User’s Manual

TEMPERATURE CONTROLLER SYSTEM

Model: TCS-302
(Rev : 30/03/2022)

Manufactured by:

T ECHNO I NSTR UM ENTS

261/16, Civil Lines, Roorkee-247 667
Ph.: 01332-272852, Fax: 274831
Email: technoinstrumentsindia@gmail.com
admin@technoinstruments.in ISO 9001:2015
Certified Company
Website: www.technoinstruments.in
 CONTENTS

Section Page

Copyright, Warranty, and Equipment Return 1

1. Objective 2
2. System Description 2
3. Background Summary 2
3.1 The Plant (Oven) 2
3.2 Controller 4
3.3 Temperature Measurement 5
4. Experimental Work 5
4.1 Identification of Oven Parameters 6
4.2 ON-OFF Controller 6
4.3 Proportional Controller 7
4.4 Proportional-Integral Controller 7
4.5 Proportional-Integrla-Derivative Controller 8
4.6 Further Experimentation 8
4.7 Computer Interface Experiments (MATLAB) 9
5. Typical Result 10
6. Limitations of the System 11
7. References 12
8. Packing List 12
9. Technical support 13
10. List of Experiment 14
 COPYRIGHT AND WARRANTY

Please – Feel free to duplicate this manual subject to the copyright restriction given below.

COPYRIGHT NOTICE

The Techno Instruments Model TCS-301, Temperature Controller System manual is

copyrighted and all rights reserved. However, permission is granted to non-profit educational
institutions for reproduction of any part of this manual provided the reproduction is used only
for their laboratories and is not sold for profit. Reproduction under any other circumstances,
without the written consent of Techno Instruments is prohibited.

LIMITED WARRANTY

Techno Instruments warrants this product to be free from defects in materials and workmanship
for a period of one year from the date of shipment to the customer. Techno Instruments will
repair or replace, at its option, any part of the product which is deemed to be defective in
material or workmanship. This warranty does not cover damage to the product caused by abuse
or improper use. Determination of whether a product failure is the result of manufacturing
defect or improper use by the customer shall be made solely by Techno Instruments.
Responsibility for the return of equipment for warranty repair belongs to the customer.
Equipment must be properly packed to prevent damage and shipped postage or freight prepaid.
(Damage caused by improper packaging of the equipment for return shipment will not be
covered by the warranty). Shipping costs for returning the equipment, after repair, will be paid
by Techno Instruments.

EQUIPMENT RETURN

Should this product have to be returned to Techno Instruments, for whatever reason, notify
Techno Instruments BEFORE returning the product. Upon notification, the return authorization
and shipping instructions will be promptly issued.

Note : No equipment will be accepted for return without an authorization.

When returning equipment for repair, the units must be packed properly. Carriers will not
accept responsibility for damage by improper packing. To be certain the unit will not be
damaged in shipment, observe the following rules:
1. The carton must be strong enough for the item shipped.
2. Make certain there is at least two inches of packing material between any point on the
apparatus and the inside walls of the carton.
3. Make certain that the packing material can not displace in the box, or get compressed, thus
letting the instrument come in contact with the edge of the box.

Techno Instruments TCS-302 Page 1

 A PRODUCT OF AN
P I D ISO 9001 : 2008
CERTIFIED COMPANY

HYSTERESIS SET TIMER

HI LO °C sec

MEASURE
0 1 0 1 0 1
P
OVEN
PAUSE
I DRIVER
REF COOL OFF HEAT
RESET RUN
+ D
-

R FEEDBACK
SENSOR
GAIN
ON
TEMPERATURE CONTROLLER SYSTEM, TCS-02 T TECHNO INSTRUMENTS, Roorkee

Panel Drawing Temperature Controller System, Model TCS-02

TEMPERATURE CONTROLLER SYSTEM TCS-302

1. OBJECTIVE
To study the performance of various types of controllers used to control the temperature
of an oven.

2. SYSTEM DESCRIPTION
Temperature control is one of the most common industrial control systems that are in
operation. This equipment is designed to expose the students to the intricacies of such a system
in the 'friendly' environment of a laboratory, free from disturbances and uncertainties of plant
prevalent in an actual process. The 'plant' to be controlled is a specially designed oven having
a short heating as well as cooling time. The temperature time data may be obtained manually,
thus avoiding expensive equipment like an X-Y recorder or a pen recorder. A solid state
temperature sensor converts the absolute temperature information to a proportional electric
signal. The reference and actual temperatures are indicated in degree Celsius on a switch
selectable digital display.
The controller unit compares the reference and the measured signals to generate the
error. Controller options available to the user consist of ON-OFF or relay with two hysteresis
settings and combination of proportional, derivative and integral blocks having independent
coefficient settings. A block diagram of the complete system is shown in Fig. 1.
In addition to the above, terminals have been provided at the back of the main unit for
interfacing with a computer. This enables the user to realize the controller fully in MATLAB
environment and conduct all the experiments through a personal computer. The various
resposes, viz., open loop, close loop with a variety of controller settings etc. may be displayed
on the computer screen and also stored in excel files. Necessary software is supplied with the
unit while the user is expected to have MATLAB installed in the laboratory computer. Steps
for executing this feature are outlined in Section 4.7. It must however be emphasized that the
computerized operation is not an alternative but is an added feature. As a first experience the
student must therefore be encouraged to go through the hardware format.

3. BACKGROUND SUMMARY
The first step in the analysis of any control system is to derive its mathematical model.
The various blocks shown in Fig. 1 are now studied in detail and their mathematical
descriptions are developed. This would help in understanding the working of the complete
system and also to implement control strategies.

3.1 The Plant (Oven)

Plant to be controlled is an electric oven, the temperature of which must adjust itself in
accordance with the reference or command. This is a thermal system which basically involves
transfer of heat from one section to another. In the present case we are interested in the transfer
of heat from the heater coil to the oven and the leakage of heat from the oven to the atmosphere.
Such systems may be conveniently analysed in terms of thermal resistance and capacitance as
explained below. However, this analysis is not very accurate, since the transfer of heat
essentially takes place from every part of the oven - thermal resistance and

Techno Instruments TCS-302 Page 2

 error e(t) Relay

Reference R m(t) Actuator Plant Output c(t)

Hys
r (t) (Driver) (Oven) Temperature
+
-
Proportional

Kp P
0-20

Derivative

Kd D
0-20

Integral
I
Ki
0-0.2

10mV/°C

Temperature
Sensor Circuit
Feedback

Fig.1. Block Diagram of the Temperature

I R R
1+ sCR I
C

Fig. 2 Electrical Analog

 capacitance are obviously distributed. The lumped parameter model described here is
therefore only an approximation. For a precise analysis, a distributed parameter model must be
used. Another difficulty associated with temperature control systems is that whereas the
temperature rise is produced by energy input, which is controllable, the temperature fall is due
to heat loss which is uncontrollable and unpredictable. This implies that the oven will have
different time constants while heating and cooling. Again, these will depend on the ambient
temperature and the set point chosen. Such a system is therefore rather difficult to control.
There are three modes of heat transfer viz. conduction, convection and radiation. Heat
transfer through radiation maybe neglected in the present case since the temperatures involved
are quite small. For conductive and convective heat transfer

 = T
where,  = rate of heat flow in Joule/sec.
T = temperature difference in C
 = Constant
t = time in seconds
Under assumptions of linearity, the thermal resistance is defined as, R = Temperature-
difference/rate of heat flow = T/  = 1/. This is analogous to electrical resistance defined
by I = V/R. In a similar manner thermal capacitance of the mass is defined by
 = Cd(T)/dt
which is analogous to the V-I relationship of a capacitor, namely I = C dV/dt. In the case of
heat,
C = Rate of heat flow/Rate of temperature change
The equation of an oven may now be written by combining the above two equations, implying
that a part of the heat input is used in increasing the temperature of the oven and the rest goes
out as loss. Thus
 = C dT/dt + (1/R)XT,
with the initial condition T(t=0) = Tamb. Now, taking Laplace transform with zero initial
condition
T (s ) R
= (1)
 (s ) 1 + sCR
An analogous electrical network and block diagram may be drawn as in Fig.2 defined
by the equation
I = C dV/dt + V/R
Eq.(1) is an extremely simplified representation of the thermal system under
consideration and it gives rise to a transfer function of the first order and type zero. Such a
system should be easily controlled in the closed loop. Difficulties are however faced in the
system due to the following reasons:
(a) The temperature rise in response to the heat input is not instantaneous. A certain amount of
time is needed to transfer the heat by convection and conduction inside the oven. This
requires a delay or transportation lag term, exp(-sT1), to be included in the transfer function,
where T1 is the time lag in seconds.

Techno Instruments TCS-302 Page 3

Tref + R
A T
1+ sCR

Fig. 3 Closed Loop Temperature Control System

M1

Controller input Controller output

e(t) m(t)

M2
H

Fig. 4 ON-OFF Controller

c(t)

Hysteresis

Fig. 5 Response of ON-OFF Control System

(b) Unlike the equivalent electrical circuit of Fig. 2, the heat input in the thermal system cannot
have a negative sign. This means that although the rate of temperature rise would depend
on the heat input, the rate of temperature fall would depend on thermal resistance R. The
conventional analysis methods then become inapplicable.
(c) Referring to the closed loop oven control system of Fig. 3, it may be seen that in the steady
state the error ess is given as
ess = lim (Tref -T) = Tref /(1+AR)
t→

In this system, A cannot be increased excessively in an attempt to reduce error, since

a large gain is likely to lead to instability due to transportation lag. Also, every time (T ref -
T) becomes negative, the heat input is cut off and the oven must cool down slowly. The
temperature T therefore oscillates around the nominal value.

3.2 Controller
Basic control actions commonly used in temperature control systems are
• ON-OFF or relay
• Proportional
• Proportional-Integral
• Proportional-Integral-Derivative
These are described below in some detail.

(a) ON-OFF or Relay type controllers, also referred to as two position controllers, consist of
a simple and inexpensive switch/relay and are, therefore, used very commonly in both
industrial and domestic control systems. Typical applications include air-conditioner and
refrigerators, ovens, heaters with thermostat. Solenoid operated two position valves are
commonly used in hydraulic and pneumatic systems. The basic input-output behaviour of
this controller is shown in Fig. 4. The two positions of the controller are M 1 and M2, and H
is the hysteresis or differential gap.
The hysteresis is necessary, as it enables the controller output to remain at its present
value till the input or error has increased a little beyond zero. Hysteresis helps in avoiding
too frequent switching of the controller, although a large value results in greater errors. The
response of a system with ON-OFF controller is shown in Fig. 5. Describing function
technique is a standard method for the analysis of non-linear systems, for instance, one with
an ON-OFF controller.
(b) Proportional controller is simply an amplifier of gain Kp which amplifies the error
signal and passes it to the actuator. The noise, drift and bias currents of this amplifier set
the lower limit of the input signal which may be handled reliably and therefore decide the
minimum possible value of the error between the input signal and output. Also the
saturation characteristics of this amplifier sets the linear and non-linear regions of its
operation. A typical proportional controller may have an input-output characteristics as in
Fig. 6. Such controller gives non-zero steady state error to step input for a type-0 system as
indicated earlier. The proportional (P) block in the system consists of a variable gain
amplifier having a maximum value, Kp max. of 20.

Techno Instruments TCS-302 Page 4

 e(t) m(t)

Fig. 6 Proportional Controller with Saturation

KP

e(t) m(t)
+

KI / S

Fig. 7 P-I Controller

1000 1000
+ +

56K
e(t) -

+
I

Fig.8 Circuit for Integrator

(c) Proportional-Integral (PI) controller: Mathematical equation of such a controller is given
by
t t

 
m(t) = K P e(t) + K I e( t ) dt = K P e(t) + 1 / TI e( t ) dt
0 0
and a block diagram representation is shown in Fig. 7. It may be easily seen that this
controller introduces a pole at the origin, i.e. increases the system type number by unity.
The steady state error of the system is therefore reduced or eliminated. Qualitatively, any
small error signal e(t), present in the system, would get continuously integrated and
generate actuator signal m(t) forcing the plant output to exactly correspond to the reference
input so that the error is zero. In practical systems, the error may not be exactly zero due to
imperfections in an electronic integrator caused by bias current needed, noise and drift
present and leakage of the integrator capacitor.
The integral (I) block in the present system is realised with a circuit shown in Fig.8
and has a transfer function

Gr(s) = 1/(28s) = KI /s (2)

The integral gain is therefore adjustable in the range 0 to 0.036 (approx.). Due to the
tolerance of large capacitance’s, the value of KI is approximate.
(d) Proportional-Integral-Derivative (PID) controller: Mathematical equations governing the
operation of this controller is as
t


m( t ) = K P e( t ) + K I e( t ) dt + K D de( t ) / dt
0
t


= K P e( t ) + 1 / TI e( t ) dt + TD de( t ) / dt
0
so that in the Laplace transform domain,
M(s)/E(s) = (Kp + TDs + 1/TIs)
A simple analysis would show that the derivative block essentially increases the damping
ratio of the system and therefore improves the dynamic performance by reducing overshoot.
The PID controller therefore helps in reducing the steady state error with an improvement
in the transient response.
The derivative (D) block in this system is realised with the circuit of Fig. 9. This
has a transfer function
GD(s) = 19.97 s (approx.) (3)
The derivative gain is therefore adjustable in the range 0 to 20 approximately.
Again, the approximation is justified due to the higher tolerance in the values of large
electrolytic capacitance’s.
PID controller is one of the most widely used controller because of its simplicity.
By adjusting its coefficients KP, KD (or TD) and KI (or TI) the controller can be used with a
variety of systems. The process of setting the controller coefficients to suit a given plant is
known as tuning. There are many methods of 'tuning' a PID controller. In the present
experiment, the method of Ziegler-Nichol has been introduced which is suitable for the
oven control system, although better methods are available and may be attempted.

Techno Instruments TCS-302 Page 5

 85K

470 470
+ +
e(t) -

+
D

Fig. 9 Circuit for Differentiator

T1
T (oC)

TIME (sec.)
T2

Fig. 10 Open Loop Response of the Oven

3.3 Temperature Measurement
The oven temperature can be sensed by a variety of transducers like thermistor,
thermocouple, RTD and IC temperature sensors. In the present setup, the maximum oven
temperature is around 90C which is well within the operating range of IC temperature sensor
like AD590. Further, these sensors are linear and have a good sensitivity, viz. 1A/K.
Associated electronic circuits convert this output to 10mV/C which may be easily measured
by a DVM. The time constant of the sensor has however been neglected in the analysis since it
is insignificant compared with the oven time constant.

4. EXPERIMENTAL WORK
A variety of experiments may be conducted with the help of this unit. The principal
advantage of the unit is that all power sources and metering are built-in and one needs only a
watch or use the built-in timer to be able to note down the temperature readings at precise time
instants. After each run the oven has to be cooled to nearly the room temperature, which may
take about 20-25 minutes with forced cooling provided. This would limit the number of runs
to about four in an usual laboratory class. The experiments suggested could be completed in
about 6-8 hours.

4.1 Identification of Oven Parameters

Plant identification is the first step before an attempt can be made to control it. In the
present case, the oven equations are obtained experimentally from its step response as outlined
below. The procedure is as per Ziegler-Nichol reaction curve method.
In the open-loop testing, the oven is driven through the P-amplifier set to a gain of 10.
The input to this amplifier is adjusted through reference potentiometer (the one next to switch
S2). This input can be seen on digital display, so that when you set 5.0C, the input to
Proportional amplifier is 50 mV (@ 10mV/C) and its output (which acts as input to driver
circuit) is 0.5V (50mVX10).
 Keep switch Oven Switch to 'WAIT', Set-Measure Switch to 'SET' and open
'FEEDBACK' terminals. (refer panel drawing)
 Connect P output to the driver input and switch ON the unit.
 Set P potentiometer to 0.5 which gives Kp=10. Adjust reference potentiometer to
read 50.0 on the DVM. This provides an input of 0.5 V to the controller, i.e. 5V to
the driver.
 Put switch S2 to the 'MEASURE' position and note down the room temperature.
 Put switch S1 to the 'RUN' position and note temperature readings every 10 sec.,
till the temperature becomes almost constant. Use the timer on the panel to monitor
time.
 Plot temperature-time curve on a graph paper. Referring to Fig. 10, calculate T1
and T2 and hence write the transfer function of the oven including its driver as
G(s) = K exp(-sT2)/(1+ sT1), with T in C.
4.2 ON-OFF Controller
 Keep switch S1 to 'WAIT' position and allow the oven to cool to room temperature.
Short 'FEEDBACK' terminals.

Techno Instruments TCS-302 Page 6

 Temperature in °C Temperature in °C

Temperature in in
Temperature
°C°C

T2=15 sec.
T1=255 sec.

Time in Seconds
Time in Seconds
1000
  Keep switch S2 to the 'SET' position and adjust reference potentiometer to the
desired output temperature, say 60.0C, by seeing on the digital display.
 Connect R output to the driver input. Outputs of P, D and I must be disconnected
from driver input. Select 'HI' or 'LO' value of hysteresis. (First keep the hysteresis
switch to ‘LO’).
 Switch S2 to 'MEASURE' and S1 to 'RUN' position. Read and record oven
temperature every 10 sec., for about 20 minutes.
 Plot a graph between temperature and time and observe the oscillations (Fig. 15)
in the steady state. Note down the magnitude of oscillations.
 Repeat above steps with the ‘HI’ setting for hysteresis and observe the rise time,
steady-state error and percent overshoot.
4.3 Proportional Controller
Ziegler and Nichols suggest the value of KP for P-Controller as
1 T
KP =    1
 K  T2
 Starting with a cool oven, keep switch S1 to 'WAIT' position and connect P output
to the driver input. Keep R, D and I outputs disconnected. Short 'FEEDBACK'
terminals.
 potentiometer setting needs some explanation here. The formula for Kp above
is for an unity feedback system and has the dimension of Volts/C. In the present
unit a temperature sensor having sensitivity of 10mV/C (0.01V/C) is used
between oven output and controller input. Thus, the Kp calculated above will need
to be divided by 0.01 to obtain the P-control potentiometer setting. KD and KI have
dimensions of sec. and sec-1 respectively hence do not require any further
consideration. These values may be set directly on the respective potentiometers.
 Select and set the desired temperature to say 60.0C.
 Keep switch S1 to 'RUN' position and record temperature readings as before.
 Plot the observations on a linear graph paper and observe the rise time, steady-state
error and percent overshoot.

4.4 Proportional-Integral Controller

Ziegler and Nichols suggested the value of KP and KI for P-I controller as
 0.9  T1 1 1
KP =   ; TI = = 3.3 T2, giving KI =
 K  T2 K1 3.3 T2
 Starting with a cool oven, keep switch S1 to 'WAIT', connect P and I outputs to
driver input and disconnect R and D outputs. Short feedback terminals.
 Set P and I potentiometers to the above values of KP, and KI respectively, keeping
in mind that the maximum value of KP is 20 and that of KI is 0.036.
 Select and set the desired temperature to say 60.0C.
 Keep switch S1 to 'RUN' position and record temperature readings as before.
 Plot the response on a graph paper and observe the steady state error and percent
overshoot.
Techno Instruments TCS-302 Page 7
4.5 Proportional-Integral-Derivative Controller
Ziegler and Nichols suggest the values of KP, KD and KI for this controller as
 1.2  T1 1 1
KP =   ; TI = = 2T2, giving KI =
 K  T2 K1 2 T2
KD = TD = 0.5T2
 Starting with a cool oven, keep switch S1 to 'WAIT' position and connect P, D and
I outputs to driver input. Keep R output disconnected. Short feedback terminals.
 Set P, I and D potentiometers according to the above calculated values of K P, KI
and KD keeping in mind that the maximum values for these are 20, 0.036 and 23.5
respectively.
 Select and set the desired temperature, say 60.0C.
 Switch S1 to 'RUN', and record temperature-time readings.
 Plot the response on a linear graph paper and observe the rise time, steady state
error and percent overshoot.(See Fig. 14)
 Compare the results of the various controller options.
 Set P potentiometer to the above calculated value of K p, keeping in mind that the
maximum gain is 20. The measurement and interpretation of Kp and P-control Keep
switch S2 to the 'SET' position and adjust reference potentiometer to the desired
output temperature, say 60.0C, by seeing on the digital display.
 Connect R output to the driver input. Outputs of P, D and I must be disconnected
from driver input. Select 'HI' or 'LO' value of hysteresis. (First keep the hysteresis
switch to ‘LO’).
 Switch S2 to 'MEASURE' and S1 to 'RUN' position. Read and record oven
temperature every 10 sec., for about 20 minutes.
 Plot a graph between temperature and time and observe the oscillations (Fig. 15)
in the steady state. Note down the magnitude of oscillations.
 Repeat above steps with the ‘HI’ setting for hysteresis and observe the rise time,
steady-state error and percent overshoot.

4.6 Further Experimentation

The controller settings suggested by Ziegler and Nichols are not optimum. It is therefore
possible to experiment with other methods available in the literature or to attempt trial and error
settings. Students at the master's level may attempt to calculate theoretically the optimum
values of KP, KD and KI based on some performance criterion and then verify them results on
the setup. It may be convenient to use a pen recorder or X-Y recorder for such experiments. A
terminal has been provided at the back of the unit for this purpose with a sensitivity of
10mV/C.
Additional laboratory work may involve modification of the oven parameters and then
repeating the basic experiments. This may be done simply by putting thermal load into the
oven, thus increasing its thermal capacitance or by providing insulation to the oven thus
increasing its thermal resistance. These may also act as disturbance inputs to the oven while it
is operating under steady-state conditions, and their effect may be studied.

Techno Instruments TCS-302 Page 8

Fig.A Open Loop Response with PID Parameter Computation

Fig.B Typical PID Response with Target Temperature of 70 Degrees

4.7. Computer Interfaced Experiments (MATLAB)

Installation Steps:
Ensure you have MATLAB 2015b version or later installed on your computer. Install the
FT232 driver provided with the hardware setup onto your computer, then click on the setup file
provided and the computer will install all the required libraries into the default toolbox folder
of MATLAB.

Experimental Procedure:
The object of this experiment is to operate the TCS-301 hardware with the help of MATLAB
commands and see the results on the computer screen. In addition provisions are there to store
the results in an excel file for further analysis. As a first step all hardware connections on the
front panel needs to be removed. The SET/MEASURE switch is to be put at MEASURE to
continuously display the temperature. Further the TECH-CAMM needs to be connected to the
TCS main unit at the back panel as well as the PC through USB while identifying the COM
port used. Then power both units and open MATLAB. On the top line of window click ‘Add
ONs’, then ‘Manage Add ONs’ and finally ‘open folder’ on TCS.
Put the OVEN switch to OFF.

(a) Initiate the Program by typing,

x=Techno_TCS(‘COM...’)

(b) Operate the unit to determine the PID parameters using Ziegler-Nichol method
This part would give the user an open loop response of the oven. The various default
setting are:
(i) Starting temperature is the room temperature
(ii) Final temperature is around 80 degrees
(iii) Run time set at 600 seconds, however user may stop using the button at lower
left corner of the graphics screen when it is felt that steady temperature is
reached.
(iv) Computed values of the PID parameters will be available on the graphic screen.
All the above settings may be changed by the user any time. Following command now
will operate the oven.
x.open_loop(‘PID’) , or, x.open_loop(‘PI’) , or, x.open_loop(‘P’)
Put the OVEN switch to HEAT immediately after running the above command.
Response as shown in Fig.A will be seen on the screen.
(c) Operate the unit with PID parameters obtained above
Before this set the final temperature to a reasonable value, say 70 degrees by the
command,
x.set_ref(70)

Techno Instruments TCS-302 Page 9

Temperature in °C

1000
Time in Seconds
Temperature in °C

Time in Seconds
 Now run the oven using the parameters computed above,
x.run_PID(), or, x.run_PI(), or, x.run_P(), or, x.run_Relay()
depending on the type of control chosen. Typical response for PID control is shown in
Fig.B
x.set_start(...) and x.set_ref(...)
(a) To change various parameters
x.set_P(...) Choosing a new P-value
x.set_I(...) Choosing a new I-value
x.set_D(...) Choosing a new D-value
x.set_tot_time(...) To change display time to other than 600 seconds
x.calc_PI() To calculate only PI parameters from the open
loop response
x.calc_P() To calculate only P parameters from the open
loop response
(e) To export data to an excel file and to close the program
x.export_data() Choose a suitable folder
x.close()

5. TYPICAL RESULTS

(a) Open - loop measurement : The constant K for oven plus driver controller is given by

Final temperatu re Oven - Ambient te mp. 92.0 − 34.0 58.0

K= = = =116.0
Input (Volts) 0.5 0.5
From the graph between temperature and time Fig.11, the final oven temperature for a input
of 0.5 volt is 92C. Hence, K=58.0/0.5=116.0C/V. With reference to Fig.10, T1 and T2, as
measured from the open-loop graph are: T1 = 255 sec.; T2 = 15sec. (Note that these values
may differ from unit to unit).

(b) Calculation for KP, KI, KD: The coefficient settings according to Ziegler and Nichols are
different for different types of control. The calculations for them are illustrated below.

1 T  1  255
(i) P Control : KP =    1 =  x = 0.1466 V/°C
 K  T2  116.0  15
With temperature-sensor sensitivity of 10 mV/C and maximum gain of P-amplifier as
20, actual Kp max.=0.1V/C. Hence P-setting required for proportional control is 73%.
The Temperature vs Time plot is shown in Fig.12.

 0.9  T1  0.9  255

(ii) P-I Control : KP =   = x = 0.1319
 K  T2  116.0  15
hence, P-setting required = 66%.
TI = 3.3T2 = 3.3X15=49.5 sec; KI = 1/TI = 1/49.5 = 0.020/sec.;

Techno Instruments TCS-302 Page 10

 KI max. = 1/28 = 0.036, {see Eq. 2}
I-setting = (0.020/0.036)X100 = 0.555X100 = 55.5%  56%
The Temperature vs Time plot is shown in Fig.13.

 1.2  T1  1.2  255

(iii) P-I-D Control : KP =   = x = = 0.1758
 K  T2  116.0  15
This gives a P-coefficient setting of 88%
TI = 2.0 T2 = 2.0X15 = 30 sec;
KI = 1/12 = 1/30 = 0.033 sec
I-setting = (0.033/0.036)X100 = 0.916 X 100 = 91.6%  92%
KD = TD= 0.5 T2 = 0.5 X 15 = 7.5 sec.
KD max. = 23.5 sec., {see Eq. 3}
D-setting = (7.5/23.5) X 100 = 0.319 X 100 = 32%
The Temperature vs Time plot is shown in Fig.14.

c) Results : Fig. 12-15 show the graph of temperature vs. time using P, PI, PID controller
with above coefficient settings, for a set temperature of 60.0C and also the realy control. A
comparison of the graphs with that obtained using P control only should reveal the effectiveness
of I and D controls in reducing steady-state error and percentage overshoot.
Since our intereset in mainly in the transient part of the resposes as well as the final
steady state value of the temperature, the graph may be drawn with break along the time axis,
as shown in Fig. 11-14. This would give an expanded view of the initial part of the response
for better clarity.

6. LIMITATIONS OF THE SYSTEM

It must be appreciated that this is a purely experimental model designed for studying
the different control strategies available for controlling temperature. No effort has therefore
been made to optimise a particular method for the circuits involved, which would be possible
and desirable in an actual industrial controller. Nevertheless the salient features of the
techniques have been brought out clearly for an easy understanding.
The performance of the system is naturally limited by the imperfections of the
components used. These include the offset and drift in the operational amplifiers, leakage of
the integrator and differentiating capacitors, and temperature dependence of a number of
components. As a consequence, the steady-state error is not exactly zero inspite of Integral
control in operation, contrary to what would be expected from theoretical analysis. Also, the
accuracy of the temperature displayed on the panel may not be better than  5%.

Techno Instruments TCS-302 Page 11

Temperature in °C

1000

Time in Seconds
7. REFERENCES
[1] ‘Modern Control Engineering’, K. Ogata, Prentice Hall India.
[2] ‘Applied Control Theory’, J.R. Leigh, Peter Pergamon Ltd.

8. PACKING LIST

(1). Tempertaure Controller System : One

(2). Patch Cords : 6 nos
a) Red (12”) : Three
b) Black (12”) : Three
(3). Tempertaure Controller Oven: One

Techno Instruments TCS-302 Page 12

 TECHNICAL SUPPORT

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* Phone : +91-1332-272852, 277118

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Model number and Revision (listed by month and year on the front cover).
Have the manual at hand to discuss your questions.

Techno Instruments TCS-302 Page 13

 List of Control Laboratory Experiments manufactured by us

• Digital Control System

Study of microprocessor control of a simulated linear system
• A.C. / D.C. Servomotor study
Study of characteristics of a 2-phase a.c. motor/ d.c motor. It allows the determination of torque-speed
characteristics, inertia and friction parameters of an a.c. motor. Transfer function can also be evaluated in
this system. A digital display is available for time constant measurement.
• A.C. / D.C. Position Control
Study of an a.c. / d.c servomotor angular position control system.
• D.C. Speed Control
Study of a d.c. motor speed control system
• Temperature Controller System
To study a typical temperature control system (Compact Oven)
• PID Controller
Performance evaluation and design of PID Controller
• Study of Synchro Devices
Study of synchro transmitter-receiver pair with calibrated dials. Receiver can be used as control
transformer. Built-in balanced demodulator circuit. Digital display of ac/ dc voltages.
• Linear Variable Differential Transformer
Study of the performance characteristics of a LVDT.
• Magnetic Levitation System
Analysis and design of feedback control system to keep an object suspended in air.
• Stepper Motor Study
To study the operation and characteristics of a stepper motor with an 8085 based P-Kit and user software
EPROM.
• Relay Control System
To analyze a simulated relay control systems.
• Compensation Design
To design a suitable cascade compensator for the given system and verify the resulting improvement.
• Study of Second Order Networks
Study of synchro transmitter-receiver pair with calibrated dials. Receiver can be used as control transformer.
Built-in balanced demodulator circuit. Digital display of ac/ dc voltages.
• Linear System Simulator
To study the performance of First, Second and Third order Systems.
• Potentiometric Error Detector
To study the performance of a potentiometer type d.c. position error detector.
• Light Intensity Control
P and PI control of light intensity with provision for disturbance and transient studies
• Microprocessor Device Controller
Study of 8085 P based switching control of LED, Relay sequence, 7-Segment display. Besides it also allow
the study of switch state input through 8255 port and SID/ SOD operation of a microprocessor.
• Study of Temperature Transducers
Study of input-output characteristics of some common transducers like, thermistors (PTC and NTC),
thermocouple, semiconductor sensors
• Stroboscope
For measurement of shaft speed using stroboscope principle in harsh laboratory environment.
• Function Generator
10Hz-2MHz; Square/Sine/ Triangular; Amplitude 0-3V (p-p); 4 digit digital counter
• Study of Digital to Analog Convertor
Detailed study of D/A schemes – 4 bit weighted resistance, R-2R discrete network and 10-bit IC based circuits
with 8085 based P-kit and interface for CRO included.

Techno Instruments TCS-302 Page 14