LEVEL SENSOR & ON-OFF CONTROL OF LEVEL

Date Performed: December 2, 2017

The experiment aims to determine the characteristic of the differential transformer as

position transducer, to understand the operation of a closed-loop on-off control system,
and to understand the effects of hysteresis on the control. At a water level of four
centimeters, the voltage value was set to zero. At a water level of fourteen centimeters,
the voltage value was set to ten. A linear relationship exists between the water level and
the voltage value or reading. Hysteresis values of 0 %, 15 %, and 30 % were used. The
lower limit set points were determined to be 10.70 cm. 10.10 cm, and 9.40 cm for each
hysteresis value, respectively. The upper limit set points were found to be 10.80 cm,
11.40 cm, and 12.10 cm for each respective hysteresis value. The level was plotted
against lowering time and upraising time for each hysteresis value. It was found that a
higher hysteresis value leads to a larger upper limit set point and a smaller lower limit
set point.
1. Introduction
Liquid level measurement is of considerable importance in the process

industries and methods range from a simple dip stick or sight glass to sophisticated

computerized systems giving the total mass of liquid in a large storage tank. Level

sensors detect the level of liquids and other fluids and fluidized solids, including

slurries, granular materials, and powders that exhibit an upper free surface. A

reference level is necessary to control levels. Depending on the method used, the

complexity ranges from easy to those complex controls just to ease burden on the

pumps, negate errors is level changes or to cope with different kind of processes

involving in the industry. (Stenerson, 2003)

An arrangement of physical components connected or related in such a

manner as regulate itself or another system is called a control system. Nowadays,

these controls are automated to negate errors and to lessen man power needed to

maintain. Sensors are invented and integrated into these systems to help maintain

these parameters as needed by a process. (Ejim, 2003 - 2017)

On-off controllers are simple, inexpensive feedback controllers. They are

commonly used as thermostats in home heating systems and domestic refrigerators.

On-off controllers can also be used in noncritical industrial applications such as

some level control loops and heating systems. It can be modified to include a dead

band for the error signal to reduce sensitivity to measurement noise. This type of

control is considered a special type of proportional control with a very high controller

gain. There are only two possible values for the controller for an ideal on-off control.

The oscillatory nature of the control makes it suitable only for those

purposes where close control is not essential or where its non-linear action can be
taken into account. One disadvantage of the on-off control is that it results in

continual cycling. This produces excessive wear on the control valve.

2. Materials and Methods

a. Materials and Equipment
 DL 2314 DeLorenzo Process Control Trainer
 Connecting Leads
 Digital Multimeter
 Stopwatch
b. Methods
i. Level Sensor
Nodes 1 and 2 of the level sensor were connected to the
corresponding nodes on the Level Interface. The positive terminal of the
multimeter was then plugged to node 13 of the Level Interface and the
negative terminal to a ground node on the process control device.
Multimeter was set to DC Voltmeter mode. Node 18 of the Linear Driver
was connected to Set Point 1, and Nodes 19 and 20 to its matching nodes
on the same region. DL 2314 was turned on. Set Point 1 knob was
regulated/turned to start the pump. The level of the water inside the
process tank was brought to 6 cm. Upon achieving 6 cm, Set Point 1 knob
was regulated to have a reading of 0V on the multimeter. Using the drain
valves the level of the water was brought back to 4 cm. The voltage
reading was checked using the multimeter. It was then set to 0 using the
Offset trimmer. This step is the method for setting the minimum working
point of the level sensor. The pump was switched on and the level was
brought to 14 cm. The pump was stopped and the voltage reading was
verified to be at 10 V. If not, the Gain Trimmer was used to regulate until
the reading desired is met.
The setting was verified to be OK by repeating steps mentioned in
the paragraph above. The level was drained while the voltage readings
from 14 cm down to 4 cm were recorded. The trainer was then turned off.
All connections by leads were removed.

ii. On-off Control of the Level

On the Level Sensor Region, Nodes 1 and 2 were connected to its
matching nodes on the Level Interface Region. On the Linear Driver
region, Nodes 19 and 20 were connected to its corresponding nodes on its
right side to allow it to operate. Set Point 1 was then connected to Node
14 on the On-Off controller and Node 13 of the Level Interface to the Node
13 on the On-Off controller region. The positive terminal of the multimeter
was plugged to the backside of the node plugged at Set Point 1. The other
terminal was plugged on a Ground Node on the DL2314. The multimeter
was set to DC. The process control trainer was turned on. Set Point 1 was
regulated to emit 5V by regulating the knob and stopped when the reading
at the multimeter said the desired value. The positive terminal of the
multimeter was transferred to node 13 of the On-Off controller. Voltage
there was regulated to be at 2V. The positive terminal of the multimeter
was then transferred to node X4 of the On-Off controller region. Node 18
of the On-Off controller was connected to the Node 18 of the Linear Driver
region. Pump started while the reading at X4 reduced. As soon as the
voltage difference shown at node X4 turned null or zero, the pump
automatically turned off. The level on the pump was at 9 cm more or less.
The drain valve was slowly regulated to allow the level to slowly drop. This
made the voltage reading on node X4 increase. The pump started again.
The level or voltage reading on X4 was noted. Pumping of water into the
tank increased if the rate of draining was lower than the rate water was
pumped back to the tank. The level lowering and raising was noted. The
opening of drain or needle valve was regulated in such a way that the rate
of both pumping was equal to the drain rate. A timer was used and the
upraising and lowering of the levels was timed. The scenario at the tank
was that the level was lowering and upraising in an endless cycle. The
 level where the pump starts and stops was noted. The main valve was
turned to regulate the water pumped onto the tank until the reading on the
rotameter read 20 liters per hour. This was done when the pump was
running which was when the level was upraising. The upraising and
lowering of the levels was recorded. This setting was at zero hysteresis.
The method mentioned above was repeated for other hysteresis
values such as 15 and 30%. The upraising and lowering time as well as
the levels where the pump starts and pumps was recorded. Drain and
Needle Valves were then closed after the experiment and data gathered
were enough. The trainer was turned off. All connections were
disconnected.

3. Results and Discussion

The following are the results from the data gathered all throughout the
experiment and the graphs generated which is used in analyzing and interpreting
these data.

 Level Sensors (Calibration Step)

Level(cm) 14 13 12 11 10 9 8 7 6 5 4

8. 6. 3. 1.
Voltage 10 7.8 5.5 4.3 2.4 0.8 0
9 7 2 6
Table 1. Calibration Data
 Level Control Calibrati on
16
14
f(x) = 0.976718720243763 x + 4.45381832031994
12 R² = 0.993589316320701

10
Voltage

8
6
4
2
0
0 2 4 6 8 10 12
Level (cm)

Figure 1. Voltage reading vs Level of the fluid within the process tank of the DL 2314 Process Control Trainer equipment

 On-off Control of the Level

HYSTERESI
S
0% 15 % 30 %
Uppe Chang Chang Chang
Limit Set Lower Upper Lower Upper Lower
r e e e
Point (cm) 10.8 10.7 0.1 11.4 10.1 1.3 12.1 9.4 2.7
Raisin Lowerin Lowerin
Total Raising Total Raising Lowering Total
g g g
Time of the
Level (sec) 133.6 228.7 289.0 190.7 479.8
8.73 7.69 16.42 95.12
4 6 8 8 6
Table 2. On-Off Control Data for Limit Set Point and Time of the Level

Figure 2. Effect of Hysteresis (0%) on the system under an on-off control with a constant drain opening
Figure 3. Effect of Hysteresis (15%) on the system under an on-off control with a constant drain opening

Figure 4. Effect of Hysteresis (30%) on the system under an on-off control with a constant drain opening
 Figure 5. Comparison of Effects of Hysteresis (0, 15, 30%)

The voltage reading obtained was the water level was decreased from 14
cm to 4 cm are summarized in Table 1. It can be seen that that the desired
values set during the experiment were obtained. At a water level of 14 cm, the
voltage reading was noted to be 10 V while at a water level of 4 cm, the voltage
reading was noted to be 0 V.
Figure 1 shows the plot of the water level against the voltage reading.
Values from Table 1 were used to produce the plot. It can be seen that there is a
linear relationship between the water level and the voltage reading. This
relationship is approximated by the equation presented in Figure 1.
Data obtained from the on-off experiment are summarized in Table 2. It
can be seen that as the value for hysteresis is increased, the upper limit set point
also increased and the lower limit set point decreased. The same can also be
observed with the lowering time and the up-raising time.
Figures 2, 3, and 4 plots the effect of hysteresis at 0, 15, and 30%,
respectively on water level and time. Figure 5 summarizes it.
 4. Conclusion
The water level and the voltage reading, when plotted, show a linear
relationship. In level control, the water level can be related to a specified voltage
value. This relationship can be used to determine or specify the water level at
which a pump is started or turned off.
Hysteresis (dead band) is used in controls to prevent or minimize on-off
switching at short time intervals. Damage to equipment can also be minimized. A
higher value for hysteresis leads to an increase in the upper limit set point and a
decrease in the lower limit set point. A higher value for hysteresis also leads to
increased values for lowering time and upraising time.

References:
 Stenerson, J. (2003). Industrial Automation and Process Control. Upper Saddle
River, New Jersey: Prentice Hall.
 Ejim, E. (2003 - 2017, February 12). What is the Importance of Process Control?
Accessed December 13 2017, from wiseGEEK: http://www.wisegeek.com/what-is-
the-importance-of-process-control.htm
 De Lorenzo. (n.d.). DL 2314 Process Control Trainer Manual.