International Islamic University Islamabad

Faculty of Engineering & Technology

Department of Electrical Engineering

CONTROL SYSTEMS LAB

Experiment No. 5: Study and Analysis of ON/OFF controller

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Registration No.: ……………………………………..

Date of Experiment: …………………………………

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Experiment No. 5: Study and Analysis of ON/OFF controller using Hardware Page 1
Objectives:
 To learn the basic knowledge of a controller and its different types.
 To study and analyze the ON/OFF (two position) controller.
Equipment Required:
 DMM
 PID Trainer
 Connecting wires
Theory:
Overview of a Controller:
In process control, a controller is the mechanism which seeks to minimize the difference
between the actual value of a system (i.e. the process variable) and the desired value of the
system (i.e. the set point). Normally, controller consists of a reference and a control element.
The reference element calculates the error signal “E(s)” from the difference between
reference “R(s)” and feedback variable “F(s)”, while the control element generates the
manipulated variable “Y(s)” from the error signal, as shown in Figure 5.1. A controller is
employed to control the temperature, pressure, flow or speed etc in different application.

Figure 5.1: Controller

There are two main types of controllers: continuous and discontinuous controllers as
presented in Figure 5.2. In discontinuous controllers, the manipulated variable changes
between discrete values. Depending on how many different states the controlled
(manipulated) variable can assume, a distinction is made between two-position, three-position
and multi-position controllers. The main feature of continuous controllers is that the
controlled (manipulated) variable can have any value within controller’s output range.

Experiment No. 5: Study and Analysis of ON/OFF controller using Hardware Page 2
 Figure 5.2

PID Controller Trainer is available in our laboratory. The front view of that PID trainer
is shown in Figure 5.3. The ON/OFF controller block of PID trainer will be analyzed in this
lab session.

Figure 5.3
ON/OFF Controller:
ON-OFF control is the simplest form of feedback control, in which the “control element”
has only two positions, either it is fully closed or fully opened. In this type of control, the
output of the controller is quickly changed to either a maximum or minimum value depending

Experiment No. 5: Study and Analysis of ON/OFF controller using Hardware Page 3
upon whether the controlled variable is greater or less than the set point (SP) or in other
words depends upon the actuating error signal “e(t)”. A common example of ON-OFF control
is the temperature control in a domestic heating system. When the temperature (“process
variable” or PV) goes below the set point, the heating system is switched ON and when the
temperature is above the set point, the heating system switches OFF as demonstrated in
Figure 5.5. If the heating system switches ON and OFF at the instant, when the measured
temperature crosses the set point, the system would chatter; it repeatedly switches ON and
OFF at a very high frequency. Thus, the boiler wouldn’t last very long.

Figure 5.5
To avoid this chattering effect, practical ON-OFF controllers usually have a dead-band
(differential gap) around the set point. The differential gap can also be defined as the range
through which the actuating error signal must move before the switching occurs. When the
measured value lies within this dead-band, the controller does nothing. When the value
moves outside this dead-band, controller will take the desired action. In this type of
controller, the control variable always oscillates with a frequency which increases as the
width of the differential gap decreases. The decrease in differential gap increases the ON-
OFF switching of the controller. Therefore, the useful life of the plant decreases. Hence,
dead-band should be designed to prevent the oscillations in an ON-OFF controller.
Another application of ON-OFF controller could be a pressure switch in an air
compressor: when the pressure (PV) drops below the threshold (SP), the pump is powered.
Refrigerators and vacuum pumps have also such type of controlling mechanisms.
Procedure:
a. The connections diagram for ON/OFF controller is shown in Figure 5.6.
b. After making all required connections on the board, switch ON the power supply.
c. Set +2V at TP1 by varying the Set Point knob of PID trainer, and apply it to the input
(SP) of ON/OFF controller. Initially, set the knob of ON/OFF controller to minimum
position.
d. Apply the disturbance as a variable input to the variable input of ON/OFF controller and
vary the knob of disturbance block as required.

Experiment No. 5: Study and Analysis of ON/OFF controller using Hardware Page 4
 e. Now by varying disturbance, measure the voltage of variable input (Vin) of ON/OFF
controller with DMM and observe the status of LED connected at TP8.

Figure 5.6
f. Since the knob of ON/OFF controller is at minimum position, you will observe that LED
will glow as voltage of variable input (Vin) goes slightly above the set point voltage (VSP);
which means differential gap is less when knob is at minimum position. Measured the
value of variable input voltage (Vin) at this instant and record it in Table 5.1.
g. When LED is in ON state, start reducing the variable input voltage until the LED is
turned OFF. Record that value of variable input voltage (Vin) in Table 5.1.
Key Note: As you move the knob of ON/OFF controller towards maximum position, the
differential gap will increase.
h. Repeat the above-mentioned steps (c to g) for the desired set point voltages & knob
positions of ON/OFF controller and analyze the ON/OFF controller’s output. Record your
results in Table 5.1.
Table 5.1
Variable Input Variable Input
Set Point Knob
voltage (Vin) voltage (Vin) Differential Gap
Position
Sr. Voltage to turn ON the to turn OFF the [Z = X-Y]
of
No. (VSP) LED LED (measured)
ON/OFF
(measured) [X] [Y] (volts)
controller
(volts) (volts)
1 2V Minimum
2 2V Middle
3 2V Maximum
4 4V Minimum
5 4V Middle
6 4V Maximum

Experiment No. 5: Study and Analysis of ON/OFF controller using Hardware Page 5
 Exercise Problems
Question:
a. Using Proteous software, implement the ON/OFF controller given in Figure 5.7 and fill
the Table 5.2.
b. Take print of different snapshots of the working Proteous circuit and submit to lab
instructor along with lab handouts.
Given:
R1 = R2 = R3 = R4 = R5 = 1-kΩ, Rpot-1 = 100-kΩ, Rpot-2 = 1-kΩ,
Vin = 0 to 15V (variable), Vs = 15V, +V = +15V, -V = -15V.

Figure 5.7

Table 5.2
Variable Input Variable Input
Knob
Set Point voltage (Vin) voltage (Vin) Differential Gap
Sr. Position
Voltage to turn ON the to turn OFF the [Z = X-Y]
of
No. (VSP) LED LED (measured)
Potentiometer-1
(measured) [X] [Y] (volts)
(Rpot-1)
(volts) (volts)
1 2.1V 10 %
2 2.1V 50 %
3 2.1V 90 %
4 5.1V 10 %
5 5.1V 50 %
6 5.1V 90 %

Experiment No. 5: Study and Analysis of ON/OFF controller using Hardware Page 6