Automatic Industrial Control Laboratory

Process Control
Unit 1
Labs
Lab 1.1: Process-Control Instrumentation
What is the purpose?
The control of processes in most industries requires accurate knowledge of process
conditions, and this, in turn, requires accurate measurement of these conditions. Without
measurement, there can be no error signal for the controller and no signal to the final
control element for a corrective action to occur. The purpose of this lab is to familiarize
you with the various devices that are used in practical process-control systems to measure
conditions, develop corrective signals, and apply a corrective influence over the process.
Use this opportunity to examine some real-world devices. In the textbook, the devices are
represented by a symbol. There are no pictures of real-world devices. This lab will help
you get acquainted with different types of sensors, actuators, controllers, and final
elements.
What are the steps?
Task 1:
Procedure
1. Use the ITT Tech Virtual Library or the Internet to identify the different
types of devices used in a process-control system. Use the following key
words to streamline your search:
o Sensors
Thermal sensors
Strain sensors
Pressure sensors
Level sensors
Velocity sensors
o Process controllers
PID controllers
Temperature controllers
Flow controllers
o Actuators
Actuator motors
Linear actuators
Valve actuators
Heaters
2. List at least three manufacturers of each device you have identified.
3. List the part ID# of each device you have listed.
4. Record the operating range of each device listed.
ITT Educational Services, Inc.
15
Date: 04/06/2012
Process Control
Unit 1
5. Construct a table similar to the following one to tabulate your findings.

Devices
Types of
Devices
Manufacture of Device
and Device No.
Operating
Range
Sensors
Process
controllers
Actuators
Task 2:
Procedure
Group the devices you have identified in Task 1 under the following
elements of the process control system:
o Measurement
o Controller
o Control element
Task 3:
Procedure
1. Draw and label a basic closed-loop block diagram for a basic
temperature-control system. The diagram should reflect your
visualization of the elements of a loop and how the elements are
connected to each other.
2. Identify devices for each block of diagram from the list you have
made for Task 1 and Task 2.
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Date: 04/06/2012
Process Control
Unit 1
Lab Report Summary
Create a lab report summary that provides supporting explanation required

and answers the following questions: Did you identify the various real-world
devices used in practical process-control systems?
Did you find manufacturer names and device IDs that are used in processcontrol systems?
Did you categorize the devices under the main elements of a process-control
system?
Did you draw and label a basic closed-loop block diagram for a basic
temperature-control system?
Did you identify devices for each block in the diagram that can be used in a
closed-loop temperature control system?
17
Date: 04/06/2012
Automatic Industrial Control
Unit 2
Labs
Lab 2.1: Analog-Signal Conditioning
Signal conditioning is commonly required to facilitate the interface between various
elements in a process-control system. This lab will help you investigate some of the
circuits used to condition signals. You will use MultiSim to work with the following:
A Wheatstone bridge
A passive filter
An op amp signal conditioning circuit
What are the steps?
Task 1: Use MultiSim to build a Wheatstone bridge and an op amp

instrumentation amplifier. The circuit should provide a 0-10Volt (V) output for a
given range of resistance change of the active resistance in the Wheatstone bridge.
Procedure:
1. In MultiSim, build the Wheatstone bridge shown in Figure L 2.1. The
fixed resistors in this circuit are R1 = R2 = 100 Ohms () and R4 = R5
= 200 . R3 is an adjustable resistor. The supply voltage, V = 12V. It
is the only variable component in the circuit.
R3
R2
10
R1
100
100
R4
R5
200
200
Figure L 2.1
2. Connect a volt meter between points a and b. Measure the voltage
range, while adjusting R3 between the minimum and maximum voltage
values. You can adjust the value of R3 by five percent intervals by
31
Date: 04/06/2012
Unit 2
pressing A for an increase and Shift +A for a decrease. Record the

minimum and maximum voltage values in the following table.
Minimum V
Maximum V
3. Design an op amp instrumentation amplifier similar to the one shown

in Figure L 2.2. Connect it to the Wheatstone bridge such that, as R3 in
the Wheatstone bridge is adjusted through a range of 0 to 10 , the
output voltage of the op amp changes from 0 to 10V. Hint: Refer to
Example 2.20 on page 94 in the textbook for ideas.
+
_
R3
R2
10
R1
+
_
100
100
R4
R5
200
200
+
_
Figure L 2.2
Note: For op amps, use a 741 analog component and connect pin 7 to
+12V (VCC) and pin 4 to 12V (VDD) on all three op amps.
4. Set R3 to 20 percent intervals and record the op amp output voltages in
the following table.
R3
0%
20%
40%
60%
80%
100%
Voltage
Task 2: Design an RC low-pass filter that will have a Vout/Vin value of less than
0.03 at 800 kilo Hertz (kHz).
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Date: 04/06/2012
Unit 2
Procedure:
1. Use Example 2.11 in the textbook on page 73 to help you design the
circuit. Record the critical frequency.
2. Using MultiSim, build the circuit you designed, apply a 5V sine wave
signal from the function generator as the input, and use an oscilloscope
to measure the output voltage for the frequencies listed in the table
provided for Step 3.
3. Record the value of Vout/Vin in the table. It is a common convention to
state the output of amplifiers and filters in decibel (dB), rather than the
ratio, Vout/Vin. Convert the Vout/Vin value to dB using the following
equation:
dB 20 Log
Frequency
100 Hz
1 KHz
10 KHz
100 KHz
800 KHz
Vout
Vin
Vout
Vout/Vin
dB
Lab Report Summary
Create a lab report summary that provides any supporting explanation required and
answers the following questions.
In Task 1, did the voltage between a and b change with a change in the value of
R3?
In Task 1, did you get a 0V output when R3 was set to 0 percent?
In Task 2, did Vout/Vin decrease as the frequency of the output voltage increased?
In Task 2, was Vout/Vin less than 0.03 at 800 kHz?
In Task 2, at what frequency will the output be -3dB?
In Task 2, at what frequency will the output be -10 dB
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Date: 04/06/2012
Unit 3
Instructor Notes for the Lab Session:
The lab should be executed in groups of two to three students. Refer to Appendix
G: General Information about Using Groups for more information on how to
conduct labs in a group.
It is recommend that you download a copy of the datasheet for ADC0808 and
distribute it to students. A copy of pin-outs will help students in wiring the circuit.
A good source of datasheets is the following Web site:
Datasheets
www.alldatasheet.com/
ALLDATASHEET.COM is an on-line electronic component datasheets search
engine. This is a datasheet search site for electronic components, semiconductors,
integrated circuits, and diodes.
Ensure that the lab is equipped with all the equipment so that students do not face
any difficulty while performing their tasks.
Students should accurately follow the required steps. Missing a single step can
cause inaccurate results.
Additional References
Appendix 2 on pp. 603-611 from the textbook
46
Date: 04/06/2012
Unit 3
Labs
Lab 3.1: Digital Signal Conditioning
Many systems use digital signal processing in process control. The analog signal must be
converted into a digital signal. This can be done using an ADC. In this hardware-based
lab, you will use an ADC to convert an analog voltage range into digital values. You will
be using an ADC 0808, which is an 8-bit microprocessor compatible ADC and has an 8
channel multiplexer. The analog channel is selected using three addressing pins. It uses a
single 5V supply and outputs transistor-transistor logic (TTL)-compatible digital values.
What are the steps?
Task 1: Build an ADC circuit.

Procedure
1. Build the circuit shown in Figure L 3.1. The equipment you will need
are listed as follows:
o ADC 0808
o Eight 330 resistors
o 1K resistor
o 10K Potentiometer
o LED display
VCC
11
12
21
VCC
9
7
CLK
ADC
0808
20
19
18
22
23
15
24
14
25
17
Bar Graph
330 ohm
10
Channel 0
26
Channel 5
16
13
Figure
Figure L3.1
3.1
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Date: 04/06/2012
Unit 3
2. Connect the DC power supply and a TTL-compatible clock, as shown

in Figure L 3.2.
VCC
10k
1k
Figure L 3.2
3. Connect the output of the voltage divider to channel 0 and select the
channel 0 input by connecting pins 23-25 to the ground.
4. Connect a voltmeter to the output of the voltage divider and apply 5V
DC to VCC connections. Set the clock to 100 kHz.
Note: The ADC 0808 has active low outputs; therefore, when you
set the input analog voltage to 0V, all LEDs will be lit, and when
the analog input voltage is 5V, all LEDs will be unlit. You will
read the binary output value by interpreting an unlit LED as 1 and
a lit LED as 0.
5. Adjust the voltage output of the voltage divider to less than 1V, and
record the binary digital output value as well as the divider voltage.
Initial binary value _____
Initial Voltage _________
6. Increase the voltage until the binary digital value has increased by
1010, and again record the binary digital value and the divider voltage.
Final binary value _____
7.
Final Voltage _________
The change in the binary value is 1010, and the change in voltage
(V) is given by Vfinal Vinitial. The resolution voltage or sensitivity is
derived by the following formula:
V
10
Record the resolution voltage in Table 1.
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Date: 04/06/2012
Unit 3
8. Follow the same process for a voltage approximately equal to 3V and

for a voltage approximately equal to 5V.
o Near 3V
Initial binary value _____ Initial Voltage _________
Final binary value _____ Final Voltage _________
o Near 5V
Initial binary value _____
Final binary value _____
Initial Voltage _________

Final Voltage _________
9. Calculate the average of the three resolution voltage values. The value
you derive is the measured resolution voltage.
The resolution voltage can be calculated with the following formula:
VCC
ResolutionVoltage n
2
In the formula, VCC is the supply voltage and n is the number of bits
of the ADC.
Record your observations in the following format:
Initial
Voltage
Final
Voltage
Resolution
Voltage
Near 1V
Near 3V
Near 5V
Table 1
Resolution Voltage:
Calculated ____________
Measured _____________
How close was the measured value to the calculated value?
Task 2: Predict the digital value for an analog input voltage and check the circuit
for the correct operation.
Procedure
1. Predict the digital output value by solving the following equation for D
and converting the value to an n-bit binary number:
V
D
n
VCC 2 1
In the formula, D is a decimal value and V is the equivalent analog
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Date: 04/06/2012
Unit 3
voltage after digital-to-analog conversion over n bits using a supply

voltage, VCC.
Convert 2.7V to an 8-bit binary number. The binary value for 2.7V is
______________.
2. Set the voltage divider to 2.7V. Does the LED display show the correct
binary value?
3. Repeat Steps 1 and 2 for 4.2V. Does the LED display show the correct
value?
The binary value for 4.2V is _______________.
Task 3: Move the voltage divider to channel 5 and reset pins 23, 24, and 25 to
select channel 5.
Procedure
value?
value?
Lab Report Summary
In Task 1, were the calculated and measured values within the .005V range
when the binary number was converted back into a voltage using the following
formula:
V
D
n
?
VCC 2 1
In Task 1, is the voltage drop across the 1k resistor linear over the range of the 10k
resister?
In Task 2, was the predicted binary value close to the circuits binary value?
In Task 2, what are valid reasons for the binary values to be different?
In Task 3, were you able to select a different analog input channel?
In Task 3, why would you expect the values to be the same on both channels?
51
Date: 04/06/2012
Unit 4
Labs
Lab 4.1: Thermistors
Temperature control is essential in the food processing industry, IC manufacturing
processes, and metal fabrication. In this hardware-based lab, you will examine the
behavior of a thermistorone of the commonly used devices for temperature control
and use it to convert temperature into a voltage signal.
What are the steps?
Task 1: Measure the change of resistance of a thermistor as its temperature

changes. You will be using the following equipment:
o
o
o
o
o
o
o
o
21T1K Thermistor
741 op amp
1K potentiometer
Two1K resistors
Two10K resistors
Two 220 resistors
180 if needed
1.8K resistor
Procedure
1. Set a digital multi meter (DMM) to measure resistance. Connect the
leads or the ohm meter to the leads of a thermistor. This thermistor
should have a resistance of 1K at 25 degrees Celsius, which is 77
degrees Fahrenheit. The room temperature will affect the resistance
you measure. It will be close to 1K. Record the resistance.
Thermistor resistance __________________
2. If a soldering iron is available, plug it in and heat it. After it is heated,
hold the iron near the thermistor and observe what happens to the
resistance. If a soldering iron is not available, pinch the thermistor
between your fingers to increase its temperature. Did the resistance
increase or decrease?
The resistance _________________ (increased/decreased)
3. If canned air is available, use it near the thermistor and observe what
happens to the resistance. If canned air is not available, cool your
fingers with some ice or a can of pop and pinch the thermistor between
your fingers to decrease its temperature. Did the resistance increase or
decrease?
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Date: 04/06/2012
Unit 4
The resistance _________________ (increased/decreased)
Task 2: Use the change in the resistance of a thermistor to convert a change in

temperature into a change in voltage.
Procedure
1. Construct the circuit shown in Figure L 4.1.
2. Remember to apply the positive and negative 12V to pins 4 and 7of
the op amp.
-12V +12V
10K
220
10K
1K
1K
1.8K
Thermistor
1K
220
Figure L 4.1
3. Using the DMM, set it to measure voltage and connect it to the output
of the circuit.
4. Adjust the 1K potentiometer until the output voltage is 0 volts. You
may have to change one of the 220 resistors to a 180 resistor to get
the voltage to drop to 0V.
5. If you have a soldering iron, hold it close to the thermistor and observe
the voltmeter reading. If a soldering iron is not available, heat the
thermistor by holding it between your fingers to increase its
temperature.
6. If canned air is available, use it near the thermistor and observe what
happens to the resistance. If canned air is not available, cool your
fingers with some ice or a can of pop and pinch the thermistor between
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Date: 04/06/2012
Unit 4
your fingers to decrease its temperature.

7. Briefly describe the effect that heating the thermistor has on the output
voltage.
Note: The results of this lab are not designed to have a specific voltage for the
temperature of the thermistor. A way to measure the temperature is required to get a set
voltage value. It will be sufficient to note that a change in temperature will result in a
change in voltage. If the temperature is measured and the change in voltage tabulated,
you can develop the transfer function for this circuit. The transfer function is stated as
volts per degree change in temperature.
Lab Report Summary
In Task 1, did the resistance change when the thermistor was heated?
In Task 1, did the resistance change when the thermistor was cooled?
In Task 1, what was the resistance range between the heated and cooled thermistor?
In Task 2, were you able to set the output of the circuit to 0V at room temperature?
In Task 2, if you were not able to null the system to 0V at room temperature, what
could you do to improve the circuit?
In Task 2, did the voltage increase as the thermistor was heated?
In Task 2, did the voltage decrease as the thermistor was cooled?
73
Date: 04/06/2012
Unit 7
Labs
Lab 7.1: TRIAC Phase Control
There are many types of final control devices. SCRs, also called thyristors, are switching
devices used in final control operations. An SCR acts like a diode. When the SCR is in
conduction mode, it will continue to conduct current even after the gate signal is
removedthe SCR remains in the On state until any Turn-Off condition occurs. Another
limitation of SCRs is that these are unidirectional and are useful for controlling current in
only one direction. To overcome this limitation, two SCRs are placed in parallel and
reversed. This device conducts current in both directions, depending on the control signal
on the gate. This device is called a TRIode for Alternating Current (TRIAC).
The purpose of this lab exercise is to provide you experience in using the TRIAC as a
final control element. In this lab, you will:
Control the power to an AC load using a TRIAC
Adjust the load power over a given range of resistor values.
What are the steps?
Task 1: Build a TRIAC phase control final control circuit.

Procedure
1. Obtain the datasheet on the SC141B TRIAC and determine the pin out
and the threshold voltage.
2. Build the circuit shown in Figure L 7.1. The following list shows the
equipment you will need:
o
o
o
o
o
SC141B TRIAC
1k potentiometer
12V lamp
10 resistor
0.47f capacitor
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Date: 04/06/2012
Unit 7
Figure L 7.1
3. Apply the 12.6VAC to the circuit.
Note: The 12.6VAC supply will be from the output of the 12.6VAC
step down transformer supplied in the lab room.
4. Connect an oscilloscope with the positive lead to MT2 and the
negative lead to MT1, and observe the waveform. The waveform will
show the voltage across the TRIAC as shown in Figure L 7.2.
Figure L 7.2
Task 2: Observe how the power dissipated by the loadthe lampchanges as

the value of R1 changes.
Procedure
1. Adjust R1 and observe how the waveform changes. You will notice
that, as the value of R1 changes, the waveform changes from a full sin
wave to almost a flat line. You will also observe that when the
waveform is a full sin wave, the lamp will not be lit. As the waveform
shape changes to almost a straight line as shown in Figure 2, what
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Date: 04/06/2012
Unit 7
happens to the lamp?

2. Use the DMM set to measure AC current and insert the meter in series
with the lamp.
3. The portion of the waveform where the sin wave is shown occurs
when the TRIAC is Off, and the portion of the waveform that is flat
indicates that the TRIAC is On. Adjust the waveform shown on the
oscilloscope so that the TRIAC is On for about 50 percent of the
positive half cycle. Record the current through the lamp. Then use the
DMM to measure the AC voltage across the lamp.
Lamp Current _____________
Lamp Voltage ____________
4. Adjust R1 until the TRIAC is on for about 75 percent of the positive
half cycle and record the current through the lamp and voltage across
the lamp.
Lamp Current _____________
Lamp Voltage ___________
5. Adjust R1 until the TRIAC is always on and record the current through
the lamp and the voltage across the lamp.
Lamp Current ___________
Lamp Voltage _________
6. For the three settings of R1, calculate the power dissipated by the lamp.
Power for 50% _______________
Power for 75% _______________
Power for always on _____________
Lab Report Summary
In Task 1, draw the predicted waveform across the lamp.
In Task 2, was the lamp voltage greater in Step 5 than it was in Step 3?
In Task 2, was the lamp current greater in value in Step 5 than it was in Step 3?
In Task 2, was the power dissipated by the lamp greater in Step 5 than it was in either
Step 3 or Step 4?
In Task 2, would a 20% change in time that the TRIAC is on result in a 20% change
in power applied to the lamp? Explain your answer and provide calculations to
support your conclusion.
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Date: 04/06/2012
Unit 8
Labs
Lab 8.1: Analog Controller Circuits
The controller is the part of the process-control system, which inputs the controlled
variable and a setpoint representing the desired value of the variable. The controller
outputs a signal representing action to be taken when the measured value of the
controlled variable deviates from the setpoint. The deviation is called an error.
In this lab, you will build controller circuits and observe the controller output signals for
various controller modes. You will do this lab exercise using MultiSim.
What are the steps?
Task 1: Build an analog PID controller in MultiSim.

Procedure
1. Build the circuit shown in Figure L 8.1 using MultiSim.
Figure L 8.1
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Date: 04/06/2012
Unit 8
Use the following component values:

o R = 10k
o R1 = 10k
o R2 = 47k
o R3 = 1.3k
o RI = 3.3k
o RD = 82k
o CI = 100nF
o CD = 4.7F
2. Use 5V for the VCC and VEE to the op amps, and set up a switch to
input at Ve so that the error input can be changed using the switch.
The Multisim circuit should now look like Figure L8.2.
R3
VEE
10k
-5V
R4
V1
10mV
R1
J1
4
R2
Key = Space
V2
10mV
10k
-5V
4
10k
47k U2
U1
R8
6
VCC
5V
3
7
10k
10k
C1
Proprotional Controller
4
R5
3.3k
U5
R10
741
VEE
-5V
741
10k
R11
3
6
VCC
5V
VEE
R9
U3
100nF
2
6
3
10k
741
2
6
3
7
Integral Controller
VEE-5V
4
R7
1.3k
741
VCC
5V
XSC1
Ext T rig
+
_
R6
A
+
82k
U4
C2
2
4.7uF
6
3
7
Derivative Controller
VCC
741
Remove these lines for

Step 1 of task 2
5V
Figure L 8.2
3. Set the V1 and V2 voltages to 10mV and connect the oscilloscope to
the output.
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Date: 04/06/2012
Unit 8
Task 2: Observe the characteristics of various controller modes.

Procedure
1. To observe the characteristics of a proportional controller, remove the
connecting lines that join the integrator and the differentiator to the
summing amplifier. Run the simulation and observe the oscilloscope
as you toggle the switch from one supply voltage to another. Print the
oscilloscope waveform using the print instrument feature. Label the
printout to indicate which controller mode is referred to.
2. Change the gain of the proportional controller by changing the value
of R2 shown in Figure 2. Print and label the oscilloscope display for
the simulation.
3. Connect the integrator circuit to the summing amplifier. This makes a
proportional-integral controller. Run the simulation and observe the
waveform on the oscilloscope while you switch the input. You may
have to adjust the oscilloscope sweep speed to observe the effect;
however, you will notice that the proportional-integral controller
responds differently than proportional controller, to the change in the
input. Print the oscilloscope waveform. Change the CI value to 10nF,
run the simulation, and print the waveform. Observe how the
waveform changes with variation in the integral gain.
4. Connect the differentiator circuit to the summing amplifier, run the
simulation, and print the oscilloscope waveform. Change the CD value
to 1F and print the oscilloscope waveform. Observe the effect of
changing the derivative gain.
Note: These oscilloscope waveforms are not the output of a controller
that is used in a closed-loop process-control system. These
waveforms represent the behavior of a controller responding to
a voltage input in an open-loop condition.
5. Use printouts of waveforms and write a short conclusion describing
the behavior of the three controller modes you simulated.
Lab Report Summary
Create a lab report summary that provides any supporting explanation

required and answers the following questions.
1. In Task 2 Step 1, did the output waveform of the proportional
controller give a square wave that followed the change in the input
switch?
2. In Task 2 Step 3, after the integrator was added, did the output
waveform of the proportional-integral controller give a waveform that
had a linear slope?
146
Date: 04/06/2012
Unit 8
3. In Task 2 Step 4, after the differentiator was added, did the output
waveform jump toward 0V when the input switch was changed?
147
Date: 04/06/2012

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5. Construct a table similar to the following one to tabulate your findings.

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