C&I Manual FINAL

CONTROL & INSTRUMENTATION LABORATORY MANUAL
Control & Instrumentation Laboratory Rules
1) Students must enter the lab in time with wearing shoes, observation copy & record
2) Prior coming to the lab, students should have written the following in their
observation copy.
a) Aim
b) Apparatus required
c) Theory
d) Circuit Diagram
3) The lab supervisors and faculty member(s) will be there to assist the students in
performing the experiments. But at the end of the semester, the students will have to
perform the experiments by their own.
4) No student is allowed to switch on supply without the permission of faculty/lab

supervisor.
5) Student cannot leave the lab without approval of the result(s) from the concerned
faculty/lab supervisor.
6) Participation of each of the student in the lab is compulsory.
7) Record should be completed in all respects and submitted in the lab as instructed by
faculty (either in the same class or in the next).
8) Late submission of record shall be penalized.
9) Extra lab may be taken for the absentees, with prior permission from the concerned
Batch Coordinator in written, after the scheduled classes are over. Students
attending the extra lab will be evaluated out of 80 and not 100.
10) Lab Exam/ quiz tests may be taken by the concerned faculty with prior notice.
Students failing to attend shall be penalized.
Lab Supervisors
(1) Manas Ranjan Mishra Faculty in-charge(s):
NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 0
(2) Sarat kumar Behera G. Sivaranjani
CONTENTS
SL.NO. EXPERIMENT NAME PAGE NO.

1 D.C. Motor Driven position Control System 02-16
2 Speed Torque Characteristics of AC Servomotor 17-27
3 Lag and Lead Compensator 28-30
4 Second Order Response of P, PI and PID Control 31-37
5 Temperature Control System 38-44
6 Position Control System using Synchros 45-49
7 Linear Variable Differential Transducer 50-55
8 J-Type Thermocouple 56-59
9 Strain Gauge 60-63
10 Thermistors 64-69
11 Speed vs Torque Characteristics of DC Servomotor 70-77
12 PLC with PC For Data Acquisition Application 78-102

1. D C POSITION CONTROL SYSTEM
EXPERIMENT-1: Study of Position Sensor
AIM:
To study the Position Sensor (Servo pot) manually using DC Position Control System Trainer
Module(PEC-01).
APPARATUS:
1. PEC-01 module
2. Motor Setup
3. Patch Chords
4. Multimeter
THEORY:
This experiment is intended to study the operation of Position Sensor. Select the switch SW1 in
downward direction and vary the motor position manually. For each step note down the motor position in
digital display and position feedback voltage in voltmeter and tabulation it.
PROCEDURE:
1. Connect one voltmeter across Position & ground point.

2. Put the SPDT switch in NC mode (Downward direction) in order to view the PV Position of
motor.
3. Now manually vary the motor position step by step.
4. For each step note down the voltmeter and position reading.
5. Tabulate the readings and observe it.
SL NO. Motor Position Position Feedback Voltage

(In degree) (In volt)

CONCLUSION:
The position sensor gives linear output voltage with respect to the degree range of 5 -340 degree and
out of this range it gives non linear output. So we can control the position of the DC motor in the
range of 5-340 degree.

EXPERIMENT-2: Study of DC Servomotor Position Controller with P Controller.
AIM:
To study the DC Servomotor Position Controller with P controller using the DC Position Control System
trainer module (PEC-01).
APPARATUS:
1. PEC-01 module
2. Motor Setup
3. Patch Chords
4. CRO
THEORY:
This experiment is intended to study the operation of DC Servomotor Position Control with P Controller.
Vary the set position knob and set any position and also vary the P gain control Knob. Note down and
tabulate input and output position and the maximum overshoot.
CONNECTION PROCEDURE:
1. Connect the terminal P1 to P6 using patch chord.
2. Connect the motor actual position terminal P2 to P7 using patch chords.
3. Connect the terminal P8 to P10 and P12 to P17 Using Patch chords.
4. DC output from P24 to P25 is connected to the input of Permanent Magnet DC Motor.
EXPERIMENT PROCEDURE:
1. Verify the connection as per the connection diagram and connection procedure.
2. Set the pulse release switch in OFF position.
3. Switch ON the power supply.
4. Vary the set position knob and set the motor position at any value.
5. Select the SPDT switch in upward direction and note the input position in digital display.
6. Slightly vary the P controller knob.

7. Switch on the pulse release switch S2.Note the maximum overshoot or maximum position
achieved by the motor.
8. Select the SPDT switch in downward direction and note the output position in digital display.
9. Check all the power circuit test points waveforms.
10. View the carrier signal across the terminals P30 and GND.
11. View the comparator output across the terminals P29A and GND.
12. View the MOSFET 1 and 2 trigger pulses across the terminals P26,P27 and GND.

13. View the MOSFET 3 and 4 trigger pulse across terminals P28,P29 and GND.
14. Tabulate the input and output position and maximum overshoot in the tabular column show below.
SL NO. Input Position In Output Position In Maximum Error In Degree

Degree Degree Overshoot In
Degree

CONCLUSION:
Thus the characteristic of DC Servo motor Position Controller with p Controller was studied.
EXPERIMENT-3: Study of DC Servomotor Position Controller with PI Controller.
AIM:

To study the DC Servomotor Position Controller with PI controller using the DC Position Control System
trainer module (PEC-01).
APPARATUS:
1 PEC-01 module
2 Motor Setup
3 Patch Chords
4 CRO
THEORY:
This experiment is intended to study the operation of DC Servomotor Position Control with PI Controller.
Vary the set position knob and set any position and also vary the P and I gain control Knob. Note down
and tabulate input and output position and the maximum overshoot.
1 Connect the terminal P1 to P6 using patch chord.
2 Connect the motor actual position terminal P2 to P7 using patch chords.
3 Connect the terminal P8 to P10 and P9 to P11 Using Patch chords.
4 Connect the terminal P12 to P14 and P13 t P15 using patch chords.
5 DC output from P24 to P25 is connected to the input of Permanent Magnet DC Motor.
1 Verify the connection as per the connection diagram and connection procedure.
2 Set the pulse release switch in OFF position.
3 Switch ON the power supply.
4 Vary the set position knob and set the motor position at any value.
5 Select the SPDT switch in upward direction and note the input position in digital display.
6 Slightly vary the P and I control knob.
7 Switch on the pulse release switch S2.Note the maximum overshoot or maximum position
8 Select the SPDT switch in downward direction and note the output position in digital display.
9 Check all the power circuit test points waveforms.
10 View the carrier signal across the terminals P30 and GND.
11 View the comparator output across the terminals P29A and GND.
12 View the MOSFET 1 and 2 trigger pulses across the terminals P26,P27 and GND.

13 View the MOSFET 3 and 4 trigger pulse across terminals P28,P29 and GND.
14 Tabulate the input and output position and maximum overshoot in the tabular column show below.

Degree
CONCLUSION:
Thus the characteristic of DC Servo motor Position Controller with PI Controller was studied and
verified.
EXPERIMENT-4: Study of DC Servomotor Position Controller with Speed Feedback Loop.

AIM:
To study the DC Servomotor Position Controller with Speed Feedback Loop using the DC Position
Control System trainer module (PEC-01).
APPARATUS:
1 PEC-01 module
2 Motor Setup
3 Patch Chords
4 CRO
THEORY:
This experiment is intended to study the operation of DC Servomotor Position Control with Speed
Feedback Loop. Vary the set position knob and set any position and also vary the P gain control (1,
(2))Knob and I gain control knob. Note down and tabulate input and output position and the maximum
overshoot.
1 Connect the terminal P1 to P6 using patch chord.
2 Connect the motor actual position terminal P2 to P7 using patch chords.
3 Connect the terminal P8 to P10 and P9 to P11 Using Patch chords.
4 Connect the terminal P12 to P14 and P13 t P15 using patch chords.
5 Connect the terminal P3 to P19 and P20 to P21 using patch chords.
6 DC output from P24 to P25 is connected to the input of Permanent Magnet DC Motor.
1 Verify the connection as per the connection diagram and connection procedure.
2 Set the pulse release switch in OFF position.
3 Switch ON the power supply.
4 Vary the set position knob and set the motor position at any value.
5 Select the SPDT switch in upward direction and note the input position in digital display.
6 Slightly vary the P gain control(1).I gain control and P gain control (2) knobs.
7 Switch on the pulse release switch S2.Note the maximum overshoot or maximum position
8 Select the SPDT switch in downward direction and note the output position in digital display.
9 Check all the power circuit test points waveforms.
10 View the carrier signal across the terminals P30 and GND.
11 View the comparator output across the terminals P29A and GND.
12 View the MOSFET 1 and 2 trigger pulses across the terminals P26, P27 and GND.

13 View the MOSFET 3 and 4 trigger pulse across terminals P28, P29 and GND.
14 Tabulate the input and output position and maximum overshoot in the tabular column show below.
Degree
CONCLUSION:
Thus the characteristic of DC Servo motor Position Controller with speed feedback loop was studied
and verified.
RELATED QUESTIONS:
1. What do you understand by position control?

2. What is the need of a controller?
3. What are the effects of using feedback?
4. What are the various methods of speed control?


2. TWO PHASE AC SERVOMOTOR TRANSFER FUNCTION &

SPEED CONTROLLER
1. MEASUREMENT OF TRANSFER FUNCTION PARAMETERS.
1.1 Determination of Motor Constant K2
AIM:
To determine the motor constant K2.
EQUIPMENTS REQUIRED:
1. Two phase A.C servo motor speed control and transfer function study trainer (PEC-00A).
2. Patch chords.
3. Volt meter (0-20 V)
THEORY:
Detailed theory is given in section 2.
PROCEDURE:
1. Connect G1K1 of pulse isolation output to G1K1 of SCR1.
3. To operate open loop control mode using switches S1.
4. 9 Pin D - Connector is connected from motor setup to backside of the trainer (PEC-00A).
5. Keep Speed indicator switch is in PV mode.
6. Connect AC voltmeter (0 - 20V) or multimeter across the control phase winding (C1, C2).
EXPERIMENTAL PROCEDURE:
1. Switch ON the 230V AC supply to the reference winding.
2. Switch ON the 230V AC supply to the motor setup.
3. Switch ON the pulse ON / OFF switch S2.
4. Vary the control voltage pot (C.V) and set the rated voltage (11.4V) to control phase winding.
5. Apply the load on the motor step by step upto motor will run at 0 rpm
6. For each step note the readings (Load, Speed) as shown in the table 1.
7. To calculate the torque value.
8. Plot the graph Speed Vs Torque.
9. The slope of speed - torque curve given the motor constant K2.
FORMULA TO BE USED:
Torque (T) = 9.81 r s
Where
s = Applied Load in Kg.
r = Radius of shaft in m=0.068meter
TABLE 1:
Control Voltage = Rated Voltage (11.4V)
Sl . Speed (N) rpm Load (Kg) Torque (Nm)

No
MODEL GRAPH:
RESULT:
Thus the motor constant K2 was obtained.

1.2 Determination of Motor Constant K1
AIM:
1. Two phase A.C servo motor speed control and transfer function study trainer (PEC-00A).
2. Patch chords.
3. Volt meter (0-20V) MC
THEORY:
Detailed theory is given in section 2.
PROCEDURE:
3. To Operate open loop control mode using switch S1.
4. 9 Pin D - Connector is connected from motor setup to backside of the trainer (PEC00A).
5. Keep speed indicator switch is in PV mode.
6. Connect AC voltmeter ( 0 - 20V) or multimeter across the control phase winding (C1,C2)
1. Switch ON the 230V AC supply to the reference winding.
2. Switch ON the 230V AC supply to the motor setup.
3. Switch ON the pulse ON / OFF switch S2.
4. Vary the control voltage pot (C.V) and set the rated voltage (11.4V) to control phase winding.
5. Apply the load on the motor step by step up to motor will run at 0 rpm.
6. For each step note the load and voltmeter readings as shown in the table -2.
7. To calculate the torque value.
8. Plot the graph Torque Vs control voltage.
9. A slope of Torque - control voltage curve gives the motor constant K1.
FORMULA TO BE USED
Torque (T) = 9.81 r s
Where
s = Applied Load in Kg.
r = Radius of shaft in m.
= 0.068 m
TABLE 2:
S. No Load (Kg) Control Voltage (Vc) Torque (Nm)

MODEL GRAPH:
RESULT:
Thus the motor constant K1 was obtained.
1.3 Determination of AC Servomotor Transfer Function
Transfer function of A.C Servomotor is,
km = k1 / (k2 + B) motor gain constant
using the graph find out the values of K1 and K2 and substitute in equation.
The values of J and B are given here by the manufacturers

J = 52 gm / cm2 = 0.052 Kg cm2, B = 0.01875
Substitute in the above equations.

2. THEORY
2.1 Introduction
An AC servomotor is basically a two phase induction motor except for certain special design features.
Figure 1. Speed Torque characteristics of induction motor and AC Servomotor

A two phase servomotor differs in the following two ways from a normal induction motor.
a) Normal induction motor b) AC Servomotor
1. The rotor of the servomotor is built with high resistance, so that its X/R (Inductive reactance /
Resistance) ratio is small which results in linear speed torque characteristics.(But conventional
induction motors will have high value of X/R which results in high efficiency and non-linear
speed-torque characteristics). The Speed-torque characteristics of normal induction motor (Curve-
a) and AC servomotor (Curve-b) are shown in figure-1.
2. The excitation voltage applied of two stator windings should have a phase difference of 90.
2.2 Construction of AC Servomotor
The AC servomotor is basically a two phase induction motor with some special design features. The
stator consists of two pole-pairs (A-B and C-D) mounted on the inner periphery of the stator, such that
their axes are at an angle of 90 in space. Each pole-pair carries a winding. One- winding is called
reference winding and the other is called a control winding. The exciting current in the winding should
have a phase displacement of 90. The supply used to drive the motor is single phase and so a phase
advancing capacitor is connected to one of the phase to produce a phase difference of 90. The stator
constructional features of AC servo motor is shown in figure (2).

Figure 2. Stator Construction of AC Servomotor
The rotor construction is usually squirrel cage or drag-cup type. Rotor Construction of AC Servomotor is
shown in figure - 3. The squirrel cage rotor is made of laminations. The rotor bars are placed on the slots
and short circuited at both ends by end rings. The diameter of the rotor is kept small in order to reduce
inertia and to obtain good accelerating characteristics.
Figure 3. Rotor Construction of AC Servomotor
The Drag-cup construction is employed for very low inertia applications. In this type of construction the
rotor will be in the form of hollow cylinder made of aluminium. The aluminium cylinder itself acts as
short circuited rotor conductors. (Electrically both the types of rotor are identical).
2.3 Working Principles of AC Servomotor
1. Working of Servomotor as ordinary induction motor

The stator winding are excited by voltages of equal rms magnitude and 90 phase difference. This results
in exciting currents i1 and i2 that are phase displayed by 90 and have equal rms values. These current
give rise to a rotating magnetic field of constant magnitude. The direction of rotation depends on the
phase relationship of the two currents (or voltages). The exciting current shown in figure -4 produces a
clockwise rotating magnetic field and phase shift of 180 in i1 will produce an anticlockwise rotating
magnetic field.

Figure 4. Wave form of Stator & Rotor excitation current

The rotating magnetic field sweeps over the rotor conductors. The rotor conductors experience a change
in flux and so voltages are induced in rotor conductors. This voltages circulates currents in the short
circuited rotor conductors and the currents create rotor flux. Due to the interaction of stator and rotor flux,
a mechanical force (or torque) is developed on the rotor and so the rotor starts moving in the same
direction as that of rotating magnetic field.
2. Working Principles of AC Servomotor in control system :

The symbolic representation of an A.C servomotor with control system component is shown in figure - 5.
The reference winding of A.C servomotor is excited by a constant voltage source with frequency of 50Hz.
The speed of A.C servomotor is controlled by controlling the control voltage. The error output of error
detector is fed to PI controller, due to the error, controller take control action (i.e to give control voltage)
to firing circuit. The firing circuit generate the pulse's to rotate the motor at required speed.
Figure 5. Symbolic representation of AC Servomotor in control system.
2.4 Characteristics Curves of AC Servomotor
The speed Torque characteristics of a servomotor is very important for its performance in a servo system.
The shape of this characteristics largely depends on the value of the rotor resistance. The curves shown in
figure-6 show typical speed torque characteristics for several values of rotor resistances.

Figure 6. Speed Torque characteristics of Servomotor with several values of resistance

From figure 6. it can be seen that for higher values of rotor resistance the torque speed characteristics is
linear. If the rotor resistance is either R4 or R5 , the motor is referred to as two phase servo motor. For
servo application the motor characteristics should be linear with negative slope(With positive damping).
It can be proved that for stable operation positive damping is essential. Therefore ordinary two phase
induction motor with low rotor resistance is not suitable for servo applications.
Figure 7. Speed Torque characteristics of AC Servomotor
Figure 7 shows the linear torque-speed characteristics of a two phase servo motor for various control
voltages. In this trainer (PEC-00A), we are obtained only this type of torque speed characteristics only.
In servo applications the voltages applied to the stator windings are not balanced. One of the phase
known as reference phase is excited by a constant voltage and the other phase known as the control phase
is energised by a voltage which is 90 out of phase with respect to the reference phase. The control phase
voltage is of variable magnitude and polarity. The direction of rotation of the motor reverses as the
polarity of the control voltage signal changes sign. Fig.8 shows the Torque-speed characteristics of the
AC servo motor for various control voltage magnitudes.
Figure 8. Torque versus control voltage characteristics.

Figure (8) and (9) show that the torque speed curves is not Linear except at very low speeds. For speeds
near zero, all the curves are straight lines parallel to the characteristics at rated input voltage (ec= Er), and
are equally spaced for equal increments of the input voltage. Under this assumption the torque Tc
generated by the motor is represented by the equation.
(1)
where k1 and k2 are the slopes as defined in figure 23 and 24 are motor parameters.
Figure 9. Experimental circuit diagram of Servomotor
2.5 Transfer Function
The transfer function of the AC servomotor is obtained using the torque equation. The developed torque
is given by
(2)
Where k1 and k2 are motor parameters which depend on the control voltage ee(t).
k1 is expressed in Nm / Volt
k2 is expressed in Nm / rnd / sec
Mechanical system consisting of the rotor, is described by the dynamic equation
(3)
Where TL - load torque
J - moment of inertia kg.cm2
B - viscous friction co-efficient
- speed in rad/sec
(4)

Taking Laplace transform,
(5)
This is represented by the block diagram of figure 10. The disturbance inputs are Ee(s) and TL(s). The
transfer function between (s) and Ec(s) is obtained by putting TL(s) = 0.
(6)
(7)
where km = k1 / (k2 + B) motor gain constant

and
Figure 10. Two Phase AC Servomotor Transfer Function
RELATED QUESTIONS:
1. What is the difference between AC Servomotor & 1 induction motor?

2. What is servomechanism?
3. Why the torque-speed characteristics are linear for servomotor?
4. Give some applications of AC Servomotor?

3. PANEL/WIRING DIAGRAM

3. STUDY OF FREQUENCY RESPONSE OF LAG AND LEAD
COMPENSATOR
EXPERIMENT 12.1
AIM: To study the frequency response of the lag process.
APPARATUS REQUIRED:
1 LEAD-LAG NETWORK trainer (VLLN-01).
2 Patch chords
3 CRO
THEORY:
If a sinusoidal signal is applied to a lag network, then its steady state output will have a phase lag with
respect to input. Lag process is essentially a low pass filter and so high frequency noise signals are
attenuated.
PROCEDURE:
1. Connections are made as per the connection diagram.
2. Switch ON the unit.
3. Give the sine wave as input.
4. Note down the amplitude and frequency of the input signal.
5. Observe the Lissajous pattern through CRO, by keeping the CRO in X-Y mode and calculate the
phase shift () of the input signal w.r.t input.
6. Conduct the experiment for various frequencies. Range(0-100 Hz)
7. Plot the bode plot and conclude the behavior of lag process.
8. The phase angle () is measure from Lissajous pattern as shown in the figure.
Sin() = X1/X2 = Y1/Y2

= sin-1(X1/X2) = sin-1(Y1/Y2)

TABULATION:
Frequency(Hz) X1 X2 (deg) Vout Gain(Av)(db)
DIAGRAM:

RESULT:
Thus the frequency domain characteristics of the lag process were studied.
EXPERIMENT 12.2
AIM:
To study the frequency response of the lead process.
APPARATUS REQUIRED:
.LEAD-LAG NETWORK trainer (VLLN-01).
THEORY:
If a sinusoidal signal is applied to a lead network, then its steady state output will have a phase lead with
respect to input. A lead process is basically a high pass filter and so it amplifies high frequency noise
signals.
PROCEDURE:
1. Connection is made as per the connection diagram.
2. Switch ON the power supply.
3. Give the sine wave as input.
4. Note down the amplitude and frequency of the input signal and tabulate it.
5. Observe the Lissajous pattern through CRO, by keeping the CRO in X-Y mode and calculate the
phase shift () of the output signal w.r.t input.
6. Conduct the experiment for various frequencies. Range(100 Hz-850 Hz)
7. Plot the bode plot and conclude the behaviour of lead process.
8. The phase angle () is measure from Lissajous pattern as shown in the figure.
TABULATION:
Frequency(Hz) X1 X2 (deg) Vout Gain(Av)(db)
DIAGRAM:
RESULT:
Thus the frequency domain characteristics of the lead process were studied.
RELATED QUESTIONS:
1. What are the advantages of frequency domain analysis over time-domain analysis?
2. Where do we use lead compensators?
3. Why do we need compensation?
4. What are gain margin & phase margin?

4. TIME RESPONSE OF A SECOND ORDER PROCESS WITH

P, PI AND PID CONTROL
AIM:
To observe the time response of a second order process with P, PI and PID control and apply PID control
to servomotor
APPARATUS:
1. PID-Controller kit
2. CRO
3. Patch cards
THEORY:
In practical situation the process or plant is the part of the system which produces the desired response
under the influence of command signal.
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 include time and frequency domain designs of a
variety of compensation networks. The performance of the system is evaluated in terms of a set of
performance specifications e.g. rise time, peak time, settling time, maximum peak overshoot and steady
state error in the rise time, and gain margin phase margin, closed loop bandwidth etc. in the frequency
domain.
Another approach towards improving the performance of systems has been through elementary control
actions- called controllers- inserted in the forward path of an existing control system. The block diagram
of Fig. 2 shows the location of such 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 PI, PD 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.
PROCEDURE :
1. Apply a square wave signal of 100mV p-p at the input of the error detector. Connect: P, I and D
outputs to the summer, and display controller output on the CRO.
2. With P-potentiometer set to maximum and I- and D-potentiometers set to zero, obtain maximum
value of Kc as
p - p square wave output p - p square wave output

p - p square wave input 0.1

3. With I-potentiometer set to maximum and P- nad D- potentiometers set to zero, a ramp will be
seen on CRO. Maximum value of Ki is then given by
4 x f x (p - p) triangular wave output amplitude in volts
Ki(max.)=
p - p square wave amplitude in volts
where f is the frequency of the input
4. Set D-potentiometer to maximum and P and I-potentiometers to zero. A series of sharp pulses will
be seen on the CRO. This is obviously not suitable for calibrating the D-potentiometer. Instead,
applying a triangular wave at the input of the error detector a square wave is seen on the CRO.
p - p square wave output
Kd(max.) =
4 x f x (p - p) triangular wave input
where f is the frequency of the input.
5. Set all the three potentiometers P,I and D to maximum values and apply a square wave input of
100mV(p-p). Observe and trace the step response of the PID controller identify the effects of the
P, I and D controls individually on the shape of this response.
CONNECTION DIAGRAM:

Proportional Control:
1. Make connections as shown in Fig. with process made up of time delay and time constants.
Notice that the CRO operation in the X-Y mode ensures stable display even at low frequencies.
2. Set input amplitude to 1V (p-p) and frequency to a low value.
3. For various values of Kc = 0.2, 0.4,.measure from the screen the values of peak over shoot and
steady state error and tabulate (Refer to Fig. 4 for graphical calculation).
Proportional Integral Control:

Introducing PI control with a properly selected vale of Ti should reduce the error to zero.
1. Make connections for a Ist order type-0 system with time delay (Fig. 4 with proportional and
integrals blocks connected).
2. Set amplitude to 1V(p-p), frequency to a low value and Ki to zero.
3. For Kc = 0.6(say), observe, increase Ki in small steps and record peak overshoot and steady state
error. (Observe that with increasing Ki improves the steady state performance)
Proportional-Integral-Derivative Control:
Introducing a derivative control improves the transient performance.
1. Make connections as shown in Fig. 4 with proper integral and derivative blocks connected.
2. Set input amplitude to 1V(p-p), frequency a low value, K c=0.6, Ki=54.85 (scale settling of 0.06)
and Kd=0.
3. Repeat the above step for a few non-zero values of Kd. (observe the improvement in the transient
response with increasing Kd)
4. For Kc=0.6, adjust Ki and Kd by trial and error to obtain the best overall response, Record the
values of Kc, Ti and Td. Repeat for Kc=0.4, 0.2 etc.
CALCULATION:
Calibration: The calibration results here correspond to the measurements are suggested here
a) P Control
Input : Square wave of amplitude 0.1 V (p-p)
Output: Square wave of amplitude 2.0 V (p-p)
Kc (max.) = 2.0/0.1= 20
b) I Control
Input : Square wave of amplitude 0.1V (p-p)
Time Period : 70 msec.
Frequency : 1000/70=14.286 Hz
Output : Triangular wave of amplitude 1.6 V(p-p)
Ki(max.)= 4x14.286x1.6/0.1=914.2/sec
c) D Control
Input : Triangular wave of amplitude 0.84V(p-p)
Time Period : 70 msec.
Frequency : 1000/70=14.286 Hz
Output : Square wave of amplitude 0.5 V(p-p)
Kd(max.) = 0.5/4x14.286x0.84=0.0104 sec
d) PI Control:
Input = 1V (p-p) square wave of low frequency
Kc =0.6
System = type-0 with time delay
Scale Ki (per X=2*Steady Y=2*Peak Steady %

reading sec.) state value response state overshoot
error
e) PID Control
Input = 1V (p-p) square wave of low frequency
Kc = 0.6
Ki = 0.006 x 914.2
System = type-0 with time delay (Fig. 4)
Scale Kd (per X=2*Steady Y=2*Peak Steady %

reading sec.) state value response state overshoot
error
CONCLUSION:
From the above results it is observed that with the increase in Kd value peak over shoot is reduced and
with Ki steady state error is reduced the best values are Ki =.., Kd =..

RELATED QUESTIONS:
1. What are the specifications for any time domain response?

2. What is the function of PID controller?
3. What is maximum peak overshoot & what does it justify?
4. What are the advantages of using PI control?


5. TEMPERATURE CONTROL SYSTEM
Experiment 5.1
OBJECTIVE: To study the action of ON/OFF control of a Temperature Control System using VTCS-
02.
APPARATUS REQUIRED:
1. VTCS-02 UNIT
2. Heater setup
3. Thermistor sensor
THEORY:
Two position control (ON/OFF) is a position type of control action in which the manipulated variable is
quickly changed to either a maximum value depending up on whether the process variable is greater or
lesser than the set point.
WITHOUT OVERLAP
In a two-step controller the output signal changes from one pre-determined value to another when the
deviation changes sign. This leads to a system in which the controlled condition alternates above and
below a mean value at a frequency determined by the energy level at which the correcting element
operates.
With overlap applied, the controller changes to its higher value when the process variable falls below a
lower limit, and to its lower value when the process variable exceeds an upper limit.
OVERLAP:
Overlap is the region in which the control causes the manipulated variable to maintain its previous value
until the control variable has moved slightly beyond the set point.
Small Over lap is not preferred because it will introduce oscillations an reduces the life of the final
control element

WITH OVERLAP
PROCEDURE:
1. Interface the heater, blower, thermistor with VTCS-02 as shown in the interfacing diagram.
2. Keep the ON-OFF/PID switch in ON-OFF position. SW1 should be in downward direction.
3. Overlap POT is kept at minimum position
4. Set the desired temperature (35-95oC) by varying the set value POT.
5. Switch ON the heater and the blower. Blower should not be switched ON before heater switching.
6. Tune the overlap to maintain the process variable at set point.
7. View the response at different set points and throttle opening.
BLOCK DIAGRAM:

RESULT
Thus ON-OFF control action on temperature process control system was studied.
INTERFACING DIAGRAM:
Experiment 5.2
AIM:
To study the action of proportional control on temperature control system
APPARATUS REQUIRED:
1. VTCS-02
2. Blower
3. Heater setup
THEORY:
Two position controls applied to a process results in a continuous oscillation in the quantity to be
controlled. This draw back was overcome by a continuous control action which could maintain a
continuous balance of the input and output. Proportional control is defined as follows


it is a controller action in which there is a continuous linear relation between the value of the
controlled variable and position of the final control element within the proportional band
Controller output =kp(Err)+Bias
FullScaleDeviation
PB = 100
Kc
The sustained deviation present in proportional controller is depending on the proportional bandwidth.
As proportional band is decreased, deviation is reduced until a point is reached at which the system
becomes unstable.
PROCEDURE:
2. Keep the ON-OFF/PID switch in ON-OFF position. SW2 should be in downward direction.
3. Patch the proportional control section (P-P1).
4. Set the desired temperature(35oC-95oC) by varying the set value POT
5. Switch ON the heater and blower. Blower should not be switched ON before heater switching.
6. Tune the proportional band to maintain the process variable at set point.
7. View the response of different set points and proportional band.
SUPPLY DISTURBANCE
A step change in set point is produced by SW2 toggle, switch. An immediate change in controller output
and delayed response in measured value due to distance/velocity and transfer lag.
RESULT:
Thus proportion control action on the temperature control process was studied.

Experiment 5.3
AIM:
To study the action of PI Controller on Temperature Control System using VTCS-02.
APPARATUS REQUIRED:
1. VTCS-02
2. Blower
3. Heater setup
THEORY:
The three mode controller contains the stability of proportional control and the ability to eliminate the
offset because of reset (integral) control and the ability provide an immediate correction for the
magnitude of a disturbance because of rate (Derivative) control.
PROCEDURE:
2. Keep the ON-OFF/PID switch in PID position. SW2 should be in downword direction. Patch the P-P 1,
I-I1 and D-D1.
3. Set the desired temperature (35oC-95oC) by varying the set value POT.
4. Switch ON the heater and blower. Blower should not be switched ON before heater switching.
5. Tune PB, Ti, and Td potentiometer to maintain the process variable at set point.
6. View the response for different set points and PID value.
Supply Disturbance
A step change in set point is produced by SW2 toggle, switch. An immediate change in controller output
and delayed response in measured value due to distance/velocity and transfer lag.
RESULT:
Thus the PID control action on the temperature control system was studied.
RELATED QUESTIONS:
1. What do you understand by control system?

2. What is the function of an ON-OFF controller?
3. What is an actuating signal?
4. Which controller action is preferable ON-OFF or PID? Why?

6. SYNCHRO TRANSMITTER/RECEIVER
EXPERIMENT 6.1
OBJECTIVE:
To measure the stator output voltage with respect to rotor position and plot the graph.
EQUIPMENT REQUIRED:
1. Synchro Transmitter / Receiver (PEC03) Trainer kit.

2. Patch chords
THEORY:
Working Principle of Synchro Transmitter:
When the rotor is excited by AC voltage, the rotor current flows, and a magnetic field is produced. The
rotor magnetic field induces an emf in the stator coil by transformer action. The effective voltage induced
in any stator coil depends upon the angular position of the coils axis with respect to rotor axis.
Figure 1. Electrical circuit of synchro transmitter
Working Principle of Synchro Control Transformer:
The generated emf of the synchro transmitter is applied as input to the stator coils of control transformer.
The rotor shaft is connected to the load whose position has to be maintained at the desired value.
Depending on the current position of the rotor and the applied emf on the stator, an emf is induced on the
rotor winding. This emf can be measured and used to drive a motor so that the position of the load is
corrected.
INITIAL ADJUSTMENT:
1 Connect digital voltmeter across the any two stator output of synchro transmitter.
2 Connect synchro transmitter stator outputs to corresponding stator terminals of synchro receiver.
3 Power ON the all ON/OFF Switches
4 Verify the Stator output voltage of 0V at 0 degree, if it is not make 0V at 0 degree to adjust the
pointer of both transmitter and receiver.
1 After verification of initial adjustment disconnect the stator coil connection.

2 Switch ON the power and SPDT switch.
3 Adjust the transmitter rotor position step by step.
4 Now note down the output voltage for various rotor position in the table 1.
5 Repeat the Same procedure for other pair of Synchro transmitter coils.
Table-1
SL.No Synchro Transmitter
Rotor Position (degree) Output Voltage (V)

MODEL GRAPH
Figure 2. Model graph

RESULT:
Thus the synchro transmitter stator output voltage with respect to rotor position was studied
and the graph was plotted.
EXPERIMENT 7.2
OBJECTIVE:
To study the rotor position of synchro transmitter and receiver.
EQUIPMENT REQUIRED:
1. Synchro Transmitter / Receiver (PEC03) module
2. Patch Chords
PROCEDURE:
1. Connect digital voltmeter across to the any two stator output of synchro transmitter.
2. Connect synchro transmitter stator outputs to corresponding stator terminals of synchro receiver.
3. Power ON the all ON/OFF Switches
4. Verify the stator output voltage 0v at 0 degree, if it is not make 0v at 0 degree to adjust the pointer
of both transmitter and receiver.
5. Adjust the transmitter rotor position step by step by using knob
6. Now note down the rotor position of transmitter and receiver in the table-2.

TABLE - 2
Sl. No Synchro Transmitter Synchro Receiver Rotor Error = Rotor position

Rotor Position (degree) position (degree) (Transmitter - Receiver)
RESULT:
Thus the rotor position of synchro transmitter and receiver was studied.
RELATED QUESTIONS:
1. What do you understand by position control?

2. What is the major difference between a synchro-transmitter & receiver?
3. What is null position in synchros?
4. Give some applications of synchros.

PANEL-DIAGRAM:

7. DISPLACEMENT VOLTAGE CHARACTERISTICS OF LINEAR

VARIABLE DIFFERENTIAL TRANSFORMER (LVDT)
OBJECTIVE:
To study the characteristics of an LVDT position sensor with respect to the secondary output voltage. And
measure the voltage due to the residual magnetism.
APPARATUS REQUIRED:
1. ITB -12CE unit
2. LVDT setup
3. Multimeter /(CRO)
4. Power Chord
THEORY:
Principle of Operation:
LVDT is constructed by connecting an iron core with a non-magnetic rod move freely inside the
windings. The iron core is only responsible for flux linkages and the non-magnetic rod does not interface
in its action.
The two identical secondary coils have included in them. A sinusoidal voltages of the same frequency as
the excitation; however, the amplitude varies with the position of the iron core. When they connect the
secondaries in series opposition, a null position at which the net output e0 is essentially zero. Motion of
the core from null then causes a larger mutual inductance (coupling) for one coil and a smaller mutual
inductance for the other. The amplitude of e0 becomes a nearly linear function of core position for a
considerable range on either side of null position.

The voltage e0 undergoes a 180 phase shift in going through null. The output e 0 is generally out of the
phase with the excitation eex. however, this varies with the frequency of e ex, and for each differential
transformer there exists a particular frequency at which this phase shift is zero. If the differential
transformer is used with some readout system that requires a small phase shift between e 0 and eex,
excitation at the correct frequency can solve this problem. If the output voltage is applied directly to an
Ac meter or an oscilloscope, this phase shift is not a problem. The origin of this phase shift can be seen
from analysis.
Advantages of LVDT:
1. High range:
The LVDT has a very high range for measurement of displacement. This can be used for
measurement of displacements ranging from 1.25 mm to 250 mm. However, the dynamic
response is slower than the 2.5 KHz excitation signal.
2. Friction and Electrical Isolation:

The LVDT is a frictionless device. This permits its use in critical measurements that cannot
tolerate the addition of a low mass core but cannot tolerate friction loading. The absence of
friction between coil and core of an LVDT means that there is no wear out. This gives an LVDT
essentially infinite mechanical life.
3. Immunity from External Effects:

The separation between LVDT core and LVDT coils permits the isolation of media such as
pressurized, corrosive, or caustic fluids from the coil assembly by a non-magnetic barrier
interposed between the core and inside the coil.
4. High input and high sensitivity:

The LVDT gives a high output without amplifier. The transducer possesses a high sensitivity.
5. Ruggedness:
These transducers can usually tolerate high degree of shock and vibrations especially when the
core is spring loaded without any adverse effects. They are simple in construction and by virtue of
their being small and light in weight.
6. Low Hysteresis:
LVDT show a low hysteresis and so repeatability are excellent under all conditions.
7. Low Power Consumption:

Most of LVDT consumes power that is less than 1 W
CIRCUIT DESCRIPTION:
In this unit, the spring loaded LVDT is used to measure the displacement. Generally, it is a mutual
inductance device making use of a primary and two secondary windings. An in-build AC oscillator
supplies a constant 2 Vpp at 4 KHz voltage for the primary winding to excite. A magnetic field is created
between the primary and secondary windings of the Transformer. Whenever a non magnetic core cuts the
magnetic flux lines, an emf is induced. Based on the core movement, two different flux intensities formed
between the identical secondary winding and corresponding voltage drop across the winding. The two
voltages are fed to the differential amplifier. The differential output of the amplifier is given to the phase
sensitive demodulator circuit. It is used to detect the voltage magnitude and phase angle changes and
condition the secondary coil outputs to provide purely DC output signal. The low pass filter is designed to
filter the noise and allow only DC signals Using the gain adjustment POT, the output of the lowpass filter
amplified to a desired level. The offset adjustment POT is used to nullify the display at 10 mm
displacement in the Micrometer. The signal conditioned output voltage (-5V-0 +5 V) is correlated to
display the LVDT core displacement of ( -10 mm-0+10 mm) in the unit.
INTERFACING AND CALIBRATION :

1. Interface the 9 pin D connector of an LVDT position sensor into ITB- 12CE sensor interface
section.
2. Adjust the Micrometer to 10 mm position and tune the zero adjustment POT to display 0 mm in
the unit. The voltage across T6 and T7 should be 0V.
3. Adjust the Micrometer to 20 mm position and tune the span adjustment POT to display 10 mm in
the unit. The voltage across T6 and T7 should be 5V.
4. After completion of the calibration, the unit should not be disturbed during the experiment.

PROCEDURE:
1. Install the LVDT position sensor and interface the 9 pin D type cable with ITB -12CE unit.
2. Switch ON the unit.
3. Connect the multimeter or CRO (in AC mV mode) across the T4 and T7 for the secondary
output voltage measurement.
4. Set the micrometer position at 10mm and calibrate the display at 0'mm using zero
potentiometer.
5. Set the micrometer position at 20mm and calibrate the display at 10mm using span
potentiometer.
6. Repeat the zero and span calibration until the core displacement is 0.00mm for 10 mm
displacement in micrometer and core displacement is 10.00mm for 20 mm displacement in
micrometer.
7. After completion of the calibration, place the core of the LVDT to 10mm by adjusting the
micrometer.
8. Gradually increase the micrometer displacement from 10 mm to 20 mm and note down the
forward core displacement from zero mm to 10 mm on the displpay and the secondary output
voltage (mV) across T4 and T7.
9. Similarly, decrease the Micrometer displacement from 10 mm to zero mm and note down the
reverse core displacement of zero to -10 mm on the display and secondary output voltage (mV)
across T4 and T7.
10. Tabulate the readings of the core displacement, Micrometer displacement and secondary output
voltage (mV).
11. Plot the graph between core displacement (mm) across X axis and secondary output voltage (mV)
across Y axis.
TABULATION:
Micrometer Core (mm) Secondary Output

Displacement (mm) voltage (mV)

MODEL GRAPH:
RESULT:
Thus, the characteristics of an LVDT position sensor with respect to the secondary output voltage was
studied.
PRECAUTIONS:
1. During the offset adjustment, the Micrometer reading should be 10 mm and voltage across T6 and
T7 should be zero volt.
2. During the gain adjustment, the Micrometer should be 20 mm and the voltage across T6 and T7
should be 5 volt.
3. While taking the readings on the Micrometer scale, you should eliminate the parallel axis error.
4. The LVDT core movement should be smooth and gradual.
RELATED QUESTIONS:
1. What is a transducer ? Differentiate between a transducer & sensor.

2. What is null position of the core ?
3. Where can we use LVDTs?


8. TEMPERATURE VOLTAGE CHARACTERISTICS OF J
TYPE THERMOCOUPLE
AIM:
To study the temperature voltage characteristics of thermocouple.
APPARATUS REQUIRED:
1. ITB-05CE
2. Thermocouple
3. Water bath
4. Thermometer
5. Digital multi meter
6. Power Chord.
THEORY:
The thermocouple is one of the simplest and most commonly used methods of measuring process
temperatures. The operation of a thermocouple is based upon Seebeck effect which states that when heat
is applied to junction (hot junction) of two dissimilar metals, an emf is generated which can be measured
at the other junction (cold junction). The two dissimilar metals form an electric circuit, and current flows
as a result of the generated emf as shown in below figure.
The emf produced is function of the difference in temperature of hot and cold junctions.
Seeback Effect:
Using solid state theory, the above mentioned situation may be analyzed to show that its emf can be given
by an integral over temperature.
E=

E = emf produced in volts
T1, T2= Junction temperature in K
QA, QB = Thermal transport constants of the two metals.
This equation, which describes the see back effect, shows that the emf produced is proportional to the
difference in temperature and further, to the difference in the metallic thermal transport constant. Thus, if
the metals are the same, the emf is zero and if the temperatures are the same, the emf is also zero.
J-type thermocouple:
This active transducer is made of Iron and Constantan metals. There are two junctions, one kept as a
reference and the other is subjected to the temperature. Depending on the difference in the temperature of
the two junctions, it develops an output voltage without the need of any excitation. Hence is called an
active transducer on the principle of seeback effect. The output voltage is in millivolts. This voltage is
suitably signal conditioned to give an output in volts.
The thermocouple senses the temperature from the temperature source (Water bath) in terms of millivolts.
This millivolts output which is obtained from thermocouple is given to inverting amplifier for further
amplification. This amplifier amplifies the given millivolts in the range of (0-3.5)V.
PROCEDURE:
1. Patch the two terminals of the thermocouple across T1 & T2.
2. Insert the thermocouple and thermometer into the water bath.
3. Place the Multimeter (mill volts mode) across T3 and T4.
4. ON the water bath and note the temperature in thermometer and mV in Multimerter.
5. Tabulate the readings temperature Vs mV and plot the graph.
6.
TABULATION:
Actual Temperature (oC) Thermocouple Output (mV)


MODEL GRAPH:
Temperature( 0C)
Thermocouple Output(mV)
RESULT:
Thus the characteristics of thermocouple was studies and graph is plotted.
RELATED QUESTIONS:
1. What is a thermocouple?
2. What is Seeback effect?
3. Why do we need instrumentation amplifier?
4. Why is calibration necessary?

9. STRAIN MEASUREMENT
AIM:
To study the characteristics between strain applied to the cantilever beam strain sensor and the bridge
voltage.
APPARATUS:
1. ITB-17-CE Trainer kit
2. Multimeter
3. Cantilever beam strain sensor setup
4. Weights(100 gram x 10 Nos)
5. Power chord
THEORY:
Strain measurement can be done by using a variety of sensors with proper signal conditioning. This strain
gauge module (ITB-17-CE) is designed to measure the strain of the cantilever beam by using a four arm
bridge circuit. The strain gauges are available in many types and ranges. Based on application, proper
selection of this sensor is very important.
The cantilever beam is fixed on a rigid body. Strain gauges are placed on the surface of the beam. When
the load is applied on the end, a downward is exerted. It tend to change the dimension of the beam. This
dimensional changes are sensed by strain gauge i.e. placed on it, a strain occurred on the beam is
calculated by the formula.
6 pL
Strain = Bt 2 y
Where
- Applied load in Kg
L - Length of the beam in cm
B - Breadth of the beam in cm
t - Thickness of the beam in cm
Youngs modules of the material to be used in Kg/cm2
The change in the value of resistance by straining the gauge may be partly explained by the normal
dimensional behavior of elastic material. If a strip of elastic material is subjected to tension or in other
words positively strained, its longitudinal dimension will increase while there will be a reduction in the
lateral dimension. So when a guage is subjected to a positive strain, its length increases while its area of
cross-section decreases. Since the resistance of a conductor is proportional to its length with positive
strain. The change in the value resistance of strained conductor is more than what can be accounted for an
increase in resistance due to dimensional changes. The extra change in the value of resistance is
attributed to a change in the value of resistivity of a conductor when strained. This property is known as
piezo-resistive effect.
PROCEDURE:
1. Install the cantilever strain sensor setup and interface the 9 pin D connector with ITB-17-CE kit
2. Connect the multimeter in mill volts mode across T2 and T3 for bridge voltage measurement
3. Switch ON the module
4. Initially, unload beam & nullify the bridge voltage by using sero adjustment POT.

5. Now apply the load to the beam, strain will develop on the beam and measure the bridge voltage
(mV) across T2 and T3
6. Gradually increase the load on the beam and note down applied load and the bridge voltage (mV)
7. Tabulate the values of the applied load, theoretical strain and bridge voltage (mV)
8. Plot a graph between theoretical strain and bridge voltage (mV).
FORMULA:
6 L 6 1 21.58
Theoretical strain = 2
2 6
370 strain
Bt 2.8 0.25 2 10
Where Applied load to the beam(P) : 1 Kg

Thickness of the beam(t) : 0.25 cm
Breadth of the beam(B) : 2.8 cm
Length of the beam (L) : 21.58 cm
Youngs modulus () : 2 x 106 Kg/cm2
TABULATION:
Applied load Theoretical Bridge-voltage

(gram) strain(s) (mV)
MODEL GRAPH:
The graph between theoretical strain and bridge voltage are obtained as follows
Bridge-
voltage
(mV)
Jb,,,m,
Theoretical strain (s)
CONCLUSION :
Thus the characteristics between strain applied to the cantilever strain sensor and the bridge voltage was
studied and graph was plotted.

RELATED QUESTIONS:
1. Where do we us strain gauge?

2. What is the principle behind working of a strain gauge?
3. What is piezo-resistive effect?
4. How does the wheat-stone bridge get balanced when connected to strain guage?


10. STUDY OF THERMISTOR CHARACTERISTICS

EXPERIMENT 11.1
OBJECTIVE:
To study Temperature V/S Resistance characteristics of thermistor.
APPARATUS REQUIRED:
1. ITB-06A CE Unit
2. Thermistor
3. PC Power Chord
4. Water bath
5. Thermometer
THEORY:
The mechanical expression for the relationship between the resistance of a thermistor and absolute
temperature of thermistor is:
Where
= Resistance of the thermistor at absolute temperature T1; ok
= Resistance of the thermistor at absolute temperature T2; ok
= a constant depending upon the material of thermistor, typically 3500 to
4500ok.
Generally thermistors are made of those metals which are having high negative temperature coefficient of
resistance, making it an ideal temperature transducer. The characteristics of thermistors are no doubt
nonlinear but a linear approximation of the resistance-temperature curve can be obtained over a small
range of temperature. Thus, for a limited range of temperature the resistance of a thermistor varies as
given by Equation.
A Thermistor exhibits a negative resistance temperature coefficient which is typically about 0.05/ oC. An
individual thermistor curve can be closely approximated through the strain hart-Hart Equation:
Where T = Temperature in; ok

R = Resistance of thermistor;
A, B, C = Curve fitting constants.

PROCEDURE:
1. Interface the thermistor across T1 and T2 .Switch on the power supply.
2. For resistance measurement, SW1 should be in resistance mode (Right position).
3. Connect the multi meter (in resistance mode) across T3 & T4.
4. Insert the thermometer and thermistor into the water bath.
5. Switch on the water bath.
6. Note down the temperature in the thermo meter and the corresponding resistance output of the
thermistor.
7. Plot the graph between temperature and resistance along X and Y axis respectively.
TABULATION:
Temperature(oC) Resistance()
MODEL GRAPH:
RESULT:
Thus temperature Vs Resistance characteristics of thermistor is studied

FRONT PANEL DIAGRAM:

Experiment 11.2
AIM:
To study the temperature Vs voltage characteristics of thermistor.
APPARATUS REQUIRED:
1. ITB-06A CE Unit
2. Thermistor
3. PC Power Chord
4. Water bath
5. Thermometer
CIRCUIT DIAGRAM:

THEORY:
The temperature voltage characteristic of thermistor is similar to that of the temperature resistance
characteristics. When small voltage is applied to the thermistor, the resulting small current does not
produce sufficient heat to raise the temperature of the thermistor.
When the applied voltage is more than more current will flow. As a result large amount of heat will be
produced which raises the thermistor temperature above the ambient temperature and its resistance then
decreases. As a result more current is drawn and resistance decreases further. The current continues to
increase until the heat dissipation of the thermistor equals to the power supplied to it. Therefore under any
fixed ambient conditions, the resistance of the thermistor is largely a function of power available to raise
its temperature above ambient. Under such conditions, the temperature of the thermistor may raise 100 0C
or 200 0C and its resistance may drop to one thousandth of its value at low current.
PROCEDURE:
1. Interface the thermistor across T1 and T2 .Switch on the power supply.
2. Switch SW1 is in left Position.
3. Connect the multi meter (in DC-Volt mode) across T5 & T6.
4. During zero calibration, SW2 should be EXT mode.
5. The OFFSET POT is adjusted to 5V because thermistor is NTC type
6. Before conducting the experiment, SW2 should be in INT mode.
7. Insert the thermometer and the thermistor in to the water bath.
8. Switch on the water bath.
9. Now note down the temperature of the thermometer and corresponding voltage output.
10. Plot the graph between temperature and voltage along X and Y axis respectively.
TABULATION:
Actual Temperature(oC) Output Voltage(V)
RESULT: Thus temperature Vs voltage characteristics of thermistor is studied.

RELATED QUESTIONS:
1. What is a thermistor?
2. What is negative temperature coefficient?
3. Why the plot between temperature vs resistance is non-linear?
4. Give some applications of thermistors.

11. SPEED vs TORQUE CHARACTERISTICS OF DC

SERVOMOTOR
AIM :
To obtain Speed vs Torque characteristics and Ia vs Torque Characteristics.
APPARATUS :
D.C Servo motor trainer kit.
THEORY :
Transfer Function of the DC Motor:
The DC motor can be represented by the equivalent circuit is shown in fig.1. The armature
resistance and inductance are represented as lumped parameters as Ra and La. The field current is assumed
to be constant. This sets the constant flux in the machine.
Figure 1. Armature Controlled DC Motor

Ra - Armature resistance (ohms)
La - Armature inductance (Henrys)
Va - Voltage applied to the armature (volts)
ia - Armature current (Amps.)
eb - Armature current (Amps.)
T - Angular speed of the motor in Rad/sec.

N - Angular speed of the motor in RPM
J - Equivalent moment of inertia of the motor and load (kg-m2 )
B - Equivalent viscous friction coefficient of the motor and the load (Nm/rad/sec)
The equations governing the behavior of the motor are given below.
The electromagnetic torque developed by the motor is
(2.1)
If the flux is assumed to be constant
(2.2)
When
(Torque constant N .m. / amp) (2.3)
The back emf developed is
(2.4)
where kb - back emf constant volts / rad / sec.
The differential equation governing the armature circuit is
(2.5)
The differential equation governing the mechanical system comprising armature and load is
(2.6)
where TL = Load torque (N.m)
Taking Laplace transform, assuming zero initial condition for equations (2.2), (2.4), (2.5) and
(2.6).

(2.7)
(2.8)
(2.9)
(2.10)
From equation (2.9)
(2.11)
From equation (2.10)
(2.12)
Figure 2. Block Diagram of DC Motor
The transfer function between the output variable - the speed T(s) and the input variable V a(s) is
obtained by setting TL(s), the load torque to zero. The simplified block diagram is shown in fig. 3.

Figure 3. Block diagram of the DC motor with TL=0
The transfer function
(2.13)
where Ta = La/Ra - the armature electrical time constant
m = J/B - the mechanical time constant
(2.14)
Generally the armature electrical time constant is much smaller than the mechanical time constant. i.e.
therefore assuming a=0, La=0, equation (2.14) can be simplified as

(2.15)
(2.16)
Here
(2.17)
Gain of the motor
(2.18)
effective time constant of the motor
Usually Ra and B are very small and hence RaB << kbkt
(2.19)
Torque constant Kt = Back e.m.f of constant Kb, if speed is expresses in Radians /sec
and
(2.20)
In a similar way one can derive the transfer function between the torque (s) and T L(s) and is
given by
(2.21)
The above transfer functions of the motor are used to study the closed loop control system.

PROCEDURE:
1. Ensure power is OFF to the servo motor controller unit and the pulse ON/OFF and INT/EXT
switch is INT position.
2. Ensure that the speed feedback loop is open, so that the motor is operated on open loop.
3. Connect the motor to the output of the power amplifier in the servo controller, as shown in fig.3.4,
through (0-2)A ammeter. Connect a voltmeter (0-30)V across the motor armature.
4. Set the controller to be proportional by connecting the I controller input to ground as shown in fig.
4.
5. Set the proportional gain kp at minimum. (Unity)
6. Switch ON power to the motor controller and the "Pulse ON/OFF". Switch to ON position.
7. Set Vref = 1 Volt. Slowly increase the gain Kp voltage by means of the proportional gain
adjustment pot, and find the voltage at which the motor just starts running.
8. Run the motor at 1500 rpm by suitably adjusting the V ref and kp. Note down the armature voltage
(Va), armature current (Ia) and speed (N) as shown in table 1&2.
9. Apply load by moving the brake magnet close to the disc. Apply the load in steps such a way that
the current is increased by 0.25A in each step. Note the armature current, voltage and speed for
each step. Tabulate the readings as shown in table 1&2.
10. It may be noticed that the motor armature current may not increase when the speed drops below a
certain value. This is because when the speed is low the eddy current induced in the disc becomes
less, which reduces the load torque.
11. Decrease the load and reduce the gain to minimum.
12. Switch OFF power supply.
13. Calculate the torque as follows,
T k t Ia
where kt - torque constant
Ia - Armature current
14. Plot the Ebvs Torque characteristics an find Kb. It will be as shown in fig. 5.
15. Plot the vs Torque characteristics. It will be as shown in fig. 6.
16. Plot the Ia vs Torque characteristics. It will be as shown in fig.7.
17. From the graph calculate the value of Kb, Kt.

TABULATION :
Table 1 - Back EMF Vs Speed(Ra=8)
S. No Vref Va Ia N (rpm) Eb = Va - Ia Ra
Table 2 - vs TL and Ia vs TL Characteristics
S. No. Va (V) Ia (A) N (rpm) = 2BN/60 T = Kt Ia (N.m)
MODEL GRAPHS:
Figure 5. Back-Emf Vs Torque Characteristics
Figure 6. Speed Vs Torque Characteristics

Figure 7. Armature current Vs. Torque Characteristics
CONCLUSION :
From the characteristics of dc-servo motor for an open loop system the values of Kb, Kt obtained are.
RELATED QUESTIONS:
1. What is a transfer function?

2. Mention various methods for speed control of DC motor?

12. PLC BASED DATA ACQUISITION SYSTEM
12.1. INTRODUCTION
In this trainer we going to study about the working of PLC and PLC based Data Acquisition
system i.e., working of DC Motor Speed controller and Temperature process control using PLC
Programmable Logic Controller is user friendly, microprocessor specialized computer that carries out
control function of many types and levels of complexity. PLC will operate any system that has output
devices that go ON and OFF. It can also operate any system with variable (Analog) outputs, in the input
side by ON/OFF devices or by variable (Analog) input devices. PLC is most commonly used industrial
automation technique in the world.
By using PLC we are going to control the speed of 12V PMDC motor. The set point (SP) is given in PLC
and it produces the Analog Outputs i.e., control value (CV). It given to the driver circuit, so motor start
rotating and speed sensed by using Opto coupler sensor i.e., Process value (PV), it given to V/F converter
and given to PLC as feedback [HSL]. The PLC compares the Set point (SP) and Process Value (PV). This
process was repeated again and again. Thus the motor is controlled using PLC.
We control Temperature of water using PID controller program in PLC. The set point(SP) is given in PLC
and it produces the Analog output i.e., Control value (CV). It given to the driver circuit and it produces
the 230V AC supply to Heater. Water temperature is sensed by using RTD sensor i.e., Process value
(PV) . this sensor output given to signal conditioner board and then to the analog input of PLC i.e.,
Process value (PV). Now the PLC compares the Set point and Process value. This process was repeated
again and again. This is used to control the temperature of our desired range.


12.2. FRONT PANEL DESCRIPTION:
PLC for controlling real time applications
POWER ON/OFF SWITCH To switch ON/OFF the Trainer
Voltage source (0-5)V DC it provides variable voltage output in range
Current source (0-20)mA it provides variable current output in range
S1- S8 ON/OFF Switches for Digital inputs
I1-I8 Digital inputs read sensor feedback
Q1 Q8 Digital outputs produces by the Voltages output.
Analog Inputs It reads the variables voltages/ currents in range

(0-10)V DC
Analog Outputs It produces the variable voltage/current in range (0-10)V DC or
(0-20)mA or (4-20)mA
PWM it generates PWM pulses at this terminal.
HSC it reads high speed pulses at this terminal.
A positive terminal to Motor
AA Negative terminal to Motor
12.3.TECHNICAL SPECIFICATIONS
PLC
Make - Ge Fanuc
Model - IC200UAL005
Software - Versapro
Digital Input - 8 Numbers
Range - 24V DC
Digital Output - 6 Numbers
Range - 24V DC
Analog Input - 2 Numbers
Range - (0-10)V DC
Analog Output - 21Numbers
Range - (0-10)V DC or (4-20)mA or (0-20)mA
Communication - RS 232 serial port cable
PWM - 1 Number
HSC - 1 Number
(I) DC MOTOR SPEED CONTROL
DC MOTOR
Type - PMDC
Supply - 12V DC
Speed - 1500 RPM
Torque - 1.5 Kgcm
Current Rating - 1.3 Amps
FEED BACK SENSOR
Type - Opto coupler
Model - MOC 7811
Input - 15 V DC
DRIVER CIRCUIT
Input signal - PWM[Pulse Width Modulation]
Supply - +16V AC,+12V AC
Input Voltage - (0-5) V DC
Output Voltage - (0-12) V DC
V/F CONVERTER CIRCUIT
Supply - +12V DC,-12V DC
Input Voltage - (0-5) V DC
Output frequency - (0-5) KHz
(II) TEMPERATURE PROCESS CONTROLLER

TEMPERATURE SENSOR (RTD)
Type - Pt-100
Material - Platinum
Range - 800 degree Celsius
Length - 120mm
End Connection - BSP
WATER BATH
Heater type - Immersion Heater
Body Material - SS 304
Supply - 230V AC/50 Hz
Power - 1000 watts
Capacity - 2 Liter
DRIVER CIRCUIT (SCR)
Type - Firing Angle
Input Supply - 230 V AC/50 Hz
Output Supply - (0-230) V AC/50 Hz
Signal input - (0-5)V DC
Load - 8A(Max)
SIGNAL CONDITIONER
Input - RTD(Pt-100)
Range - (0-100) Degree Celsius
Supply - +12V DC,-12V DC
Output - (0-5)V DC
12.4. INTRODUCTION ABOUT PLC
Programmable Logic Controller is user friendly, microprocessor specialized computer that carries out
control function of many types and levels of complexity. Its purpose is to monitor crucial process
parameters and adjust process operations accordingly. It can be programmed, controlled and operated by
a person unskilled in operating computers. Essentially, a PLCs operator draws the lines and devices of
ladder diagrams with a keyboard onto a display screen. The resulting draws is covered in to computer
machine language and run as a user program. PLC will operate any system that has output devices that go
ON and OFF. It can also operate any system with variable (Analog) outputs. The programmable Logic
Control can operate on the input side by ON/OFF devices or by variable (Analog) input devices. PLC is
most commonly used industrial automation technique in the world. It is universally applied for factory
automation, process control and manufacturing systems. PLC originated from the creation of
computerized versions of relay control system used to control manufacturing and chemical process
system
PLC ARCHITECTURE
The PLC is mainly divided in to 3 parts namely the central processing unit (CPU) the Input/output (I/O)
selection and the programming device. A block diagram representing all this is shown below.
Programming Device
Programming memory
Limited Input Central control Output Flow control

switches, module unit module elements
sensors (input (Output (Relay,
control (Single or electrical
cards) cards)
push multibit switches etc)
buttons processor)
The CPU accepts (reads) input data from various sensing devices, executes the stored user program from
memory , and sends appropriate output command to control devices. The I/O system forms the interface
by which field devices are connected to the controller. The purpose of this interface is to condition the
various signals received from or sent to external field devices. The programming device, or terminal, is
using relay ladder logic. The program determines the sequence of operation and ultimate control of
equipment or machinery.
12.5. PLC SOFTWARE WORKING PROCEDURE

Step 1 : Open the Versapro software.
Step2 : Go to file and select New folder option

Step3 : In New folder window give any Folder Name and then select Finish
Step 4: Programming window will be open; here we can create the program

Step 5: In programming window select view the Hard ware configuration.
Step 6: In PLC diagram Right click and select Replace module.

Step 7 : Select the PLC Module Number, and then select OK then yes and again yes
Step 8 : In parameters window DISABLED the passwords and close the Hard ware configuration
window and then save the changes.

Step9 : Create the programs in programming window:
Step 10: Select PLC and then select connect option.

Step 11:In connect window select the port and select the Connect option.
Step 12: Go to PLC option and then select clear.
Step 13: In clear the PLC window click select all and select ok.

Step 14: Then go to PLC, and then select Store option.
Step 15: Select Store hardware configuration and store logic to PLC and select ok.
Step 16: Select PLC option and then select Run.

DC SPEED CONTROL MODULE
INTRODUCTION
The speed of the PMDC motor is controlled using PLC. In PLC programming PID block used as a
controller (PID)
DRIVER PMDC
CIRCUIT MOTOR
PC
Pc PLC
OPTOCOUPLER
SENSOR
FEEDBACK
PULSES (HSC)
SPEED CONTROL MODULE OPERATION
This module maintains the speed of PMDC motor to set point using PLC. The PLC acts as a Detector
and controller (PID). We control speed of the motor using PID controller. The set point is given in PLC
[PID program] and based on this set value initially PLC produces the PWM pluses i.e., control value.
That pulses given to the driver circuit of DC motor. So initially the motor starts rotating at some speed.
The speed of the DC motor is sensed by using Opto coupler sensor. This sensor senses the speed of the
motor and produces the high speed pulses i.e., process value, it is given ti the V/F converter and then the
output is given to the PLC. Now the PLC reads the speed feedback using HSC. Now the PLC compares
the set point and process value based on this produces controlled voltage to the controlled motor speed
based on the set point. This process was repeated again and again. Thus the motor is controlled using
PLC.


12.6. TEMPERATURE APPLICATION TRAINER
TEMPERATURE CONTROLLER
Temperature measurement plays a major role in industrial application. The various sensors are used to
measure the temperature are thermocouple, Thermistor, RTD. RTD are wire Wound and thin film devices
that measure temperature.
BLOCK DIAGRAM
DRIVER WATER BATH

CIRCUIT HEATER
PC PLC
TEMPERATURE
SENSOR
SIGNAL
CONDITIONER
WORKING OF THE SYSTEM
We control temperature of water using PID controller program in PLC. The set point (SP) Is given in
PLC[PID Program] and based on this set point (SP) initially PLC produces the Analog Output i.e.,
Control Value (CV). It given to the driver circuit of Temperature module, converted 5V DC to 230V AC
by using SCR circuit. This SCR driver circuit output given to the heater. Now the water gets heating,
temperature of the water bath is sensed by using RTD sensor i.e., process value (PV). RTD are wire
wound and thin film devices that measure temperature. It measures the based on the variation of heat,
based on this sensor resistance value will vary. This sensor senses the temperature of water and it
produces the mV output.


Experiment 1:
AIM
To control the speed of the PMDC motor using PLC
APPARATUS REQUIRED
1. VPAT-34 Kit.
2. PC with PLC software.
3. RS 232 Cable.
4. 12V DC Motor Setup
5. 9-pin cable
6. Patch Chords.
7. Power chords.
THEORY
PID CONTROLLER
One of the most powerful but complex controller mode operations combines the proportional
integral and derivative mode. This system can be used for virtually any process condition. The analytical
expression is.
Where Kp=proportional gain between error and controller output(% per %)
=rate of change of error (%S)
Kd=Derivative gain constant (%-S%)
Ki= Scaling between error and controller output.
= controller output equal to the net area under the e- time curve multiplied by Ki . We often
say that the integral term accumulates error as a function of time
For every 1% s of accumulated error time area
Procedure:
1. Switch on the trainer kit.

2. Open the PLC software in PC
3. Connect the PLC with PC using RS 232 cable
4. Connect the HSC and PWM input, output of PLC to the speed controller module PWM, HSC
terminal.
5. Write the corresponding program and download to PLC.
6. Run the program
7. Set the PID parameters and Enable the HSC, PWM channels
8. To vary the speed of the motor by using set point values in PID block
9. We can see the set point(SP), Process Value (PV) and control value (CV) in program.
10. Thus speed of the DC motor was controlled using PLC.

RESULT
Thus the speed of the PMDC motor was controlled using PLC

Experiment 2:
AIM
To study the working of temperature controller using PLC.
APPARATUS REQUIRED
1. VPAT-34 Kit.
2. Water bath.
3. RTD sensor.
4. Patch Chords.
5. Power chords.
Procedure:
1. Switch on the trainer kit.

2. Open the PLC software in PC
3. Connect the PLC with PC using RS 232 cable
4. Connect the PLC Analog output to Temperature trainer kit Analog input.
5. Connect the PLC Analog input to Temperature trainer kit Analog output
6. Write the corresponding program and download to PLC.
7. Run the program
8. Set the PID parameters
9. To vary the temperature by using set point values in PID block
10. We can see the set point (SP), Process Value (PV) and control value (CV) in program.
11. Thus the working of temperature controller was studied using PLC.


RESULTS
Thus the working of temperature controller was studied using PLC.

RELATED QUESTIONS:
1. What do you understand by data-acquisition system?

2. Why PLCs are used?
3. What are the different processes & control we can access in a PLC and how?
4. Give some applications of PLCs.

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CONTROL & INSTRUMENTATION LABORATORY MANUAL

Control & Instrumentation Laboratory Rules

4) No student is allowed to switch on supply without the permission of faculty/lab

6) Participation of each of the student in the lab is compulsory.

8) Late submission of record shall be penalized.

(2) Sarat kumar Behera G. Sivaranjani

SL.NO. EXPERIMENT NAME PAGE NO.

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 1

1. D C POSITION CONTROL SYSTEM

EXPERIMENT-1: Study of Position Sensor

1. Connect one voltmeter across Position & ground point.

SL NO. Motor Position Position Feedback Voltage

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 2

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 3

EXPERIMENT-2: Study of DC Servomotor Position Controller with P Controller.

1. Connect the terminal P1 to P6 using patch chord.

2. Connect the motor actual position terminal P2 to P7 using patch chords.

2. Set the pulse release switch in OFF position.

3. Switch ON the power supply.

6. Slightly vary the P controller knob.

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 4

9. Check all the power circuit test points waveforms.

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 5

SL NO. Input Position In Output Position In Maximum Error In Degree

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 6

EXPERIMENT-3: Study of DC Servomotor Position Controller with PI Controller.

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 7

1 Connect the terminal P1 to P6 using patch chord.

2 Connect the motor actual position terminal P2 to P7 using patch chords.

3 Connect the terminal P8 to P10 and P9 to P11 Using Patch chords.

2 Set the pulse release switch in OFF position.

3 Switch ON the power supply.

6 Slightly vary the P and I control knob.

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 9

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 10

EXPERIMENT-4: Study of DC Servomotor Position Controller with Speed Feedback Loop.

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 11

1 Connect the terminal P1 to P6 using patch chord.

2 Connect the motor actual position terminal P2 to P7 using patch chords.

3 Connect the terminal P8 to P10 and P9 to P11 Using Patch chords.

2 Set the pulse release switch in OFF position.

3 Switch ON the power supply.

9 Check all the power circuit test points waveforms.

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 13

1. What do you understand by position control?

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 15

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 16

2. TWO PHASE AC SERVOMOTOR TRANSFER FUNCTION &

1. MEASUREMENT OF TRANSFER FUNCTION PARAMETERS.

1.1 Determination of Motor Constant K2

Sl . Speed (N) rpm Load (Kg) Torque (Nm)

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 18

S. No Load (Kg) Control Voltage (Vc) Torque (Nm)

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 19

Transfer function of A.C Servomotor is,

km = k1 / (k2 + B) motor gain constant

The values of J and B are given here by the manufacturers

Substitute in the above equations.

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 20

Figure 1. Speed Torque characteristics of induction motor and AC Servomotor

2.2 Construction of AC Servomotor

NATIONAL INSTITUTE OF SCIENCE & TECHNOLOGY 21

Figure 2. Stator Construction of AC Servomotor

Scale Ki (per X=2Steady Y=2Peak Steady %

Scale Kd (per X=2Steady Y=2Peak Steady %