HEM ELECTRONIQUES MIDC MIRAJ (M.S.

)INDIA

ON/OFF TEMPERATURE CONTROLLER

INTRODUCTION: On/Off controller or two position controller is one of the various controller modes, which shows discontinuous changes in the controller O/p as controlled variable error occurs. Although an on-off type control does not qualify as a continuous control ,it is used in numerous residential ,commercial, and industrial applications. It is commonly used in control of home appliances ,hot plate and oven-temperature control, refrigerator temperature control and dishwasher water level control .It is by far the method of choice for environmental temperature control of all residential and commercial buildings. Some may even argue that a digital controller is nothing but an extremely fast and fancy On/Off controller.

TYPES OF ON/OFF CONTROL. On-off controllers can be operated in three different ways. (strict)on-off control Two position control Floating control (strict)On-off control:- In this method of control ,controller O/P changes at the instant the error changes from positive to negative or vice versa. Whenever the controlled variable is below the set point (positive error) the controller O/P is at 100%,and if the controlled variable is higher than the set point (negative error) the controller O/P drops to 0%. A Strict On-Off method of control is not practical one, because in the majority of applications ,controller O/P would constantly be switching between full-scale (100 %)and zero (0 %)O/P .thus ,a strict On-Off method of control is seldom used. A modified form of on-off control, two position control, is more commonly used. Processes with small time constants:On-Off control cannot be used for process with a small time constant ,such as a DC motor with a light load. if an attempt is made to control the motor speed through a switching relay, the relay will be constantly chattering (switching On/off )and will not last very long.

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Processes with Large Time constants:On-off control can be used in the processes where the process inertia is very large compared to the energy supply unit, such as when a large building is heated with a relatively small or moderately sized furnace .On-off control can also be used in the situations where measuring instruments have built in hysteresis.

TWO POSITION CONTROL Two position control is an improvement over the basic on-off .The controller O/P still swings between 0% and 100 % ,but an additional hysteresis element (neutral zone) is now incorporated.

NEUTRAL ZONE The neutral zone is the region of error over which the controller does not change its O/p. The neutral zone is also known by the terms dead band and error band .Generally,the neutral zone is symmetrical about 0% error,but there is no rigid rule.

FIELD OF APPLICATIONS:Generally two position controller mode is best adapted to large scale systems,with relatively slow process rates.Thus in either form ,heating or airconditioning system,the capacity of the system is very large in the terms of air volume and overall effects of the heater or the cooler is relatively slow. Sudden large scale changes are not common to such systems .the process under two position control must allow continued oscillation in the dynamic variable .Because by its very nature ,this mode of control always produces oscillations. For large systems, these oscillations will be long duration, which is partially a frequency of the natural zone size.

CIRCUIT OPERATION:PT-100(Platinum resistance temperature Detector )is used as a sensor for measuring the temp. in the range 0-200 Degree Celsius. TEMPERATURE MEASURMENT: RESISTANCE TEMPERATURE DETECTOR(RTD)

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 INTRODUCTION: (refer fig. A,B, &C) The principle of operation of resistance temperature detectors (RTD) is based on the fact that the electrical resistance of many metals increases almost directly with temp. And is reproducible to high degree of accuracy. The term used to express this characteristic is well known temperature coefficient of resistance and is defined by the appropriate formula: Rt = Ro (1 + t) where -Temp coefficient of resistance for the metal used. Ro - Resistance of the element at 0 degree Celsius t - Temperature of the element in degree Celsius. Platinum ,Nickel and copper are generally used as basic materials for RTD. We may note the following as regards the RTD as transducer for temp. measurement. 1. The resistance of R.T.D. increases as the temp. increases. The resistance and temp. are linearly related over a wide temp. range. 2. In general, resistance thermometers are larger and less convenient to apply than the thermocouple. They are massive and hence exhibit poor time response characteristics. 3. They require bridge balance circuitry and have rather restricted upper temp. range. They exhibit higher accuracy, reliability than thermocouples.

Circuit analysis:
In this circuit RTD is made an arm of a simple bridge circuit. The RTD exhibits a change of about 39 % in resistance from 100 ohms at 0 degree centigrade to 139 ohms at boiling point of water (100 degree C) . So in case RTD is made part of a bridge circuit with equal arms , there will be a non linear relationship between resistance change and the bridge output voltage.Typically when X = 20 % (where X is fractional change in resistance ) then error will be about 9% , where as for X = 30% , error will be 13 %. In order to overcome this non linearity problem,the resistance ratios of the top elements to the bottom bridge elements are made large. This process however reduces the bridge sensitivity. But the sensitivity problem can be readily taken care of by using amplifier. Refer figure . In this arrangement differential output from the bridge is amplified by an operational amplifier. The top arms of the bridge are about 8 kohm in value and the lower arms are around 100 ohms. The MIN and MAX controls are shown in the figure. We shall develop our understanding about linearity of the bridge output with respect to changes in resistance. Case 1: (fig A) R3= 100 ohms i.e. RTD at 0 degree C. Vout = 0.0mV = Va - Vb
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Case 2:(fig B) R3= 139 ohms i.e. RTD at 100 degree C,we have , Va = R3 /( R1 + R3) * 5000milivolt where bridge excitation is 5 volts. Therefore Va = 139/7939 *5000milivolts = 87.54 milivolts. We have Vb = R4 / /( R2 + R4) * 5000milivolts = 63.29 milivolts. Hence for 100 degrees change in temperature Va - Vb = 87.54 63.29 (milivolt) = 24.25 milivolt .(1) Case 3: We can check for intermediate values of temperature of 30 degrees centigrade. We know that resistance of RTD R3 will be 112 ohms at 30 degree C temperature. So by similar calculation we have,

Va = (112/7912) * 5000mV =70.77mV where as Vb = 63.29mV (of course unchanged) Va - Vb = 7.48 milivolt .(2) For linearity for 100 degree centigrade Va - Vb = 24.25milivolt. Therefore for 30 degree centigrade V0 = 24.25 * 0.3 = 7.27 milivolt .(3) So comparing equation No 2 and 3 for full scale output of 24.25 milivolts , percentage error at 30 degree centigrade =(7.48mV 7.27mV) /24.25 * 100 = 0.21 /(24.25) *100 = 0.86% which is much better than equal arm arrangement.

In this set-up MIN and MAX controls are provided in terms of TRIM pots located on the PCB for signal conditioning .(PCB near the front panel.)MIN control gives adjustment for 0 degree centigrade(100 ohm for RTD) and MAX control gives adjustment for 100 degree centigrade (139 Ohms for RTD)

The O/P from signal conditioning is provided to the I/P of On-Off controller P.C.B. alongwith set point adjustment POT P1 on the front panel. IC 1 forms the error amplifier (Summation block).Its O/P is given as error voltage E = SP (voltage ) PV (voltage) IC 2 acts as two position controller .Voltage Vr at the non-inverting terminal is governed by the saturation voltage ,Vsat of IC 2 and two resistors R2 and R3.It varies between two limits (error bands ) and can be determined from the following expression. Vr = +- (R3/(R2 + R3) )* Vsat
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= + - Beta * Vsat Vref is +ve when IC 2 O/P Vsat is Positive and is negative when IC2 O/P is at Vsat ve value . The controller O/P switchs state is based upon its two I/P , error voltage E and Ref voltage Vref. Error voltage E is measured at TP1 and Vref is measured at TP2 W.r.t. ground at rear panel.The total dead band (Neutral zone for the circuit is , Dead Band = 2*beta*Vsat (Beta is variable with the help of pot P2 on the front panel.) OPERATING INSTRUCTIONS. 1) Connect the RTD sensor PT-100 two the binding post provided on the front panel. 2) Connect the heater cable on the rear side socket. 3) Keep rotary switch on the front panel in 0 degree position. And switch on the supply. 4) The D.P.M. should indicate 0.0 degree centigrade. 5) When select switch is taken to 100 Degree position ,DPM should indicate 100 degree C.This completes calibration check and ensures that MIN and MAX controls on the PCB are properly adjusted . 6) Keep select switch in SET position and adjust SET TEMP.(P1) pot to 55 degree C.Keep Dead-band pot to most C.C.W. position.(MIN) 7) Take select switch to RTD position.Now you can observe that RTD temp. goes on increasing and the controller keeps the temperature of the process around the set point depending on Dead-Band adjustment. 8) You make take temp. readings at regular interval of 10 Sec. or 15 sec. and plot a graph for temp. Vs time readings. 9) You may adjust dead band to most C.W. position (MAX) and repeat the above process again. 10) If you keep a fan near the process model ,you may again take another set of readings and observe oscillations in the temp.

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PRECAUTIONS: 1) Operate the select rotary switch carefully. 2) RTD connections should be firm.

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