Worksheets C Automated Measurement and Control

Part C – Practice-based learning: automated measurement, open-loop and
closed-loop control
1. Basic principles __________________________________________________________________ C-3

1.1 Computer-aided control technology __________________________________________________ C-3
1.2 System conversion for automated measurement and control ______________________________ C-5
2. Automated measurement _________________________________________________________ C-13

2.1 Project task: bath recirculation _____________________________________________________ C-13
2.1.1 Task description _________________________________________________________________ C-13
2.1.2 Setting up the system, inspection ___________________________________________________ C-16
2.1.3 Experiment: operating the pump with variable voltage values ____________________________ C-17
2.2 Project task: pressure measurement during recirculation ________________________________ C-17
2.2.3 Experiment: pressure measurement using a pressure sensor _____________________________ C-20
2.3 Project task: flow measurement ____________________________________________________ C-20
2.3.3 Experiment: flow measurement using a flow sensor ____________________________________ C-21
2.4 Project task: determine the fill level of the upper tank___________________________________ C-21
2.4.3 Experiment: measuring the fill level using an ultrasonic sensor ___________________________ C-23
3. Automated open-loop control ______________________________________________________ C-25

3.1 Project task: filling process ________________________________________________________ C-25
3.1.3 Experiment: metered filling via the pneumatic actuator _________________________________ C-26
3.2 Project task: filtering process in a galvanising plant ____________________________________ C-26
3.2.3 Experiment: determining pressure and volumetric flow rate ______________________________ C-29
3.2.4 Experiment: creating a characteristic pump curve ______________________________________ C-30
3.3 Project task: water supply _________________________________________________________ C-33
3.3.3 Experiment: filling the tank from below using the pump _________________________________ C-34
3.3.4 Experiment: filling the tank from above using the pump _________________________________ C-35
3.3.5 Experiment: filling the tank from above while simultaneously withdrawing water_____________ C-36
3.4 Project task: dosing an amount of liquid ______________________________________________ C-37
3.4.2 Experiment: dosing an amount of liquid ______________________________________________ C-38
© Festo Didactic GmbH & Co. KG 563971 C-1

Part C – Practice-based learning: automated measurement, open-loop and closed-loop control
4. Automated closed-loop control ____________________________________________________ C-41

4.1 Project task: controlling the fill level using a two-step controller __________________________ C-43
4.1.4 Commissioning __________________________________________________________________ C-45
4.1.5 Experiment: controlling the fill level using a two-step controller ___________________________ C-45
4.2 Project task: controlling the fill level using a continuous controller ________________________ C-49
4.2.2 Experiment: controlling the fill level with a continuous controller __________________________ C-50
4.2.3 Experiment: controlling the fill level using a proportional controller________________________ C-51
4.2.4 Experiment: controlling the fill level using an integral controller __________________________ C-52
4.2.5 Experiment: controlling the fill level using a proportional-integral controller
(parallel P and I components) ______________________________________________________ C-54
4.3 Project task: refrigerating plant _____________________________________________________ C-56
4.3.3 Commissioning report ____________________________________________________________ C-57
4.3.4 Experiment: flow control using a proportional-integral controller __________________________ C-57
5. Evaluation of learning objectives for automated measurement, open-loop

and closed-loop control ___________________________________________________________ C-59
C-2 © Festo Didactic GmbH & Co. KG 563971

1. Basic principles
1.1 Computer-aided control technology
Information
This is an introduction to automated control technology and is based on the knowledge of manual control
that has already been acquired. You’ll learn the basics of computer aided control with the help of practical
examples.
Every control circuit consists of a controlled system and a controller.
1 Setpoint specification
2 System deviation = setpoint - actual value
System deviation is calculated by means of a control function and is transmitted to the controlled system as a manipulated variable
(3). The control function is generally processed with the help of software.
3 Manipulated variable
4 The manipulated variable must be boosted so that the actuator’s final control element receives a signal with which it can work.
5 The controlled system (e.g. fill level) is changed by means of the manipulated variable.
6 The controlled system’s actual value is measured and fed back to point 2.
In most cases, the actual value must be electronically converted.
Software solutions for a controller in a PC or a PLC work in a cyclical fashion, i.e. points 2 through 6 are run continuously.

1. Basic principles
Examples of controlled systems:

– Maintain a constant fill level in a tank
– Change and maintain temperature in a room
– Keep motor speed at a specified value
– Travel accurately to an axis position
– Maintain constant pressure in a piping system
Types of controllers:
 Discontinuous controller
These controllers are characterised by the fact that their manipulated variables are only capable of
changing between the on and off states, i.e. two-step controller.
 Continuous controller
With continuous controllers, the manipulated variable is infinitely adjustable, e.g. PID controller.
In conventional control technology, a difference is made between the following controllers according to how
the manipulated variable is determined (simplified excerpt).
Controller Graphic symbol Determination of the manipulated variable via the control function
2-step controller The manipulated variable is compared with an upper and a lower limit
value.
P controller System deviation is influenced by means of a factor.
I controller The sum of all system deviations is influenced by means of a factor.
PI controller The characteristics of the P-controller and the I-controller are combined.
PID controller The manipulated variable is determined by the

D parameter based on the time factor by which system deviation is
changed.

1. Basic principles
Technical learning objectives

Participants will:
 Learn to convert electrical actuation to actuation with a PC
 Become familiar with how to set up and adjust sensor signals
 Become familiar with practical PC measurement technology
 Learn to differentiate between various types of controllers and control circuit performance
 Learn to use continuous and discontinuous control for automated measurement, open-loop and closed-
loop control
 Become familiar with using a PC as a control and regulating device in combination with FluidLab® PA
software
1.2 System conversion for automated measurement and control
Information
The system is, as in the section on “manual measurement, open-loop and closed-loop control”, equipped
with a control panel used for manual measurement, open-loop and closed-loop control. The system must
now be modified so that signals can be transmitted via the EasyPort PC interface. The depicted control panel
is not used for automated measurement and control.

1. Basic principles
The basic setup for automated measurement, open-loop and closed-loop control will be demonstrated using
pump control as an example:
Item 1 2 3
Digital pump control , on/off PC transmits Bit3 to EasyPort generates a voltage Motor runs at nominal power
EasyPort. signal (relay) of 0 V or 24 V. with 24 V.
Analogue control PC transmits a decimal value EasyPort generates a control The motor controller boosts the
(e.g. double word) which signal of 0 to 10 V. signal to within a range of 0 to 24
corresponds to a voltage V. The motor runs at an infinitely
within a range of 0 to 10 V. adjustable speed.

1. Basic principles
Task
The system will be equipped with a preassembled I/O board. Carry out conversion as described in the
following steps:
1. Switch off supply power.
2. Unplug the laboratory cable via with safety valve socket.
3. Unplug the pump motor.
4. Mechanical removal of the control panel from the rectangular profile
System with control panel System without control panel

1. Basic principles
5. Screw the preassembled I/O boards to the rectangular profile.
Important modules are required for operation via a PLC or via a PC and EasyPort, in order to process
measured values and control the actuator.
Assembly Figure Description
F-U converter for flow sensor Depending on the flow rate, the flow sensor generates a
pulse frequency within a range of 40 to 1200 Hz. This
pulse frequency is converted to a voltage value within a
range of 1 to 10 V by the F-U converter.
Motor controller The analogue manipulated variable of 0 to 10 V from the

EasyPort or a PLC is boosted to 0 to 24 V and an
appropriate amperage by the motor controller. Amperage
must be limited in order to ensure safe operation.
Modules on the I/O board
Further information is included in the data sheets on the CD-ROM.

1. Basic principles
6. Connect the EasyPort to the I/O board with a SysLink cable.

7. Connect the EasyPort to the PC (USB or serial cable).
8. Connect a 24 V power supply unit.

9. Connect the outputs for analogue and binary signals between the I/O board and the EasyPort.

1. Basic principles
10. Install the software.

– Install the EasyPort driver from the EasyPort CD-ROM.
– Install FluidLab® PA.
11. Test the system.

– Supply EasyPort with power.
– Start FluidLab® PA software.
Note
After starting the software, a message indicates whether or not a connection has been successfully
established. If this is not the case, check all connections within the system. Otherwise, exit the software
and disconnect the USB plug. Reinsert the USB plug after 5 seconds. Start the software again.
12. Select the “Setup” menu.

The outputs can be activated with the sliders in the user interface.

1. Basic principles
13. Assignment of inputs and outputs on the I/O board:
Name Device Abbreviation Note
Digital output 0 2-way ball valve with pneumatic A0 Spring return

actuation
Digital output 2 Changeover relay A2 Relay = 0: pump is binary controlled

Relay = 1: pump is analogue controlled
(0 to 10 V)
Digital output 3 Pump A3
Analogue output 0 Pump AOUT 1
Analogue input 0 Fill level (ultrasonic) AIN 0
Analogue input 1 Flow sensor AIN 1
Analogue input 2 Pressure sensor AIN 2
1 2 3 4 5 6 7 8
1: I/O terminal 2: Analogue terminal 3: Relay 4: Motor controller

5: Measuring transducer 6: Starting current limiter 7: Motor clamp 8: H-rail
Complete layout plan

1. Basic principles

2. Automated measurement
2.1 Project task: bath recirculation
2.1.1 Task description

Depending on the setup, water can be transferred to lower tank B101 or pumped into upper tank B102 with
the pump.
The pump can be operated by switching 24 V supply power on or off (output 3). Alternatively, it can be
variably supplied with control voltage within a range of 0 to 10 V (analogue output 0). The control signal is
boosted by means of a motor controller.
The type of control used (on/off or analogue) is selected with a changeover relay (output2).


Task
The pump will be connected and tested during the following experiment. Simply pumping water into lower
tank B101 is sufficient for this function test.
– Set up the fill-level system with one tank as specified in section 1.1.1, part A.
– Base yourself on the PI flow diagram.
– Before commissioning, make sure all the project kit’s modules and piping function correctly and do not
leak.
– Replace any damaged parts.
V101
B102
V103 V102
FI
101
PI B101
103
P101
V105

2.1.2 Setting up the system, inspection
– Plug the pump into the I/O board. The allocations are included in the circuit diagram on the CD-ROM.
– Set up the water circuit (see flow diagram).
Note
The pipe connection to tank B102 must be interrupted or equipped with a closed stopcock. Close V101
and V105, open V102 and V103.
– Fill B101 approximately half full with water.

– Connect the 24 V power supply unit to mains power.
– Switch the power supply unit on.
– Start the software (FluidLab® PA).
– Open the “Setup” menu in the software and operate the system using the buttons (see below).

2.1.3 Experiment: operating the pump with variable voltage values
– Select each of the values listed below and document your observations.
No. Digital outputs Analogue outputs Pump (observe)

(set at sliders)
1 A3 = on A2 = off 0V
2 A3 = on A2 = on 0V
3 A3 = off A2 = on 4V
4 A3 = off A2 = on 8V
5 A3 = off A2 = on 10 V
2.2 Project task: pressure measurement during recirculation

Pressure plays a significant role in fluid systems. In practice pressure changes due to reactions which occur
in mixtures, during filtration or recirculation, and must be continuously recorded and documented. In order
to be able to read out the value with the help of a PC, the pressure gauge with indicator is replaced by a
pressure sensor. As a rule, pressure sensors require 24 V DC supply power and generate an analogue
voltage signal within a range of 0 to 10 V, which is proportional to pressure.
The purpose of the pressure sensor is to measure liquid pressure directly downstream of the pump. According to
the data sheet, the sensor reads out a voltage of 0 to 10 V within a pressure range of 0 to 400 mbar.

– Switch the system off and pull the mains plug.

– Drain the water via stopcock V105.
– Install the pressure sensor downstream of the pump.
– Electrically connect the pressure sensor in accordance with the circuit diagram (CD-ROM).
– Valve settings: V101 and V105 closed, V102 and V103 open, remove piping to tank 102, insert a
blanking plug into the end of the pipe or install a stopcock in the bottom inlet and close it.
– Fill with water.
– Set up the software.
– Set the pressure value at the PC after opening the “Setup” menu:
– Determine factor and offset: calculate the physical display value:
Physical value = sensor voltage  factor + offset
If values are to be displayed in bar, the factor is calculated as follows:

The following data are specified for the sensor: a pressure range of 0 to 0.4 bar and a voltage range of
0 to 10 V.
0.4bar
Factor   0.04
10V  0V

Default setting for the pressure duct: factor = 0.04 and offset = 0.0 (see figure)
1 Voltage read out by the sensor 2 Factor 3 Offset

4 The signal can be filtered (attenuated). The higher the number, the greater the attenuation.
In order to ensure correct representation of the scales in the diagrams, it’s important to always enter the
maximum physical value and the appropriate unit of measure (see the two right-hand columns in the
screenshot).
Task
At a pressure of 0 to 10 bar, the pressure sensor reads out a voltage within a range of 2 to 10 V.
– Calculate factor and offset.
Final value
Factor  
Final voltage  Initial voltage
Offset  Factor  Initial voltage 

2.2.3 Experiment: pressure measurement using a pressure sensor
– Operate the pump with the three following voltage values and make a note of what you observe at the
software pressure display.
No. Digital outputs Analogue outputs Pressure display (observe)

(set at sliders)
1 A3 = on A2 = off 0V
2 A3 = off A2 = on 5V
3 A3 = off A2 = on 10 V
2.3 Project task: flow measurement

The purpose of the flow sensor is to measure the pump’s volumetric flow rate. Liquid flows through the
measuring transducer and causes a vane to rotate. The vane is equipped with an inductive sensor which
generates pulses. The pulses are converted into a voltage which is proportional to the volumetric flow rate
by an F/U converter. At a volumetric flow rate of 0 to 7.5 litres per minute, the flow sensor generates a
voltage signal within a range of 0 to 10 V.

– Install the flow sensor downstream of the pump.
– Connect the flow sensor electrically according to the circuit diagram (see CD-ROM).
– Fill with water.
– Start the software and open the “Setup” menu.
– Set factor and offset: the physical display value is calculated as follows:
Flow rate display in litres per minute, factor = 0.75, offset = 0

2.3.3 Experiment: flow measurement using a flow sensor
– Change the pump speed again by setting supply voltage to three different settings and make a note of
what you observe at the flow rate display in the software.
No. Digital outputs Analogue outputs Flow rate display (observe)

(set at sliders)
1 A3 = on A2 = off 0V
2 A3 = off A2 = on 5V
3 A3 = off A2 = on 10 V
2.4 Project task: determine the fill level of the upper tank

The ultrasonic sensor measures distance and can be used to detect fill levels. The ultrasonic waves are
refracted at the surface of the water and returned to the sensor. At a distance of 50 to 270 mm from the
water, the sensor reads out a voltage within a range of 0 to 10 V. The ultrasonic sensor is attached to the
inside of the lid of tank B102, from where it measures the fill level.

LIC
102
V101
B102
V103 V102
FI
101
PI B101
103
P101
V105
– Mount upper tank B102 and lay piping for the system in accordance with the PI flow diagram.
– Mount the ultrasonic sensor onto the upper tank.
– Electrically connect the ultrasonic sensor in accordance with the circuit diagram (CD-ROM).
– Set the valves so that liquid can be pumped into the upper tank: V101 open, V103 open , V102 approx.
5% open.
– Start the software and open the “Setup” menu.
– Set factor and offset
The physical display value is calculated as follows:

Depending on which physical quantity is to be displayed, factor and offset are entered as follows:
The following applies in the case of a sensor signal within a range of 0 to 3 litres and a voltage of 0 to 10 V:
Fill level in litres Factor = 0.27 Offset = 0.0

Fill level in mm Factor = 22 Offset = 0.0
Note
The sensor signal lies within a range of 0 and 2.7 l, which corresponds to 0 to 10 V. Due to the fact that
the bottom of the tank is conical, measurement begins as of the cylindrical portion of the tank and
roughly the first 0.5 l are disregarded in this example.
2.4.3 Experiment: measuring the fill level using an ultrasonic sensor
– Fill upper tank B102 according to the entries in the table and document your observations.
– Complete the table.
No. Digital outputs Tank B102, fill level Observation

sensor (litres)
1 A3 = off A2 = off Empty =
2 A3 = on A2 = off
Approx. 50% full =
100% full =
3 A3 = off A2 = off


3. Automated open-loop control
3.1 Project task: filling process

The automated filling process will be demonstrated with the help of the 2-way ball valve with pneumatic
actuation. The ball valve is installed between the upper and the lower tank. Information on operating the 2-
way ball valve can be found in section 2.2, part B, and in the data sheet (CD-ROM).
– Set the system up according to the PI flow diagram.
LA+
111
V101
B102
LS–
114
V107 V112 V102

V103
FIS+
101
PIS+ B101
103 LS–
113
P101
V105


– Connect 2-way ball valve V102 according to the circuit diagram (CD-ROM).
– Complete tubing connections for pneumatic actuation (semi-rotary actuator) of the 2-way ball valve (at
least 5 bar compressed air).
– Fill the lower tank with water.
3.1.3 Experiment: metered filling via the pneumatic actuator
– Carry out the experiment as indicated in the table and document your observations.
No. Digital outputs Step Observation
1 A3 = on A0 = off Pump water into B102.
2 A3 = off A0 = off –
3 A3 = off A0 = on Water flows through V102.
3.2 Project task: filtering process in a galvanising plant

The acid bath at a galvanising plant has to be continuously recirculated and filtered. As contamination in the
acid bath increases, resistance upstream of the filter increases and circulating pressure rises. When a
specified pressure is exceeded, the filter must be cleaned or replaced. The cross section in the valve is
reduced with hand valve V103. This corresponds to a clogged filter in actual practice. We are thus able to
simulate filter contamination with hand valve V103.
The experiment is intended to demonstrate the relationship between resistance (filter contamination) and
pressure in the piping system.
The pump is controlled via the PC and pressure is measured with a pressure sensor. The characteristic
pressure curve is recorded in a time diagram.

– First, modify the system according to the PI flow diagram or the figure. A setup including one tank, the
pressure sensor and the flow sensor is required.
– Double check the piping layout and the electrical connections before commissioning.
– Test the pump, the pressure sensor and the flow sensor for correct functioning.
– Fill tank B101 with 2 to 2½ litres of water.
V103 V102
FI
101
PI B101
103
P101
V105
B101
FI101
PI103
P101

Task
– Connect the EasyPort, start the software and select the settings menu.
– Enter and double-check factor and offset settings for the sensors.
– Enter the corresponding values in the table.
Setting checked Comment
Sensor settings Pressure bar Factor = 0.04 Offset = 0
or pressure kPa Factor = 4 Offset = 0
or pressure PSI Factor = 5.8016 Offset = 0
Volumetric flow l/min. Factor = 0.75 Offset = 0

rate
Valve settings V101
V102
V103
– Create a commissioning report for the system.
Characteristic, requirement for component Fulfilled Failed, comments
Piping assembled and leak-proof
Pressure sensor installed
Flow sensor installed
Electrical wiring and connecting cables connected
Lower tank filled with 2 to 2½ litres of water
Software installed, sensor values adjusted
Test pump on/off with PC
Test the signal from the pressure sensor
Test the signal from the flow sensor

3.2.3 Experiment: determining pressure and volumetric flow rate
– Measure pressure and volumetric flow rate with changing line resistance.
– Carry out the steps specified in the table and document your observations.
Menu: Control and measure
No. Task Data from the diagram Note/observation
1 Pump on, A3 = on Pressure =

Hand valve open completely Volumetric flow rate =
2 Slowly close hand valve V103
3 Hand valve V103 closed Pressure =

Volumetric flow rate = 0 l/min.
4 Slowly open hand valve V103
1 Volumetric flow rate 2 Pressure
Diagram of the sensor signal while closing hand valve V103

Task
– What is the relationship between the pipe’s cross section, volumetric flow rate and pressure?
_________________________________________________________________________________________
_________________________________________________________________________________________
– Why is volumetric flow rate reduced with a smaller cross section?
_________________________________________________________________________________________
_________________________________________________________________________________________
– How would a significantly longer piping network influence the system?
_________________________________________________________________________________________
_________________________________________________________________________________________
3.2.4 Experiment: creating a characteristic pump curve

In this section volumetric flow rate with changing line resistance and analogue pump control will be
examined. The pump can be operated with a control voltage within a range of 0 to 10 V with the help of a
motor amplifier. Control must also be switched on and off with the help of a relay.
1: Set changeover relay to 1 2: Preset voltage to 0 to 10 V
Sample settings in the settings menu

Menu: Select characteristic U-Q curve
– Carry out the experiments described below, document your observations in the table and create a
characteristic curve.
No. Task Data Note/observation
1 Increase voltage at the pump from 0 to Voltage [V] Volumetric

10 V, and then decrease it back to 0 V flow rate
again. [l/min.]
2 Hand valve open all the way 4
3 Take values from the diagram 6
10
1 Voltage is increased from 0 to 10 V. 2 Voltage is decreased from 10 to 0 V.
Sample characteristic U-Q curve

Task
– How does the pump respond to rising control voltage?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– What is the effect of varying the speed at which control voltage is changed?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– What does hysteresis mean?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

3.3 Project task: water supply

Water is pumped into a water tower from springs, rivers and lakes in order to supply households with water.
Water is directed to domestic households from the tower. The upper tank will be filled with water during two
experiments. There are several different ways to fill the tank:
 The fill pipe enters the upper tank from below.
 The fill pipe enters the upper tank from above.
 The fill pipe enters the upper tank from above while water is simultaneously being withdrawn from
below.
LA+ LA+
111 111
V101 V101
B102 B102
LS– LS–
114 114
V107 V112 V102 V107 V112

V103 V103
FIS+
101
PIS+ B101
103 LS–
113
P101
V105
– Set the system up with two tanks as shown in the flow diagram. Connect and test the pump and the
ultrasonic sensor.
– Base yourself on section 2.4 during setup.
– Double-check the piping layout and the electrical connections.

3.3.3 Experiment: filling the tank from below using the pump
No. Task Done Observations
1 V101 closed
V107 closed
V103 open
V102 closed (A0 = off)
V112 closed
2 Fill B101 with 3 litres of water.
3 Open the “Control and measure” menu

in the software.
Pump A3 = on
4 After roughly 40% filling

Pump A3 = off
5 V102 open (A0 = on)

V112 open
Characteristic curve for filling from below

3.3.4 Experiment: filling the tank from above using the pump
1 V101 open
V107 open
V103 closed
V102 closed (A0 = off)
V112 closed (while filling)
2 Fill B101 with 3 litres of water

in the software, pump A3 = on

Pump A3 = off
5 V102 open (A0 = on)

V112 open
Characteristic curve for filling from above

3.3.5 Experiment: filling the tank from above while simultaneously withdrawing water
1 V101 open !
V107 open
V103 closed
V102 open (A0 = on)
V112 20% open
2 Fill B101 with 3 litres of water.

in the software, pump A3 = on

Pump A3 = off
5 V102 closed (A0 = off)
Characteristic curve for filling from above while simultaneously withdrawing water

Task
– Why is the surface of the water less turbulent when the tank is filled from below?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– How could reverse flow through impeller pumps be prevented?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– Why does the fill level rise more slowly when water is withdrawn simultaneously?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
3.4 Project task: dosing an amount of liquid

A certain amount of water must be fed to a mixture of solids in a cement mixer. The quantity is time-
controlled. A constant volumetric flow rate must be maintained as a prerequisite, for example 2 litres per
minute. The pump is controlled via a PC. The analogue output is used as the manipulated variable.
Volumetric flow is measured with a volumetric flow rate sensor. The characteristic curve is recorded in a
time diagram. One litre of water should be added to the mixture.
Task
– Set the system up with one tank in accordance with the PI flow diagram.
– Connect and test the pump, the pressure sensor and the flow sensor.
– Double-check the piping layout and the electrical connections before commissioning.

3.4.2 Experiment: dosing an amount of liquid
– Connect the EasyPort to the PC and start the software.

– Enter the appropriate settings in the settings menu.
V103 V102
FI
101
B101
P101
V105
1: Activate the changeover relay 2: Adjust control voltage

– Carry out the work steps described below and record your observations in the table.
No. Work step Setting Comment

checked
1 Volumetric flow Volumetric flow l/min Factor = _______

rate sensor rate Offset = 0
2 Valve settings V101
V102
V103
3 Set to analogue A2 = on
mode
4 Adjust Volumetric flow rate Control voltage Increase the

manipulated Q = 2 l/min. U = = _______ V manipulated variable
variable until Q = 2 l/min.
5 Pump off A3 = off

A2 = off
6 Switch pump on A3 = off Measure with

for 30 seconds A2 = on stopwatch or read from
Control voltage the diagram
U = = _______ V
7 Evaluate the Values from the diagram:

diagram. Volumetric flow rate Q = ___________ l/min.
Time t = ____________ sec.
Calculated water quantity over time: Q  t = ________

Sample solution for dosing procedure
Task
– Why isn’t the amount of water exactly correct?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– How long does the pump have to run (Q = 2 l/min.) in order to deliver 0.5 litres of water?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

4. Automated closed-loop control
Information
A control circuit always consists of a control device (closed-loop controller) and a device to be regulated
(controlled system), for example a fill-level system.
Controller Controlled system
Y
Final control element
Control function
Process
(system)
e=w-x
Comparator Measuring sensor
– X Measuring
transducer
+
Setpoint generator
Schematic diagram of a regulating system
Description
The task of the closed-loop controller (control function) is to control the controlled system so that it remains
at setpoint w. Actual value x is continuously measured and compared with setpoint w to this end. The
regulator calculates manipulated variable y. The manipulated variable influences the process via a final
control element.
Knowledge of the characteristics of the controlled system is essential for selecting and adjusting the
regulator. Characteristics of controlled systems are usually determined during a test run.
Discontinuous and continuous controllers:

The actual value is measured using analogue sensors for both types of controllers. In the case of
“discontinuous controllers”, the manipulated variable has only two states (on/off). In the case of “continuous
controllers”, the manipulated variable is displayed in an infinitely adjustable fashion (e.g. 0 to 10 V).
The characteristics of the controlled system, “tank B102”, will be observed as described below. The tank will
be filled from above via a piping system.

Case 1: tank has no drain

In this case, the tank represents an integral system during filling. The container is filled in a linear fashion.
Graphic symbol
Fill-level
Input quantity
(pump power)
Time
Case 1: tank has a drain

If water is withdrawn at the same time via a drain valve, the tank represents a PT1 system (system with
equalisation).
Graphic symbol
Input quantity
(pump power)
Fill-level
63 %
Zeit
Note
Due to the minimal fill level (hydrostatic pressure), the exponential function is not very distinctive.

Systems which demonstrate these characteristics are called 1st order systems. The characteristic variable is
time constant T [seconds]. It’s the time required to achieve approximately 63% of the final level. As system
performance varies, the control circuit also responds variously. In the experiments described below, we will
only examine the performance of a control circuit with a PT1 system.
Task
– How does the integral system perform when the pump is switched off during filling from above?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– How does the PT1 system perform when the pump is switched off during filling from above?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
4.1 Project task: controlling the fill level using a two-step controller

In the case of water supply, households withdraw various quantities of water. Two experiments will be used
to find out how a specified fill level can be constantly maintained in the upper tank. There are different
control methods:
 Switch the pump on and off: 2-step control.
 Change control voltage to the pump: analogue control.
Disturbance variables include, for example, opening and closing hand valves V101 and V103, as well as 2-
way ball valve V102 with pneumatic actuation.

– Set the system up with two tanks according to the PI flow diagram.
– Connect the pump, the flow sensor and the 2-way ball valve with pneumatic actuation and test them.
– Double-check the piping layout and the electrical connections.
LA+
111
V101
B102
LS–
114
V107 V112 V102

V103
FIS+
101
PIS+ B101
103 LS–
113
P101
V105

4.1.4 Commissioning
– Please check all the points listed in the following report and confirm completion of all tasks before
commissioning.
Task Completed Note/observation
Piping assembled and leakproof
Tank filled with 2.5 litres of water
2-way ball valve with pneumatic actuation installed

Factor = ____________
Offset = ____________
Test pump on/off using PC
Test the signal from the fill-level sensor
4.1.5 Experiment: controlling the fill level using a two-step controller

Fill-level control (discontinuous control) is to be carried out with the pump in binary mode (on/off). The
same experiment, i.e. maintaining a constant fill level by switching the pump on and off manually, was
conducted as part of the learning section on manual control. In the current example, the pump will be
switched on and off by a software controller.
Information
The values in the control circuit are specified in a standardised fashion, i.e. 0 and 1 or 0 and 100%. These
values are frequently converted to physical values for the user, for example so that the fill level can be
specified in litres or the water level in mm.
Designations within the control circuit:
Term Symbol
Setpoint w
Actual value x
Switching difference sd
Manipulated variable (pump on/off) y
As a rule, the value of switching difference sd is at the middle of the setpoint.

Fundamental performance of a control circuit as an example of a fill-level system with open outlet (PT1) and
a 2-step controller
Actual value
Switching difference
Setpoint
Manipulated variable
w (0...1) Controller Process

Setpoint Manipulated
variable Signal amplifier Controlled system Sensor Actual value
Switching difference
y (0...1) x (0...1)
sd (0...1)
Where actual value  (setpoint - switching difference/2) setpoint with storage = 1

Where actual value  (setpoint + switching difference/2) setpoint with storage = 0
2-step controller logic
Various settings must be entered in order to test performance. In order to be able to draw any conclusions
about the control circuit, it’s always advisable to change only one parameter at a time and then conduct the
experiment. The respective settings included in the following table are suggestions.

– Start the software and open the “Two-step controller” menu.

– Set digital output A3 according to the setpoints and the switching difference from the table.
Settings – standardised values (0 to 1) Observations
Setpoint w Switching difference sd Disturbance variable z:

hand valve V103
1 0.2 0.05 10% open
2 0.4 0.05 10% open
3 0.6 0.05
4 0.4 0.01 10% open
5 0.4 0.1 10% open
6 0.4 0.1 40% open
Sample solution for controlling the fill-level with a 2-step controller

Task
– How does switching difference affect control?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– How does the interference variable affect the outcome of the experiment?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
Information about the practical use of 2-step controllers

2-step controllers are used wherever system deviation is reliable.
Examples: irons, refrigerators, heaters, solar systems, fill levels for cooling lubricant, fill levels in galvanising
systems and swimming pools etc.
These systems have a large time-constant, so that only minimal switching frequencies occur despite a small
switching difference.

4.2 Project task: controlling the fill level using a continuous controller

If no system deviation is permissible within the control circuit, continuous controllers must be used.
Continuous controllers are characterised by, for example, an analogue manipulated variable in the event
that the sensor has generated an analogue signal. Depending on the control function, the manipulated
variable is calculated by means of various mathematical formulas.
Schematic diagram of a control circuit with a continuous controller

A fill-level system with open outlet (PT1 performance), for example, is used within the control circuit.
Controller Process
w (0...1) Manipulated
Control function Signal amplifier Controlled system Sensor Actual value
Setpoint variable
Y = ... y (0...1) x (0...1)
The following controller functions (selection) could be used:
Controller Graphic symbol Function
P controller y = kp  e
kp = adjustable amplification factor
e = system deviation w - x
I controller y = esum  TA/Ti

Adjustable integral time (Ti)
esum = sum of system deviation e

System deviation e is added up during each cycle.
PI controller Y = kp  ( e + esum  TA/Tn)

Adjust kp and reset time (Tn)
TA = sampling time, programme cycle time
PID controller Y = kp  (e+ esum  TA/Tn+ (e-e_alt)  Tv/TA)

Adjust derivative time (Tv),
e_alt = system deviation from the previous cycle
Note
The pump must be operated in the analogue mode for continuous control. Control voltage from the
EasyPort to the motor control is between 0 and 10 V. Changeover relay K1 must be set with A2 = 1 to this
end.

4.2.2 Experiment: controlling the fill level with a continuous controller

In this experiment the fill level will be controlled with a continuous controller. In the example included in the
chapter entitled “Manual control of fill level”, the fill level was kept constant by varying the power supply
unit’s output voltage. The manipulated value will now be read out by the software. The experiment should
be carried out with four different controllers.
Various settings must be entered in order to test the performance of the control circuit. In order to be able to
draw any conclusions, it’s always advisable to change only one parameter at a time and then conduct the
experiment. The settings included in the following table are suggestions.
– Start the software and open the “Continuous control” menu.

– Check the software settings: set changeover relay A2 = 1 and specify the setpoint.
– Carry out the experiment with P, I and PI controllers.
– Add your observations to the table.
Depending on the software revision level, the setpoints may also have to be entered in a sub-window.

4.2.3 Experiment: controlling the fill level using a proportional controller
Note
Empty B102 before each start-up!
– Select each of the values listed below and carry out the experiment.
– Document your observations.
Settings Observations
No. Setpoint w, Setpoint w Amplification Disturbance

physical (standardised) kp variable z, hand
valve V103
1 1 litre 0.3 0.5 10% open
2 1 litre 0.3 2 10% open
3 1 litre 0.3 10 10% open
4 1 litre 0.3 5 0% open
5 1 litre 0.3 5 20% open
6 2 litres 0.2 5 100% open
Sample solution for fill-level control with a P controller

Task
– Which characteristics is the control circuit (P controller, PT1 system) displaying?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
4.2.4 Experiment: controlling the fill level using an integral controller
Note
Empty B102 before each start-up.
Software setup
The manipulated value of the I controller is calculated as follows:
Y = total of all system deviation (e:sum) x sampling time (TA)/integral action time (Ti)
This formula makes it clear that Y is quickly changed by the controller when Ti is small, and Y is changed
slowly, i.e. the controller is sluggish, when Ti is large. Make sure that Ti does not drop to 0, otherwise Y
would be undefined in this case. Switch the software to “I controller”.
The physical setpoint depends on the size of the tank and whether the unit of measure of the fill level will be
in litres or in mm.

– Select each of the values listed below and carry out the experiment.
No. Setpoint w, Setpoint w Integral Disturbance

physical (standardised) action time variable z, hand
(Ti) valve V103
1 – 0.3 1 10% open
2 – 0.3 0.5 10% open
3 – 0.3 0.1 10% open
Note
It is possible that no stabilisation occurs in an actual system and that continuous oscillation takes place.
Sample solution for controlling the fill-level with an I controller

Task
– What is the effect of integral time?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– What can we say about system deviation?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
4.2.5 Experiment: controlling the fill level using a proportional-integral controller (parallel P and I
components)
In order to take advantage of the positive characteristics of both the P and the I controller, the two will be
combined. This can be done in two different ways:
kp = 1
kp
The controllers are connected in parallel in the combination shown on the left and in series in the combination
on the right. In actual industrial practice, the combination shown on the right is used in accordance with
IEC 60050-351.
Note
Empty B102 before each start-up.
– Select each of the values listed below for the PI controller and carry out the experiment.

No. Setpoint w Amplification Reset time Tn Disturbance

(standardised) kp variable z, hand
valve V103
1 0.5 litres 00.5 1 sec. 10% open
2 0.5 litres 1 1 sec. 10% open
4 0.5 litres 3 0.1 sec. 10% open
Sample solution for controlling the fill-level with a PI controller
Task
– What can we say about reset time Tn?
_________________________________________________________________________________________
_________________________________________________________________________________________
– What can we say about system deviation?
_________________________________________________________________________________________
_________________________________________________________________________________________

4.3 Project task: refrigerating plant

The throughput of a coolant (volumetric flow rate) in a refrigerating plant needs to be controlled. A PI
controller is used. Water will simply be pumped to tank B101 for this experiment.
Liquid in piping
PI controller Motor and pump system
Control circuit concept
– Set the system up with one tank according to the PI flow diagram, or disconnect the piping to upper
tank B102 and seal the bottom outlet of tank B102 with a blanking plug.
– Connect and test the pump and the flow sensor.
V103 V102
FI
101
PI B101
103
P101
V105
– Install and start the software, and select “Continuous controller” from the menu. Entries are
standardised from 0 to 1.

4.3.3 Commissioning report
– Please check all the points listed in the following report and confirm completion of all tasks before
commissioning.
Task Completed Note/observation
Piping assembled and leakproof
Tank filled with 2.5 litres of water

Factor = _____________ , offset = _____________
Test pump with PC at 0 to 10 V

Changeover relay: A2 = 1
Test the signal from the volumetric flow rate sensor
4.3.4 Experiment: flow control using a proportional-integral controller
Note
Various settings must be entered in order to test performance. In order to be able to draw any
conclusions, it’s always advisable to change only one parameter at a time and then conduct the
experiment. The settings included in the following table are suggestions.
No. Setpoint w Amplification Reset time Tn Disturbance

(standardised) kp variable z, hand
valve V103
1 0.5 litres 0.5 1 sec. 50% open
4 0.5 litres 3 0.1 sec. 50% open
5 20% open
6 100% open

Sample solution for flow rate control with a PI controller
Task
– Find a setting at which the controller overshoots only once.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– How does the interference variable affect the outcome of the experiment?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

5. Evaluation of learning objectives for automated measurement, open-loop
and closed-loop control
1. Describe how to set up a computer aided control circuit.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
2. List various controlled systems with one practical example for each.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

5. Evaluation of learning objectives for automated measurement, open-loop and closed-loop control
3. Describe the performance of a control circuit with a PT1 system.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
4. Data (e.g. actual value x) is acquired using sensors. The following, for example, appears in a data sheet
for a sensor: pressure range: 0 to 400 mbar, signal: 0 to 10 V. How is the signal processed by the PC so
that the physical value is displayed on the PC monitor?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

5. An ultrasonic sensor provides data in accordance with the following screenshot. Determine factor and
offset for a physical representation of the value on the screen.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

6. A pressure sensor is described as follows in the data sheet:
10
6
U
0 3
-1 0 20 40 60 mbar 100
2 1
P
1: 24 V DC supply voltage 2: 0 V DC earth 3: 0 to 10 V DC voltage output
– Which pins have to be connected to EasyPort?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– Which values do factor and offset have to be set to in order to display pressure correctly as a physical
quantity?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

7. How are actuators (e.g. pump motor) controlled with the PC?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
8. How is the EduKit PA switched from digital to analogue control?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
9. As is the case with all microprocessor controllers, the PC works cyclically according to the IPO model
(input, processing, output). The time required for a single sequence is called cycle time or sampling time
(TA).
– For example, a programme has a sampling time of 25 ms. How many measurements can be carried out
in one second?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

– In order to determine the flow rate of a medium as accurately as possible, at least 50 measurements
must be performed per second. Determine the required sampling time.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
10. A pump fills a tank from above with water. After a given period of time, the pump is switched off. Draw
conceivable characteristic fill level curves for two different cases: in case 1 the drain at the bottom of
the tank is open. In case 2 the drain is closed.

11. An impeller pump causes volumetric flow rate within a circuit. What is the relationship between
volumetric flow rate and pressure? Give reasons for your answer.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

12. The following figure depicts a characteristic pump curve. Control voltage is increased from 0 to 10 V in
case 1. In case 2, it’s decreased back to 0 V.
– Provide designations for the depicted axes.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– Give reasons for the shape of the curves.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

13. A two-step controller can be used for simple control of the fill-level.
– Explain the structure of a 2-step controller.
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– What is the effect of the switching difference?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

14. After the process, the process, measurement and control data can be stored as ASCII data.
– Why is ASCII used?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
– How can the data be further processed?
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________

Worksheets C Automated Measurement and Control

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Worksheets C Automated Measurement and Control

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Part C – Practice-based learning: automated measurement, open-loop and

1. Basic principles __________________________________________________________________ C-3

2. Automated measurement _________________________________________________________ C-13

3. Automated open-loop control ______________________________________________________ C-25

© Festo Didactic GmbH & Co. KG 563971 C-1

4. Automated closed-loop control ____________________________________________________ C-41

5. Evaluation of learning objectives for automated measurement, open-loop

C-2 © Festo Didactic GmbH & Co. KG 563971

1.1 Computer-aided control technology

© Festo Didactic GmbH & Co. KG 563971 C-3

Examples of controlled systems:

P controller System deviation is influenced by means of a factor.

I controller The sum of all system deviations is influenced by means of a factor.

PID controller The manipulated variable is determined by the

C-4 © Festo Didactic GmbH & Co. KG 563971

Technical learning objectives

1.2 System conversion for automated measurement and control

© Festo Didactic GmbH & Co. KG 563971 C-5

C-6 © Festo Didactic GmbH & Co. KG 563971

System with control panel System without control panel

© Festo Didactic GmbH & Co. KG 563971 C-7

5. Screw the preassembled I/O boards to the rectangular profile.

Assembly Figure Description

Motor controller The analogue manipulated variable of 0 to 10 V from the

Modules on the I/O board

Further information is included in the data sheets on the CD-ROM.

C-8 © Festo Didactic GmbH & Co. KG 563971

6. Connect the EasyPort to the I/O board with a SysLink cable.

8. Connect a 24 V power supply unit.

© Festo Didactic GmbH & Co. KG 563971 C-9

10. Install the software.

11. Test the system.

12. Select the “Setup” menu.

C-10 © Festo Didactic GmbH & Co. KG 563971

13. Assignment of inputs and outputs on the I/O board:

Name Device Abbreviation Note

Digital output 0 2-way ball valve with pneumatic A0 Spring return

Digital output 2 Changeover relay A2 Relay = 0: pump is binary controlled

Digital output 3 Pump A3

Analogue output 0 Pump AOUT 1

Analogue input 0 Fill level (ultrasonic) AIN 0

Analogue input 1 Flow sensor AIN 1

Analogue input 2 Pressure sensor AIN 2

1: I/O terminal 2: Analogue terminal 3: Relay 4: Motor controller

Complete layout plan

© Festo Didactic GmbH & Co. KG 563971 C-11

C-12 © Festo Didactic GmbH & Co. KG 563971

2.1 Project task: bath recirculation

2.1.1 Task description

© Festo Didactic GmbH & Co. KG 563971 C-13

C-14 © Festo Didactic GmbH & Co. KG 563971

© Festo Didactic GmbH & Co. KG 563971 C-15

2.1.2 Setting up the system, inspection

– Set up the water circuit (see flow diagram).

– Fill B101 approximately half full with water.

C-16 © Festo Didactic GmbH & Co. KG 563971

2.1.3 Experiment: operating the pump with variable voltage values

No. Digital outputs Analogue outputs Pump (observe)

2.2 Project task: pressure measurement during recirculation

2.2.1 Task description

© Festo Didactic GmbH & Co. KG 563971 C-17

2.2.2 Setting up the system, inspection

– Switch the system off and pull the mains plug.