MAK 305L SYSTEM DYNAMICS AND CONTROL LABORATORY

EXPERIMENT #1
LIQUID LEVEL CONTROL USING ON/OFF CONTROLLER

1. AIM OF THE EXPERIMENT

On/Off controllers are commonly used in industrial and daily applications since it is simple,
low-cost and easy to apply. In this type of control, the controlled variable is hold within a
band called differential gap (deadband). If the controlled variable takes any value out of the
band, control input will be either completely open or completely closed in order to hold the
controlled variable within the band. The aim of this experiment is to control the liquid level of
an open tank by using an on/off controller. During the experiment, it will be examined how
the controlled system behaves and how it is affected by the width of the deadband.
You are required to:
 review MAK 305 lecture materials related to on/off control,
 construct the mathematical model of the experiment system,
 find the functions that define outflow and inflow curves in terms of system parameters,
 study the step response of the system
 and learn how to operate the experiment set-up,
before coming to the laboratory for the experiment. There will be a quiz prior to the
experiment to evaluate your level of preparation.

2. BEFORE THE EXPERIMENT

Complete the following before coming to the laboratory session considering what you have
learned during lectures of MAK 305 lectures.
1. The liquid level in tank B102 is
controlled during the experiment. (a)
Tank B101 is used in order to store
the liquid. Flow rate of pump P101
is the control input of the system
and it either supplies maximum
flowrate or it is completely off
during the experiment. (Should we
consider the resistance of valve
V101?) Valve V112 is kept fully
open while valve V102 is hold at a
constant opening. Let Q is flow rate
of the pump (control input), A is
area of cross-section of the tank
B102, R is total resistance of valves
(b)
V112 and V102,  is density of the
liquid, g is gravity. (A simplified
schematic of the system is given in
Figure 1.b.) Construct the
mathematical model of the
experiment set-up and find the
differential equation regarding the
system dynamics in terms of the
height of the liquid h in tank B102.
2. Find transfer function between Q
and h. (Plant transfer function)
3. Find a function in terms of system Figure 1. Model of Liquid Level Control System
parameters to describe level change
of water in tank if the tank is empty and pump is on at the beginning of the experiment
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 MAK 305L SYSTEM DYNAMICS AND CONTROL LABORATORY

(inflow curve). Find a function in terms of system parameters to describe level change
of water in tank if height of water in tank is h0 and pump is off at the beginning of the
experiment (outflow curve).
4. If the tank is empty and a step reference input h = h0h(t) with height of h0 is applied to
the system, draw a rough graph showing how water level in the tank and pump
flowrate change.
5. Read the lab document and learn how the experiment setup is run.

3. RUNNING THE EXPERIMENT SET-UP

Experiment will be performed with a set-up
produced by the company Festo which can be used
for controlling level, flow rate, temperature or
pressure. A picture of the set-up can be seen in
Figure-2. System is controlled in closed-loop with
the help of a PLC that can be programmed with a
control interface.

Figure 2. General Purpose Closed Loop Control

Experiment Set-up

Preparing the experiment set-up

1. Check the set-up with your eyes only without touching any switch or knob before
giving energy to the system from any source. During this inspection, check if
i. Power connections (signal or energy) are linked correctly,
ii. Pipes and hydraulic connections are sturdy and leak-proof,
iii. There is any problem in pressurized air hardware and connections,
iv. There is any visual damage in physical elements (wear, loose connection, etc.).
2. Check the connections of energy and signal cables which supply interconnection in the
set-up (Figure 3). These include;
i. Connecting Port 1 output (digital I/O) of Easyport device and XMA2 socket (2)
of main station by using Syslink cable (5).
ii. Connecting Port 2 output (analog I/O) of Easyport device and X2 socket of
main station by using analog signal cable (6).
iii. Connecting computer and Easyport device by RS-232 cable (4).
iv. Making energy connection of Easyport by using power cable (with blue/red
banana connector) Red = +, Blue = -.
Note: You will find these connections ready on the experiment set-up.
3. Pressurized air connection should be done. Air at a pressure of 6 bar should be
supplied to the air pipe in the set-up.
4. Power cable should be connected to 220VAC plug on power supply of experiment set-
up for electricity connection. System works with a potential of 24VDC (Max. 5Amps).
5. Valve and actuator arrangements should be made according to information given in
Table 1.
6. Lastly, change the position of the switch on the power supply of the experiment set-up
from 0 to 1. Yellow light shall be on if all the electricity connections are done
properly.
7. Wait about 10 seconds in order the system to turn on.

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1. Easyport Digital/Analog signal device

2. I/O Signal Terminal
3. Analog signal terminal
4. RS232 cable
5. SysLink cable
6. Analog signal cable with 15 pins

Figure 3. Easyport Cable Connections

Table 1. Valve and actuator scheme for on/off control experiment

Pump P101 Manual*

Proportional valve V106 Off
Heater E104 Off
Manual valve V101 On
Ball valve V102 On
Manual valve V103 Off
Manual valve V104 Off
Drainage valve V105 Off
Manual valve V107 Off
Manual valve V108 Off
Manual valve V109 Off
Manual valve V112 On**
*Pump will be set according to FluidLab software.
** Lab instructor will set the opening of valve

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Running Fluid Lab-PA Software

It will be worked with Fluid Lab-PA software which is loaded on the computer next to the
experiment set-up during the laboratory session. It should be ensured that experiment set-up is
ready to operate and settings in Table 1 are applied. Easyport should be connected to the
experiment set up and energized.
Click on the symbol on desktop or “Start>Programs>Festo Didactic>FluidLab-
PA>FluidLab-PA_Compact_Workstation>FluidLab-PA” to run the software.

1. Startup screen
It is the very first screen when the software is run (Figure 4). Check Table 2 for details.

Figure 4. Fluid Lab-PA startup screen

Table 2. Details about Startup Screen

Number Function
1 Opens Measurement and Control for system details
2 2 points closed loop level control
3 Continuous closed loop control
®
4 Opens relevant Fluid Lab –PA folder
®
5 Saves relevant Fluid Lab –PA folder
®
6 Information about Fluid Lab –PA
7 Language choices
8 Set-up
®
9 Fluid Lab –PA version
10 Demo version if there is no license
11 Warning about communication problem with Easyport
12 License information

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2. Position Closed Loop Control Window

Figure 5 can be seen for two point on/off closed loop control window. Press 2 at startup
screen to get to this window.

Figure 5. Two point closed loop control window

To do the experiment using Easyport (Check Table 3 for details);
 Input the desired value and deadband width by sliding relevant arrows (w and Range
of manip.)
 Arrange graphic selections accordingly (Presetting).
 Set digital outputs as follows:
i. Output 0 (Spherical valve - V102) : 1 (On)
ii. Output 1 (Heater) : 0 (Off)
iii. Output 2 (Turn on pump digitally) : 0 (Off)
iv. Output 3 (Turn on pump) : 0 (Off. Checked automatically)
 In “Select manip. value” menu, select “Digital Output 3”.
 Set desired arrangements in “setup”.(These will be done by experiment inspector
before you come to the laboratory. Check Appendix-1)
 Run the experiment by clicking “Start”.
 When experiment is over, click “Stop”. Observe and save the results. You can save by
using save button which is described in Table 3 and take print out by clicking print.
Figure 6 shows details of the highlighted section (1) in Figure 5. In this window, you can also
see experiment selection, start in simulation mode and stop menu.

1.Stop simulation
2.Start simulation
3.Experiment selection
4.Load picture to the graphics screen
5.Delete and restart graphics

Figure 6. Start stop simulation menu for 2 point closed loop control

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Table 3. Explanation for 2 point closed-loop control screen

Function Function view Details

Analog input channels 0…3

w: desired value
x: measured value
Measured Values
y: signal
w-max: upper boundary value
w-min: upper boundary value

Delete Graphics Delete: Deletes graphics screen

Design Design: Load relevant pictures
Factor physical Scale Factor physical Scale: Expansion coefficient of screen
Max. measurement time Max. measurement time: Value for time axis

Digital input/output

Analog output values

Start Start and stop measurement

Controlled digital output

Desired value, Adjust desired value as percentage and boundary values

max and min values (Phys. val. = Measured val x factor (w)

Save and print Save desired data (ASCII format) and print

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4. CONDUCTING THE EXPERIMENT

Experiment 1:
i. Enter the reference value of liquid level in tank B101 (w) and deadband (range of
manip.).
ii. Start the simulation.
iii. As the experiment is running, change reference value by increasing and decreasing it
as the system is within deadband. Observe the system output on computer screen.
Save the graphics of liquid height change and take a screen shot.
iv. Stop the simulation.

Experiment 2:
i. Enter the reference value of liquid level in tank B101 (w) and deadband (range of
manip.).
ii. Start the simulation.
iii. As the experiment is running, change deadband after some time by increasing and
decreasing it such that you get at least 5 different value. Run the system for a while
within deadband after each increase or decrease. Observe the system output on
computer screen. Save the graphics of liquid height change and take a screean shot.
iv. Stop the simulation.

Experiment 3:
i. Enter the reference value of liquid level in tank B101 (w) and set deadband (range of
manip.) as zero.
ii. Start the simulation.
iii. Wait until tank is empty. Observe the system output on computer screen. Save the
graphics of liquid height change and take a screen shot.
iv. Stop the simulation.

Note: Do not ever change the opening of the valves during experiments.

5. REPORT
Unorganized reports in which experiment data are given in random order will not be
accepted. Report should hold qualities of a technical document with a proper proofreading.
Part of the grading of the report will depend on presentation, grammar, shape of graphs and
figures. You should consider the following in your report:

 Details about the preparation works before the experiment

 Data output from the experiment, observations during the experiment, screen shots
 Calculations done in order to identify system parameters in experiment 3. (Pump flow
rate is 26 l/min, cross-section of tank is 30cmx30cm, fluid is water.)
 Comparison and comment on theoretical charts of loading and draining curves and
the data you obtained from experiments 1 and 3.
 Presenting graphically the relation between periods of observed oscillations within
deadband boundaries and width of deadband, comparing with theory,
studying/explaining the differences.
 Evaluating what you have gained from the experiment

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 MAK 305L SYSTEM DYNAMICS AND CONTROL LABORATORY

APPENDIX 1: SOFTWARE SETUP

Press Setup (8) in Figure 4 to get into the Setup window (Figure 7).

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Figure 7. Setup window

 Select the connection port between computer and Easyport from COM menu at the
top. (COM1 usually) In case a different port is selected, software should be restarted.
 There are small switches in the highlighted section (1) for observing and controlling
digital inputs and outputs. If mouse is placed on one of the switches for more than 2
seconds, a small note is shown displaying which output is controlled by that switch
(Figure 8).

Figure 8. Displaying digital input-output information

 Controls in the highlighted section (2) are used for adjusting signal levels of analog
outputs.
 Highlighted section (3) shows 4 analog input channels. Channel numbers are displayed
on the left. Physical value can be calculated with the formula below using sensor data:

Physical value = Measured value * Factor + offset

For example, if the sensed value is within 0-200 bar and the signal is between 0-10V,
factor should be 20. If 5 bar is assumed to be zero, offset should be -5. Thus, a new
offset should be set each time.
Table 4 contains further information about the channels.

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Table 4. Channel details

Component Information

Channels Analog signal input channels ( 0.. 3)

Multiplicative factor for input voltage.

Factor
Nominal value is 1.
Offset for zero value.
Offset
Nominal value is 0.
Shows how many times it will filter the input signal.(on average 0..90 times)
Filter
Nominal value is 0.

Inverting Inverting the measured value by sensor.

 The switch in the highlighted section (4) is used to select between software simulation
and experiment via Easyport. If any change is applied, you should save and restart the
software.
 Devices connected to digital I/O signals can be seen in Table 5.
 Devices connected to analog I/O signals can be seen in Table 6.

Table 5. EasyPort digital input/output signal details

Input Output
Details Details
Signal Signal

0 Flowrate measurement sensor 0 Spherical valve driver on/off (Nominal value: 0)

1 B101 tank overload safety switch (S111)
2 B102 tank liquid level float (S112)
3 B101 tank minimum level sensor (B113)
4 B101 tank maximum level sensor (B114)
5 Spherical valve driver I off (Figure 11)
6 Spherical valve driver I on
7 Free connection
1 Heater on/off (Nominal value: 0)
Pump (P101) operation selection: digital or analog
2 Switch position 0: digital control (nominal value)
Switch position 1: analog control
3 Pump on/off by digital signal (2nd switch should be 0)
4 Proportional valve(V106) on (1) or off (0)
5 Free connection
6 Free connection
7 Free connection

Table 3. EasyPort analog input/output signal details

Input
Details
Channel
0 Level sensor – B101- (ultrasonic sensor) - with signal inverter
1 Flow rate sensor (B102) - with signal inverter
2 Pressure sensor (B103)
3 Temperature sensor – PT100 (B104) ) - with signal inverter
Output
Details
Channel
Pump (P101) analog control
0  Works only when 2nd switch of digital output channel is at position 1
 Output voltage range in 0..10V
Proportional valve (V106) analog control
1  Works only when 4th switch of digital output channel is on
 Output voltage range in 0..10V

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1. Spherical valve
2. Solenoid
3. 5/2 direction valve (V102)
4. Winding SYPAR type driver
5. Sensor box

Figure 9. Spherical valve driver