Auto 221: Basic Control Engineering

Chapter 2

Automatic ON-OFF Control

At the end of the course, the students should be able to:

 Explain what ON-OFF control means

 Explain the characteristics of ON-OFF control
 Explain how ON-OFF control is utilized
 List components comprising ON-OFF control system
 Describe ON-OFF control taking some applications as examples

REFERENCES:

Jackson, L and Morton, T.D. General Engineering Knowledge for Marine Engineers.
5th ed. London, Thomas Reed Publications Ltd 1990. (lSBN 09-47-63776-1)
Joel, R. Basic Engineering Thermodynamics in S.I. Units. 5th ed. Harlow,
Longmann, 1996 (ISBN 05-82-25629-1)
Morton, TD Motor Engineering Knowledge for Marine Engineers. London. Thomas
Reed Publications Ltd, 1994 (ISBN 09-01-2856-5)
Taylor, D.A. Introduction to Marine Engineering. 2nd ed. London, Butterworth.
1990 (ISBN 07-50-6253-9)
Hall, D.T., Practical Marine Electrical Knowledge. London, Witherby & Co Ltd, 1984
(ISBN 0-900886-87-0)
Kraal, E.G.R., Basic Electrotechnology for Engineers. 3rd ed. London, Thomas Reed
Publications Ltd, 1985 (lSBN 0-900335-96-3)
Leslie Jackson, Reeds Instrumentation and Control System.Adlard Coles Nautical,
London, 1992 (ISBN 07136-6731-1)
J. Majunder & Elstan A. Fernandez: Marine Control Technology, Shroff Publishers
Distributors PVT. LTD. Navi Mumbai, 2007
On Off Control

Under Control System Sometimes, the control element has only two position
either it is fully closed or fully open. This control element does not operate at any
intermediate position, i.e. partly open or partly closed position. The control system made
for controlling such elements is known as on off control theory. In this control system,
when process variable changes and crosses certain preset level, the output valve of the
system is suddenly fully opened and gives 100% output.

Occasionally known as Two-step or two position control, this is the most basic
control mode. The final controlled element e.g. a valve is either fully open or fully closed,
with no intermediate state. Considering the fuel oil tank in a ship as shown in the figure,
the objective is to heat the fuel in the tank using the energy transferred from simple
steam coil.
In the flow pipe to the coil, the two port valve and actuator is fitted, complete with
a thermostat placed in the fuel in the tank the thermostat is set to 60 oC, which is the
required temperature of the fuel in the tank. The thermostat would have an upper and
lower switching point. This is essential to prevent over rapid cycling. In this case the
upper switching point might be 61oC (the point at which the thermostat causes the valve
to be shut) and the lower switching point might be 59oC (the point when the valve is to
open). Thus there is a built in switching difference of ±1 oC about the 60oC set point (in
the thermostat).

On/off temperature control of fuel in a tank

 This 2oC (±1oC) is known as the switching differential. A diagram of switching
action of the thermostat would look like the graph as shown. The temperature of the
tank’s contents will fall to 59oC before the valve is made to open and will rise to 61 oC
before the valve is made to be close.
Figure shows straight switching lines but the effect on heat transfer from the coil
to fuel will not be immediate. It will take time for the steam in the coil to affect the
temperature of the fuel in the tank. Not only that, but the temperature of the fuel in the
tank will rise above the 61o C (upper limit) and fall below the 59oC (lower limit).

On/Off switching action of the thermostat

The main advantage of an On/Off control is that it is simple and cheap. This is why
it is frequently found in applications such as fuel oil tank heating and colirifier, etc. where
accurate control is not the criteria. Its major disadvantage is that the operating differential
might fall outside the control tolerance required by the process. For example, on a main
engine fuel oil temperature control system, where fuel temperature requires precise
temperature control, on/off control could be unsuitable. In contrast, in the case of space
heating there are often large storage capacities (large area to heat or cool that will
respond to temperature change slowly) and slight variation in the desired value is
acceptable. In many cases on/off control is quite appropriate for this type of application

A thermostat is a simple negative feedback controller: when the temperature (the

"process variable" or PV) goes below a set point (SP), the heater is switched on. Another
example could be a pressure switch on an air compressor. When the pressure (PV) drops
below the threshold (SP), the pump is powered. Refrigerators and vacuum pumps contain
similar mechanisms operating in reverse, but still providing negative feedback to correct
errors.

Simple on–off feedback control systems like these are cheap and effective. In some
cases, like the simple compressor example, they may represent a good design choice.
In most applications of on–off feedback control, some consideration needs to be given to
other costs, such as wear and tear of control valves and perhaps other start-up costs
when power is reapplied each time the PV drops. Therefore, practical on–off control
systems are designed to include hysteresis which acts as a deadband, a region around
the setpoint value in which no control action occurs. The width of deadband may be
adjustable or programmable.

A very common example of on-off control theory is fan controlling scheme of

transformer cooling system.
When transformer runs with such a load, the temperature of the electrical power
transformer rises beyond the preset value at which the cooling fans start rotating with
their full capacity.
As the cooling fans run, the forced air (output of the cooling system) decreases
the temperature of the transformer.
When the temperature (process variable) comes down below a preset value, the control
switch of fans trip and fans stop supplying forced air to the transformer. After that, as
there is no cooling effect of fans, the temperature of the transformer again starts rising
due to load.
Again when during rising, the temperature crosses the preset value, the fans again
start rotating to cool down the transformer.
, we assume that there is no lag in the control equipment. That means, there is no time
day for on and off operation of control equipment. With this assumption if we draw series
of operations of an ideal on off control system, we will get the graph given below

But in practical on off control, there is always a non zero time delay for closing and
opening action of controller elements.
This time delay is known as dead time. Because of this time delay the actual response
curve differs from the above shown ideal response curve.
Let us try to draw actual response curve of an on off control system.
 Say at time T O the temperature of the transformer starts rising. The measuring
instrument of the temperature does not response instantly, as it requires some time delay
for heating up and expansion of mercury in temperature sensor bulb say from instant T1
the pointer of the temperature indicator starts rising. This rising is exponential in nature.
Let us at point A, the controller system starts actuating for switching on cooling fans
and finally after period of T2 the fans starts delivering force air with its full capacity. Then
the temperature of the transformer starts decreasing in exponential manner.
At point B, the controller system starts actuating for switching off the cooling fans and
finally after a period of T3 the fans stop delivering force air. Then the temperature of the
transformer again starts rising in same exponential manner.

On-Off or Two Position Control Action

This is the simplest type of control action (and controller) and being relatively inexpensive
is used in many applications where it is acceptable to maintain thecontrolled
variable within a range.
Examples: Thermostat on many domestic appliances or central heating system.
With this form of control the controlled device is only able to be positioned between two
extremes, that is, either to a maximum or to a minimum or to an ‘on’ or ‘off’ position.
On/off control is relatively cheap, is reliable and has been used a lot in the past, building
up extensive experience amongst engineers.
The figure below shows the system response to on/off control action.
The response curve is always cycling between two limits
and overshoot and undershoot occurs in practice due to the thermal inertia of buildings
and plant.
The space between the two limits is called the deadband.
If the deadband is large then control becomes ineffective.
 The controller may be a thermostat (temperature operated switch) mounted on the wall,
care having been taken to ensure that it is not located near to a heat source, window or
any other source of local variation in temperature.

Alternatively the controller may comprise a single pole, single throw on/off action for
starting and stopping a pump, burner, fan, etc., or have a single pole, double throw
change-over switch to open or close a 2-port valve on a heating pipe.

On/off control must be properly matched to the system dynamics.

It is more suitable for plant having a slow reaction rate and high capacity on the demand
side e.g. 2-port or 3-port valve on the pipework to a hot water storage calorifier.