CAPACITOR BANK:

Capacitive bank Display unitS

Frequ
(variable) frequency
ignal
ency
(Hz)
condition
generat
or ing unit

Formula:
1
F= ----------
2πRC
CAPACITIVE TRANSDUCER:
PROCEDURE:
1. Give the connections as per the patching diagram.
2. Now switch on the trainer.
3. Select the some Capacitance value in variable capacitor section.
4. Observe the frequency in Hz from Digital Panel Meter.
5. The output frequency is to determine the value of capacitance.
6. Calculate the Capacitance value by using the formula.
Model Calculation:
Capacitance (C) = 1/2πR f
Where R is 10.2K ohm
f is frequency taken from display
= 1/2π x 10.2 x 103 x 104
= 151μF

RESULT:
Thus the capacitance value was found.
 EQUIPMENT NO: 11 PRESSURE TO CURRENT CONVERTOR
Introduction:
LABTECH Current to Pressure converter trainer is a complete device, converts
a current input signal to a linearly proportional pneumatic output pressure. DPM is provided
on the front panel. It is indicates the input current values. This trainer consists of current
source, I to P Converter, pressure source indicator and Output pressure indicator.
Pneumatically actuated control valves in these plants which had to receive their
output instructions from the control computer, which sent these signals as 4-20 mA DC
analog current signals. This required a current to pneumatic conversion. The industry soon
termed these I to P or I/P transducers, with I denoting the current input and P signifying the
pneumatic output.
Most I/P transducers convert their electronic signals to pneumatic by passing the
current through a wound coil in a magnetic field, which modulates a backpressure nozzle in
a pneumatic pilot circuit that provides the 3-15 psi pneumatic output. Pressure to current
transducers employ pressure diaphragms that are mechanically linked to excited strain gages,
piezo sensors, or capacitance sensors that drive an output amplifier section. These then
transmit the required 4-20 mA DC current output to control systems.

Technical specification:

Power Supply : +/- 12 VDc, 500 mA

Current Source : (4-20) mA
Current Display : 3 1/2 digits
Pressure Source Indicator : (0 - 4.2) Kg/cm2
Pressure Source Indicator : (0 - 4.2) Kg/cm2
Air Regulator : (0 - 10.2)
Kg/cm2
I to P Converter : WAAREE Make
Current Input : (4-20) mA
Output Pressure : (0-1.2) Kg/cm2
Supply Pressure : (0-2) Kg/cm2
Principle of Operation :

Current to Pressure converter is a force balance device in which a coil is suspended in the
field of a magnet by a flexure. Current flowing through the coil generates axial movement of
the coil and flexure. The flexure moves towards the nozzle and creates back pressure which
acts as a pilot pressure to an integral booster relay. Input signal increases (or decreases for
reverse acting) cause proportional output pressure increases.
It works on force balance principle. A coil is suspended in a magnetic field on a
flexible mount. At the lower end of the coil is a flapper valve that operates against a precision
ground nozzle to create a backpressure on the servo diaphragm of a booster relay. The input
current flows in the coil and produces a force between the coil and the flapper valve, which
controls the servo pressure and the output pressure. Zero adjustment of the unit is made by
turning a screw that regulates the distance between the flapper valve and the air nozzle. Span
adjustment is made by varying a potentiometer, which shunts input current past the coil.
 Experim

ent: Aim:

To regulate the pressure using Current to Pressure Converter.

Apparatus Required:

1) LABTECH Current to Pressure Converter Trainer.

2) Pneumatic Hose
3) Patch cord
4) 3 pin power cord
5) Air Compressor

Procedure:

1. Give the connections as per the patching diagram

2. Connect the Air Compressor output to the Air regulator Input
3. Air regulator valve should be in release mode.
4. Switch ON the Air Compressor. Now pressure reading starts to increase, close the Air
regulator valve when reach the pressure 1.2 Kg/cm2 (Pressure Source)
5. Do not apply more than 1.2 Kg/cm2 pressure to the trainer.
6. Switch ON the Trainer
7. Then vary the current input in mA and measure the Output Pressure in Kg/cm2
8. Plot the graph between current input in mA in X-axis and Output Pressure in Kg/cm2 in Y-
axis.

Tabular Column:

Sl.No Current Input in mA Output Pressure in Kg/cm2

4
.
.
.
.
2
0
Model graph:

Result:
Thus the pressure is regulated by using Current to Pressure Converter.
 EQUIPMENT NO: 12 PID
CONTROLLER INTRODUCTION:
This trainer is specially designed to study about the analog PID controller with the
configuration of P, PI and PID. It consists of simulated block like controller, process, motor
drive and waveform generator. Internal of the controller block are error detector, adder
calibrator (fine tuning 10 turn) pot meter are provided for proportional gain, integral time and
derivative time constant and in waveform generator built-in synchronized square and triangle
signal source are provided with level and frequency controls. It enables the student to study
the response of PID on “CRO” and an important feature of this system is that the simulated
blocks are designed to be operated at frequency suitable for CRO viewing, and for real time
processing, DC motor controller is provided along with this trainer provided with digital
indicator for set RPM and current RPM features and temperature control as an optional
feature.
Technical Specifications:
Built in Signal Sources
Square Wave : Amplitude - 1V (p-p)
Frequency - 10 Hz to 40 Hz
Triangular Wave : Amplitude - 1V (p-p)
Frequency -10 Hz to 40 Hz
Simulated Process : Delay
Integrat
or
Time Constant I
& Time
Constant II
Error Detector
Gain
Controller Configuration: P,PI,PD & PID
Proportional band: 5% to 50 %
Controller gain: 2 to 20
Integral Time Constant: 10

to100msec Derivative time constant:

0.2 to 20msec

Experiments
● Open & Closed loop response of simulated process like delay, integrator, and time
constant.
● Study and performance evaluation of Closed loop response of P,PI,PD and PID
controller.
 OBJECTIVE:
To study the performance characteristics of an analog P, PI and PID controller under
open loop and closed loop systems.

EXPERIMENTAL UNIT:
This is a very well designed and compact unit for class room experiments on the study
of proportional-integral-derivative controllers. It comprises of a flexible process, a PID
controller, signal sources, a DVM and a stabilized power source for all the sub-systems. The
various sections along with their specifications are described below.

Process or plant
In a practical situation the process or plant is that part of the system which produces
the desired response under the influence of command signal. Usual processes are higher
order, nonlinear functions having inherent dead time or pure time delay. In process control
studies such plants are commonly modeled by transfer functions of the form

Gp(S) =
Keθs

τs +1

Where, θ is the time delay in sec τ is the effective time constant and K is the
controller gain.
In the present system, the process is an analogue simulation through a few basic
building blocks which may be connected suitably to form a variety of processes or plants.
These blocks are,
a) Integrator - having an approximate transfer function of 1/s
b) Simple pole - two identical units, each having a transfer function of 1 /(1+0.0155s)
c) Pure time delay - a time delay of about 5.64 msec. generated by a high order multiple
pole approximation of the delay function.
Note that all the above blocks, except pure time delay, have 180° phase shift between input
and output.

Controller:
The controller for the process is an analog Proportional-Integral-Derivative (PID)
circuit in which the PID parameters are adjustable. The values may be set within the
following range through 10 turn calibrated potentiometers:
Proportional Gain, Kc : 2 to 20
Proportional Band : 5% to 50%
Integral Time Constant, Ti : 10 - 100 msec.
Derivative Time Constant, Td : 2 - 20 msec.
 It may be mentioned that although in an industrial PID Controller it is common to
adjust the above parameters directly, but in the educational environment convenience and
simplicity is more important. In the present unit, therefore, it is the proportional, integral and
derivative gains viz. Kc, Ki and Kd, which are made variable through 10 turn potentiometers
calibrated from 0 to 1.
The PID block has a phase angle of 0° between its input and output.
Error Detector:
The error detector is a unity gain inverting adder which adds the command signal
with the feedback signal. To ensure negative feedback it would therefore be necessary to

have (2n+1)π phase shift in the forward path, for n = 0, 1, 2...

Uncommitted Amplifier:
It is a unity gain inverting amplifier. This amplifier may be inserted in the loop, if
required, to ensure a proper phase angle.

Signal Sources:
The signal source comprises of a low frequency square and triangular wave generator
having adjustable amplitude and frequency. The square wave is used as command input to the
system, while the triangular wave is used for external x-deflection in the CRO. This
arrangement gives a perfectly steady display even up to very low frequencies and is
convenient for CRO measurements.

BACKGROUND SUMMARY
Introduction:
The performance of a physical system is not always good enough for a given
application. In such a situation the characteristics of the system needs to be modified. This is
referred to as ‘Compensation Design’. Standard procedure available for compensation
includes time and frequency domain designs of a variety of compensation networks . Such
design methods have been successfully used in many practical dynamic control systems. The
performance of the system is evaluated in terms of a set of performance specifications e.g.
rise time, peak time, settling time, peak percent overshoot and steady state error in the time
domain, and gain margin phase margin, closed loop bandwidth etc in the frequency domain.

Fig 1: Block diagram of the Overall system

 Another approach towards improving the performance of systems has been through
elementary control actions - called control terms - inserted in the forward path of an existing
control system. The block diagram of Fig.1 shows the location of such a controller in a unity
feedback system. The controller work comprise of two or three of the following control
terms:
(a) Proportional, P
(b) Integral, I
(c) Derivative, D
The resulting controller may then turn out to be a P, PI or PID controller.
The two, and three-term controllers indicated above have been used more commonly
by process industries e.g. petroleum, chemical, power, food etc., for the control of
temperature, pressure, flow and similar variables. A common feature of these systems is their
sluggish response which calls for accurate and slow integration and sensitive differentiation.
Although near ideal electronic differentiator and integrator circuits are difficult to achieve
except with high impedance operational amplifiers and good quality component, PI and PD
controller valves have existed in the pneumatic and hydraulic environments for a long time.
In the present unit attempt has been made to expose the students to the study and
design of PID controllers using simulated systems. The speed of response has been
deliberately scaled up to have a fast and easy viewing on CRO.
Structure of PID Controller:
The equation of a PID controller is given by.
 + Kd
m (t) = Kc e(t) + Ki e(t)dt
de(t)
2

dt
Where,
e(t) = error signal
m(t) = P1D output or plant
input Kc = Proportional gain
Ki = Integral gain Kd
= Derivative gain
 1n the Laplace domain, the above equation is written as

Fig.2. Block Diagram of PID Controller

Ki
M(s) = Kc E(s) + E(s) + sKd E(s)
s
The above equation is represented as a block diagram of PID controller as shown in Fig.
2. An alternative representation of the above equation which is more commonly used in
process control literature is as follows:

⎛ 1 ⎞
M(s) = Kc ⎜1+ T s +Td s⎟E(s)
3

⎝ i ⎠

Where,

Ti = Ki
Kc
Integral time constant

Td = Kc
Kd
Derivative time constant
It is easy to develop the structure of PD, and PI controllers from above, by
substituting Ki = 0 and Kd = 0 respectively. A special terminology used in process control
literature is given below to facilitate better understanding.
1
Proportional Band = x 100%
Kc

Reset Rate per minute

Ki = 1 Kc Ti
=
Derivative Time Constant = Td
 In the present unit, the three gains are adjustable in the following range with the help
of calibrated 10-turn potentiometers.
Kc : 0 to 20
Ki : 0 to 1000
Kd : 0 to 0.01

Characteristics:
From Eq. (2), the transfer function of the PID controller may be written as

G (s) =
M (s)
s
= K s 2 +K s c s +K i
PID

4
E(s)

s (s +ω 1)(s +ω 2)
K

Where ω1 and ω2 are the two zeros of the PID controller transfer function.

Fig. 3 Bode diagram of PID controller

The above transfer function has a pole at the origin and two real zeros for K c2 > 4KdKi
Notice that a properly designed PID controller should not, in general, have a pair of complex
conjugate zeros which may result in reduced damping. Bode diagram of the PID controller is
shown in Fig. 3. It may be seen that the controller gain increase without limits as the
frequency is decreased. This is due to the integral term, and it results in a reduction of steady
state error. However, the negative phase angle introduced by the controller at low frequencies

has a destabilizing effect as well. The corner frequency ω1,

should therefore be so located that large negative phase angle occurs at sufficiently low
frequencies only, where the plant already has a good stability margin.
Again, the Bode diagram of the controller (Fig. 3) shows an increased gain at high
frequencies accompanied by a positive phase angle. The positive phase angle has a stabilizing
effect while the large gain at high frequencies makes the system respond more to fast or
sudden changes. The overall system then becomes relatively more stable, as it is capable of
taking `anticipatory' action in the presence of signals having fast variations. Design:
The PID Controller can be designed both in the frequency domain and in the s- plane,
through the classical or trial-and-error design procedure. The method needs the pole-zero
locations or frequency-phase responses of the plant, for its implementation. A large number
of process control systems are however characterized by,
Incomplete or inaccurate plant equation
Extremely slow response
Presence of time delays High
order transfer function
Limited possibility of experimentation for identification of the plant and need for fine
trimming the compensator at site
In such a situation alternative simpler techniques of setting the controller parameters (K C, Ti
Td), or tuning, are of great practical value. Presented below are three techniques of tuning a
PID controller aimed at obtaining a satisfactory step response of the overall system.
Trial-and-error tuning
This is a simple and systematic method for on-line tuning of a PID controller. The
method assumes that the three parameters Kc, Ki and Kd are available for adjustment.
Following are the steps for its implementation.
1. Disconnect or reduce derivative and integral block signals by setting K i and Kd to
zero.
2. Starting from a low value increase K c, gradually till Sustained oscillation sets in.
This condition is tested by small disturbances generated by varying the reference signal a
little. The value of- proportional gain so obtained is called ultimate gain, Kcu.
3. Set Kc to 1/2 of the value obtained in step 2.
4. Increase K, gradually until sustained oscillations start again. Set K i to 1/3 of this
value.
5. Increase Kd gradually until sustained oscillations start again. Set Td to 1/3 of this
value.
The above method, though very simple in operation, has the following limitations:
(i)A number of systems which are, or may be approximated to, first or second order transfer
functions without time delay do not oscillate. Step 3 is then not possible and the
method fails.
 (ii) Open loop unstable systems cannot be handled by this method.
(iii) Tuning of very slow systems by this method is extremely time consuming.
(iv) Sustained oscillations may not be acceptable or may be risky in some physical
processes such as a large chemical process.

(b) Continuous Cycling Method

In this method, given by Ziegler and Nichols, the first step is to determine
experimentally the value of ultimate gain, K cu as suggested in the previous method. The time
period of the resulting sustained oscillations is referred to as ultimate period P u Based on the
values of Kcu and Pu the controller settings are obtained from Table I below which is
essentially empirical in nature.

Controller Kc Ti Td

P 0.5 Kcu - -

PI 0.45 Kcu 0.833 Pu -

PID 0.6 Kcu 0.5 Pu 0.125 Pu

Table 1: Empirical values for tuning the controller

Some variation in the coefficient settings have also been suggested by various
workers. In case the above values should be taken as the `initial settings' and should
invariably be followed by fine-tuning via trial-and-error. Most of the limitations of the first
method are still present in this method; however the continuous cycling method is less time
consuming.

Fig 4 Step response of (a) Type – 0 (b) Type – 1 system

 c) Process Reaction Curve Method
This is a second on-line tuning method proposed by Ziegler and Nichols and is very
attractive because it is based on a simple experimentation. The plant is modeled as a first
order function with time delay. The open loop step response of the plant, called reaction
curve of the process, is experimentally obtained.
Typical step responses for Type-0, and higher type number systems are shown in Fig.
4(a) and 4(b) respectively. The step responses are characterized by two parameters.
(i)Slope S of the tangent drawn at the point of inflection
(ii)Time T at which the tangent intersects the X-axis.
The values of S and T are obtained graphically as shown in Fig. 4. If the input step change
was M then the PID parameters are given by the Table 2 below.

Controller Kc Ti Td
P M/ST - -
PI 0.9 M/ST 3.33 T -
PID 1.2 M/ST 2T 0.5 T
Table 2: Tuning Parameters using Process Reaction Curve.
Once again, the above values are empirical in nature and therefore fine tuning of the
parameters may be needed in specific cases. The values of Ki and K d may be calculated from
Eq. (2) for implementation on the present unit.
Although the process reaction curve method based on a single experimentation is fast
and simple, it does have some limitation as given below:
(i) The step response obtained in the open-loop may not be satisfactory in case the system is
highly nonlinear or open loop unstable.
(ii) Accuracy is limited due to the graphical procedure involved.
In conclusion it may be said that any method used to calculate the parameters must
be followed by a fine tuning on the operational process.
EXPERIMENTS:

STUDY OF PID RESPONSE

Aim:
To study the response of a PID controller under calibration mode.

Apparatus Required:
⮚ PID controller trainer kit.

⮚ CRO.

⮚ CRO probes.

⮚ Patch cards

Self Calibration of CRO:

⮚ Keep amplitude knob in 2V position in channel 1.

⮚ Keep traces at center using X-Y position.

⮚ Choose calibrate set 2V.

⮚ Give 2V input which is available in CRO for calibrating purpose to channel 1.

⮚ Verify 2V / 1 deviation in screen.

⮚ Digital panel meter for motor control.

 STUDY OF P CONTROLLER

Connection details
⮚ Connect the output of the generator (square wave) to the input of P controller.

⮚ Keep P controller knob at zero position initially (0.00) rotate anticlockwise

fully.
⮚ Connect the output of P controller to the positive terminal of CRO.

⮚ Connect negative terminal of CRO to GND of the trainer (channel 1).

Step: 1

⮚ Switch ON the trainer.

⮚ Connect CRO (channel 2) positive terminal to the waveform generator (square

wave).
⮚ Connect negative terminal of CRO to the GND of the trainer (channel 2).

⮚ Set amplitude of square wave as 0.1 V (P-P) & time period as 25msec in
square wave generator by varying amplitude knob.
⮚ Connect the output of the square wave generator to the input of the P controller.

⮚ Verify that the P controller pot in zero position.

⮚ Now vary the P controller pot from min to max position and the response
(square wave amplitude) of the P controller.

Calculate the gain by using this formula.

Input = 0.1 V (P-P).

Output = 2.0 V (P-P).

Kc(max) = P-P square wave output / square wave input.

 = 2.0/0.1

= 20V.
 Result:

Thus the response of a P controller under calibration mode was studied and the gain
was calculated.
 STUDY OF I CONTROLLER

Connection details

⮚ Connect the output of the generator (square wave) to the input of I controller.

⮚ Keep I controller knob at zero position initially (0.00) rotate anticlockwise fully.

⮚ Connect the output of I controller to the positive terminal of CRO.

⮚ Connect negative terminal of CRO to GND of the trainer (channel 1).

Step: 1

⮚ Switch ON the trainer.

⮚ Connect CRO (channel 2) positive terminal to the waveform generator

(triangular wave)
⮚ Connect negative terminal of CRO to the GND of the trainer (channel 2).

⮚ Set amplitude of square wave as 0.1 V (P-P) & time period as 70msec in
square wave generator by varying amplitude knob.
⮚ Connect the output of the triangular wave generator to the input of an I
controller.
⮚ Verify that the I controller pot in zero position.

⮚ Now vary the I controller pot from min to max position and the response
(square wave amplitude) of the P controller.

CALCULATION
Calculate the gain by using this formula.
Input = 1 V (P-P).

Output = 1.2 V (P-P).

Ki (max) = 4*f* (P-P) triangular wave output amplitude in volts / p-p square wave input
amplitude in volts.
 = 4*40*1.2/1
= 192 sec.
Integral Time Constant Ti = Kc/Ki
= 2/192 (Kc=2)
 = 10.4 msec
Ti = Kc/Ki
= 20/192 (Kc=20)
= 104 msec

Result:
Thus the response of I controller under calibration mode was studied and the gain was
calculated.
STUDY OF D CONTROLLER

Connection details
⮚ Connect the output of the generator (triangular wave) to the input of D
controller.
⮚ Keep D controller knob at zero position initially (0.00) rotate anticlockwise
fully.
⮚ Connect the output of D controller to the positive terminal of CRO.

⮚ Connect negative terminal of CRO to GND of the trainer (channel 1).

Step: 1

⮚ Switch ON the trainer.

⮚ Connect CRO (channel 2) positive terminal to the waveform generator (square

wave)
⮚ Connect negative terminal of CRO to the GND of the trainer (channel 2).

⮚ Set amplitude of triangular wave as 0.84 V (P-P) & time period as 70msec in
square wave generator by varying amplitude knob.
⮚ Connect the output of the square wave generator to the input of the D controller.

⮚ Verify that the D controller pot in zero position.

⮚ Now vary the D controller pot from min to max position and the response
(square wave amplitude) of the D controller.

CALCULATION
Calculate the gain by using this formula.
Input = 1 V (p-p)

Output = 7.5 V (p-p)

Kd(max) = P-P square wave output / 4* f* (P-P) triangular wave input

= 7.5 / 4* 40 * 1
 = 0.046

Derivative Time Constant (Td) = Kd/Kc

= 0.046/2 (Kc=2)
 = 23 msec
Td = 0.046/20 (Kc=20)
= 2.3 msec

Result:

Thus the response of a D controller under calibration mode was studied and the gain
was calculated.
 Ex.No.1 CLOSED LOOP RESPONSE OF P CONTROLLER

Aim
To find the peak overshoot and steady state error of a P controller.

Apparatus Required
⮚ PID controller trainer kit.

⮚ CRO

⮚ CRO probes Patch cards

Procedure

⮚ Set the amplitude of the square wave at 1V (P-

P) and frequency to a low value.
⮚ Connect the output of waveform
generator (square wave) to the error
detector input.
⮚ Connect the P controller output to the adder
input.

⮚ Connect the adder output the delay input.

⮚ Connect the delay output to the time constant1

input.
⮚ Time constant1 output is connected to the
amplitude input.
⮚ The amplitude output is connected to error
detector feedback input.
⮚ Ensure that the circuit will from a closed loop
control.
⮚ Connect the CRO (channel1) positive terminal
to the amplitude output.
⮚ Connect the negative terminal (channel1) of the
CRO to GND.
⮚ Connect the CRO (channel 2) positive terminal
to the triangular output.
⮚ Vary the potentiometer of the P
controller from minimum to maximum
position and note down the peak graph.
overshoot & steady state error from the

⮚ Calculate % of steady state error and peak overshoot value.

Model Graph
Tabular Column

SI.No. K X Y Stead % of
c
y state oversh
error oot

1 1 0 0.58 0.5 16
.
5

Calculation
Input = 1V (P-P) square wave low frequency
Kc = 0 to max.
Steady State Error = (P-P) input – x / (P-P) input = (1-0.5)/1
% Overshoot = y-x / x *100
=[(0.58-0.5)/0.5]*100=16%
 Patching diagram

Result
Thus the peak overshoot and steady state error of a P controller was founded out and the
graph of time Vs amplitude was plotted.
 Ex.No.2 CLOSED LOOP RESPONSE OF PI CONTROLLER

Aim
To find the peak overshoot and steady state error of a PI controller.

Apparatus Required
⮚ PID controller trainer kit.

⮚ CRO

⮚ CRO probes

⮚ Patch cards

Procedure
⮚ Set the amplitude of the square wave at 1V (P-P) and frequency to a low value.

⮚ Connect the output of waveform generator (square wave) to the error detector input.

⮚ Connect the P & I controller output to the adder input.

⮚ Connect the adder output the delay input.

⮚ Connect the delay output to the time constant1 input.

⮚ Time constant1 output is connected to the amplitude input.

⮚ The amplitude output is connected to error detector feedback input.

⮚ Ensure that the circuit will from a closed loop control.

⮚ Connect the CRO (channel1) positive terminal to the amplitude output.

⮚ Connect the negative terminal (channel1) of the CRO to GND.

⮚ Connect the CRO (channel 2) positive terminal to the triangular output.

⮚ Vary the potentiometer of the P controller from minimum to maximum position and
note down the peak overshoot & steady state error from the graph.
⮚ Calculate % of steady state error and peak overshoot value.
Model Graph
Tabular Column

Stea % of
S. Ki X Y dy oversh
No stat oot
e
error
1. 0.9 0.6 0. 0 10
66 . %
4

Calculation
Input = 1V (P-P) square wave low frequency
Kc= 0.6

Steady State Error = (P-P) input – x / (P-P) input =(1-0.6)/1=0.4

% Overshoot = y-x / x *100 =[(0.66-0.6)/0.6]*100= 10%

Patching diagram
Result
Thus the peak overshoot and steady state error of a PI controller was founded out and
the graph of time Vs amplitude was plotted.
 Ex.No.3 CLOSED LOOP RESPONSE OF PID CONTROLLER

Aim
To find the peak overshoot and steady state error o a PID controller.

Apparatus Required
⮚ PID controller trainer kit

⮚ CRO

⮚ CRO probes

⮚ Patch cards
Procedure
⮚ Set the amplitude of the square wave at 1V (P-P) and frequency to a low value.

⮚ Connect the output of waveform generator (square wave) to the error detector input.

⮚ Connect the P, I & D controller output to the adder input.

⮚ Connect the adder output the delay input.

⮚ Connect the delay output to the time constant1 input.

⮚ Time constant1 output is connected to the amplitude input.

⮚ The amplitude output is connected to error detector feed back input.

⮚ Ensure that the circuit will from a closed loop control.

⮚ Connect the CRO (channel1) positive terminal to the amplitude output.

⮚ Connect the negative terminal (channel1) of the CRO to GND.

⮚ Connect the CRO (channel 2) positive terminal to the triangular output.

⮚ Vary the potentiometer of the P controller from minimum to maximum position and
note down the peak overshoot & steady state error from the graph. Calculate % of steady state
error and peak overshoot value.
Model Graph
Tabular Column

K X Y Stea % of
d
Sl.N dy oversh
o stat oot
e
err
or
1. 0.9 0.72 0.76 0.28 5.55

Calculation
Input = 1V (P-P) square wave low frequency
Kc = 0.6 , Ki=0.006,
Steady State Error = (P-P) input – x / (P-P) input
= 1 – 0.72/ 1 = 0.28

% Overshoot = y-x / x *100

= 0.76-0.72 /0.72 * 100 = 5.55%
 Patching diagram

Result:
Thus the peak overshoot and steady state error of a PID controller was founded out and
the graph of time Vs amplitude was plotted.
 Appendices:
Circuits used in PID Controller:
EQUIPMENT NO:13
DRAW THE CHARACTERISTIC FOR A
AIM: PRESSURE RELIEF VALVE

To teach the student how to draw the characteristic

for

a
Pressure relief valve

PROCEDURE:
. Drawing the hydraulic circuit diagram
. Practical assembly of the circuit
. Setting a maximum pressure of 50bar
. Establishing the opening pressure of the pressure relief valve
. Determining the various measured values and entering them into the table
. Drawing the pressure/flow rate characteristic
. Drawing conclusions

Exercise:

Owing to a change in the production process, a package lifting device is now required to lift heavier
packages than those for which it was originally designed. It has been observed that the stroke speed is now
lower. Using the pressure/flow rate characteristic for the pressure relief valve, determine the pressure at
which flow diversion of the pump output begins.
Circuit diagram:

0Z1 Hydraulic power pack

0Z2 Pressure gage
1V Shutoff valve
1S Flow sensor
MODE GRAPH:

working pressure 35 40 42.5 45 47.5 50 bar

Flow rate q l/min

RESULT:
Every pressure relief valve has a certain opening pressure at which point diversion of the
flow through the valve begins. The difference between opening pressure and maximum pressure is
5 bar in this case. When the preset maximum pressure is reached, the entire pump delivery is
discharged via the pressure relief valve.
EQUIPMENT NO: 14 SYNCHRO TRANSMITTER & RECEIVER PAIR

A synchro is an electromagnetic transducer commonly used to convert an angular

position of a shaft into an electric signal.

The basic synchro is usually called a synchro transmitter. Its construction is similar to
that of a three phase alternator. The stator (stationary member) is of laminated silicon steel
and is slotted to accommodate a balanced three phase winding which is usually of concentric
coil type (Three identical coils are placed n the stator with their axis 120 degree apart) and is
Y connected. The rotor is a dumb bell construction and wound with a concentric coil. An AC
voltage is applied to the rotor winding through slip rings. Ref. Fig. No.1A.

Let an AC voltage Vr (t) = Vr sin Wct … (1) be supplied to the rotor of the synchro
transmitter. Thisvoltage causes a flow of magnetizing current in the rotor coil which produces
a sinusoidally time varying flux directed along its axis and distributed nearly sinusoidal, in
the air gap along stator periphery. Because of transformer action, voltages are induced in each
of the stator coils. As the air gap flux is sinusoidally distributed, the flux linking any stator
coil is proportional to the cosine of the angle between rotor and stator coil axis and so is the
voltage induced in each stator coil.

The stator coil voltages are of course in time phase with each other. Thus we see that
the synchro transmitter (TX) acts like single phase transformer in which rotor coil is the
primary and the stator coils form three secondaries.

Let Vs1 N, Vs2 N and Vs3 respectively be the voltages induced in the stator coils S1,
S2 and S3 with respect to the neutral. Then for the rotor position of the synchro transistor
shown in fig.No.1 where the rotor axis makes an angle 0 with the axis of the stator coil S2.

Let Vs1N = KVr sin Wct cos (0+120)

KVr sin Wct cos (0)
 Vs3N = KVr sin Wct cos (0+240) (4)

The three terminal voltages of the stator areVs1s2 = Vs1N – Vs2N

= 3 KVr sin (0=240) sin Wct (5)
Vs2S3 = Vs2N – Vs3N
= 3 KVr sin (0+120) sin Wct (6)
= 3 KVr sin (0) sin Wct (7)
When 0 is zero from equation (2) and (3) it is seen that maximum voltage is induced in the
stator coil s2 while it follows from equation (7) that the terminal voltage Vs3s1 is zero. This
position of rotor is defined as the electrical zero of the Tx and is used as a reference for
specifying the angular position of the rotor.

Thus it is seen that the input to the synchro transmitter is the angular position of its
rotor shaft and the output is a set of three single phase voltages given by equation (5), (6) and
(7). The magnitudes of these voltage are functions of a shaft position.

The classical synchro systems consists of two units.

1. Synchro transmitter (Tx)
2. Synchro rceiver (Tr)

The synchro receiver is having almost the same constructional features. The two units
are connected as shown in figure No.2. Initially the winding S2 of te stator of transmitter is
positioned for maximum coupling with rotor winding. Suppose its voltage is V. The coupling
between S1 and S2 of the stator and primary (Rotor) winding is a cosine function. Therefore
the effective voltages in these winding are proportional to cos 60 degrees or they are V/2
each. So long as the rotors of the transmitters and receivers remain in this position, no current
will flow between windings because of voltage balance.
When the rotor of Tx is moved to a new position, the voltage balance is disturbed.
Assume that the rotor of Tx is moved through 30 degrees, the stator winding voltages will be
changed to zero, 0.866V and 0.866V respectively. Thus there is a voltage imbalance between
the windings causes currents to 1 flow through the close circuit producing torque that tends to
rotate the rotor
of the receiver to a new position where the voltage balance is again restored.

This balance is restored only if the receiver turns through the same angle as the transmitter
and also the direction of the rotation is the same as that of Tx.
The Tx Tr pair thus serves to transmit information regarding angular position at one
point to a remote point.

System Description and Operation

The system set up is made up of synchro transmitter and synchro receiver on a single
rigid base provided with suitable swithes and anodized angular plates. The system also
containsa step down transformer for providing excitation to the rotors. Suitable test points for
rotor (R1 and R2) and stator (S1, S2 and S3) for both Tx and Tr are provided.
Experiment No.1 :
AIM: Study of synchro transmitter
In this part of the experiment we can see how, because of the transformer action, the
angular position of the rotor of synchro transmitter is transformed into a unique set of stator
voltages.

Procedure:
1. connect the mains supply to the system with the help of cable provided. Do
not connected any patch cords to terminals marked “S1, S2 and S3”
2. Switch on mains supply for the unit.
3. Starting from zero position, note down the voltage between stator winding terminals
i.e Vs1s2, Vs2s3 and Vs3s1 in a sequential manner. Enter readings in a tabular form
and plot a graph of angular position of rotor voltages for all three phases.
4. Note that zero position of the stator rotor coinsides with Vs2s1 voltage equal to zero
voltage. Do not disturb this condition.
Experiment No.2 :
AIM: Study of synchro transmitter and receiver pair.
Procedure
1. Connect mains supply cable.
2. Connect S1, S2 and S3 terminals of transmitter to S1, S2 and S3 of synchro receiver
by patch cords provided respectively.
3. Switch on SW1 and SW2 and also switch on the mains supply.
4. Move the pointer i.e rotor position of synchrono transmitter Tx in steps of 30 degrees
and observe the new rotor position. Observe that whenever Tx rotor is rotated, the Tr
rotor follows it for both the directions of rotations and their positions are in good
agreement.
5. Enter the input angular position and output angular position in the tabular form and
plot a graph.
Precautions
1. Handle the pointers for both the rotors in a gentle manner
2. Do not attempt to pull out the pointers
3. Do not short rotor or stator terminals

FRONT PANEL VIEW OF SYNCHRO TX AND TR

Note: 1) Connect S1, S2, S3 of synchro transmitter to S1, S2, S3 of synchro receiver
respectively by mans of patch cords.
2) SW1 & SW2 are switches for rotor supply (excitation) of synchro
TX & TR.
 TOP VIEW OF SYNCHRO TRANSMITTER & RECEIVER

SYNCHRO TRANSMITTER ROTOR POSITION VERSUS STATOR VOLTAGES

FOR THREE PHASES
(Vsls3, Vsls2, VS2S3)

Sr.N Position Stator / Terminal Voltages

o. rotor Vs3S1 VS1S2 (RMS)
degrees VS2S3
1 00 0.1 60.3 59
.8
2 30 33.8 34.5 68
.6
3 60 58.9 1.1 60
.7
4 90 69.1 33.7 34
.9
5 120 60.1 59.1 0.
4
6 150 36.2 68.9 32
.6
7 180 0.9 60.3 59
.3
8 210 33.9 34.8 68
.9
9 240 59.1 0.3 59
.6
10 270 68.8 33.5 34
.9
11 300 59.7 60 0.
4
12 330 33.5 69.2 35
.1
 TYPICAL RESULTS FOR

Sr Angular position in degrees Angular position in degrees

. synchro transmitter I/P synchro receiver O/P
N
o.
1 0.0 0
.
5
2 30. 30.5
0
3 60. 61.0
0
4 90. 89.0
0
5 120 119.0
.0
6 150 148.0
.0
7 180 178.0
.0
8 210 209.0
.0
9 240 240.0
.0
1 270 269.0
0 .0
1 300 299.0
1 .0
1 330 329.0
2 .0
 EQUIPMENT NO: 15
AIM: To study the operation of Oil Mist Detector
THEORY:

The OMD-21 Bilge Alarm Unit has been designed specifically for use in conjunction with
15 ppm oil-water separator units and has a specification and performance which exceeds the
requirements of the International Maritime Organization specifications for 15ppm Bilge Alarms
contained in Resolution MEPC. 60 (33).
The unit is supplied with 2 works-adjusted alarms at 15 ppm. Other set points(10 ppm or 5
ppm) are possible and can be adjusted on site at any time by using the buttons at the front panel.
If an alarm set point is exceed, the alarms are visible at the front panel and the appropriate
relays are switched.
Furthermore a 0(4) - 20 mA (equal to 0 - 30 ppm) signal output is available for driving a
recorder or external meter.

CONSTRUCTION

All components are assembled in an alloy enclosure with the protection classIP 65. The optical
components are mounted directly on the printed circuit board. The plug in technology assures an easy
changing of the components together with an compact and robust construction. The electronic is designed
to the latest state of art.
The wetted parts are produced out of Stainless Steel to assure a reliable corrosion protection for a
long time. The sample water is fed to the unit from underneath and is discharged above to the side.
The mounting brackets of the unit are prepared at the rear of the unit either for wall or bulkhead
mounting.
 1 Housing 9 Measuring Cell 1 LED "Alarm 1"
Cover 7
2 Inlet Block 1 Power Supply Unit 1 LED "Alarm 2"
0 8
3 Outlet Block 1 PSU Cover 1 LED “Error”
1 9
4 Sample Glass Tube 1 Inlet Connection ¼” 2 LED "Set Mode"
2 0
5 Optik Block PCB 1 Head Screw 2 Upper Button
3 1
6 Front Cover 1 Outlet Connection 2 Centre Button
4 ¼” 2
7 Display PCB 1 Desiccator 2 Lower Button
5 3
8 Display 1 LED "Power On" 2 Flow adjust screws
6 4

Fig. 1
PROCEDURE:

a) Switch on the power supply.

b) Allow a period of time for water entering
the sample tube.
c) Flow oil free water through the system
for a few minutes and check that the
display show 0 to 2 ppm. If not, adjust the
unit according section
10.4 “Zero adjustment”.
d) Switch the instrument sample supply
from the clean water supply to the
separator sampling point connection.
e) The instrument is now ready for use.

Operator Notes

f) When oily water flows through the

instrument the display will show the
actual value of oil content.
g) If the oil concentration exceeds the
adjusted threshold (works adjustment15
ppm), the alarm indicator 1 will be
illuminated and the associated alarm
relay will operate within the adjusted
time delay. Accordingly also the alarm
indicator 2 will be illuminated and its
associated alarm relay will take the
appropriate shut down action.
h) The function of the system can be
checked also with clean water. Press
the “ button
“ for more than approx. 5 Seconds. Yellow “Set Mode”
LED will startto flash. Electronic sensors are checked for sensitivity.
Instrument will display error code if any internal error was detected.
Alarm contacts will switch overto alarm state . Upon pushbutton
release the instrument performs the same start-up procedure as on
power up. It will resume to normal operation automatically.

RESULT:
Thus Oil Mist Detector is studied.