INSTRUMENTATION

LAB MANUAL
B. Tech IV Year - I Semester

NAME : ________________________________________

ROLL NO : ________________________________________

BRANCH : _________________________________________

DEPARTMENT OF
MECHANICAL ENGINEERING

Aurora’s Technological And Research Institute

Parvathapur, Uppal, Hyderabad-98.
 CONTENTS

Page
S. No Topic
No’s

1. Calibration of capacitive transducer for angular displacement. 3-6

Study and calibration of LVDT transducer for displacement

2. 7 - 12
measurement.
Study of resistance temperature detector for temperature
3. 13 - 17
measurement.

4. Calibration of thermistor for temperature measurement. 17 – 21

5. Calibration of thermocouple for temperature measurement. 22 – 25

Calibration of hot wire anemometer for temperature

6. measurement. 26 – 32

7. Calibration of Pressure Gauges 33 - 37

8. Calibration of strain gauge for temperature measurement. 38 – 43

Study and calibration of photo and magnetic speed pickups

9. 44 – 45
for the measurement of speed

10 Study and calibration of a rotameter for flow measurement. 46 - 55

2
 INTRODUCTION

Introduction to Transducers and Measurement systems:

Transducer: Transducer is a device which converts one form of energy into another form like Electrical to
Mechanical, Mechanical to Electrical, Thermal to Electrical and etc.,

Emphasis in the instrumentation trainers will be directed toward electronic instrumentation systems rather than
mechanical systems. In most cases electronic systems provide better data more accurately completely characterize the
design or process being experimentally evaluated. Also the electronic system provides an electrical out put signal that
can be used for automatic data reduction or for the control of the process. These advantage of the electronic
measurement system over the mechanical measurement system have initiated and sustained trend instrumentation
toward electronic methods.

An attempt is made through these “Instrumentation trainer kits” to make as easy as possible for the students to learn
about the electronic instrumentation system and various transducers used for the measurement of mechanical
component. The instrumentation tutor panels are design in such a way that block diagrams of the stages of electronic
instrumentation system are clearly pictured on them. This makes the instrumentation tutor self explanatory and also the
best teaching aid for engineering students.

Since the instrumentation tutors are not instrument as a whole the accuracy of the measurement cannot be claimed. It is
very clear that the instrumentation tutors are only for demonstration purpose and cannot be used for any external
measurement other than conducting experiments.

THE ELECTRONIC INSTRUMENTATION SYSTEM.

The complete electronic instrumentation system usually contains six sub systems or elements the TRANSDUCER is a
device that convert a change in the mechanical or thermal quantity being measured into a change of an electrical
quantity. Example strain gauges bonded in to an specimen, gives out electrical out put by changing its resistance when
material is strained.
SIGNAL
TRANSDUCER CONDITIONER AMPLIFIER RECORDER

POWER SUPPLY DATA

PROCESSOR

The POWER SUPPLY provides the energy to drive the Transducers, example differential transformer, which is a
transducer used to measure displacement required an AC voltage supply to excite the coil.

SIGNAL CONDITIONERS are electronic circuits the convert, compensate, or manipulate the out put from in to a
more usable electronic quantity. Example the whetstone bridge used in the strain transducer converts the change in
resistance. AR to a change in the resistance AE.

AMPLIFIERS are required in the system when the voltage out put from the transducer signal conditioner combination
is small. Amplifiers with game of 10 to 1000 are used to increase their signals to levels they are compatible with the
voltage – measuring devices.

RECORDERS are voltage measuring devices that are used to display the measurement in a form that can be read and
interpreted Digital/Analog voltmeters are often used to measure static voltages.

DATA PROCESSORS are used to convert the out put signals from the instrument system into data that can be easily
interpreted by the Engineer. Data processors are usually employed where large amount of data are being collected and
manual reduction of these data would be too time consuming and costly.
3
 EXPERIMENT NO.1

CALIBRATION OF CAPACITIVE TRANSDUCER FOR ANGULAR DISPLACEMENT.

Displacement measurement by Capacitive Transducer:

4
 INTRODUCTION

Unique Capacitance trainer Module is the best trainer for which demonstrate the use of capacitance as a transducer.
Two parallel plates (A1), one fixed to the base and the other moving over the fixed plate parallel with a small gap
between the two. The over lapping of the plate will act as a capacitor with air as dielectric media. The parallel
capacitor is used as a displacement sensor which measure the displacement.

The instrument is built around an NE556 integrated circuit. The NE556 is a dual 556 times IC. The first timer
is connected as a stable multi vibrator while the second time is sued as a mono stable.

At each trigger, the mono stable output a pulse whose width is determined by the Resistance and the
Capacitance of the parallel plate capacitor Cx connected across the measuring terminals. Specifically the mono stable
duration is given by T=1.1 R range X Cx, where R range is the range resistance across the measurement terminals.
From this is is seen that the width of the mono stable pulse is directly proportional to capacitance Cx (parallel plate
capacitor).

Since the mono stable duration is itself is proportional to capacitance Cx (parallel plate capacitor) across the
measurement terminals, it follows that the meter indicated is directly proportional to the capacitance. The mono stable
output is average during averaging circuit and feed to amplified for Zero setting and calibration the instrument to read
displacement.

Theory

Capacitive transducer is a device used to measure the displacement by the following equation
C =εA/d
Where c- capacitance,
ε – Dielectric medium,
A- Area of overlapping,
d- Distance between plates
BY capacitive Transducer we have three combinations for measuring Linear and Angular Displacement:
1. Change in the Area of overlapping,
2. Change in the Distance between plates,
3. Change in the Dielectric medium.
Here, in this experiment we are going to use Change in the Area of overlapping for finding the LIneasr displacement
measaurement

Aim:

To perform an experiment on Displacement measurement using capacitive transducer

OPERATING PROCEDURE

 Check connection made to the instrument

 Allow the instrument in On position for 10 minutes for initial warm up

 Pull the top plate to Zero position

 Adjust the ZERO potentiometer so that the display reads ‘000’

 Move the plate in step of 5 to 10 mm and note down the reading in the tabular column till 50mm.

5
 SPECIFICATIONS

Sensor : Parallel plate capacitor

Sensor Materia.3 : Aluminum plates

Dielectric Medium : Air

Displacement : 0 to 50 mm

Accuracy : 5 to 10%

Display : 3.5 digit LED display to read +/- 1999

counts for

Power : 230V +/- 10% 50 HZ

EXPERIMENT & TABULAR COLUMN

Measurement of displacement using capacitance is a demo model to demonstrate the use of capacitance as
displacement sensor. In measurement Repeatability, Linearity. Accuracy important factors. So the experiment to test
the Parallel plate Capacitance for all these factors.

EXPERIMENT

Known displacement is given to the parallel plate and the displacement on the scale can be noted down along with the
display readings. Graph of scale reading versus Display reading can be Plotted. Accuracy and the linearity of the
Capacitance sensor can be calculated by the graphs, Repeatability can be calculated by repeating the experiment 3 to 4
times and tabulating the readings both for ascending and descending of displacement.

TABULAR COLUMN

B
A C D E
ACTUAL SCALE
SL. INDICATOR ERROR
READINGS
NO. READINGS (MM) B-0 % ERROR
(MM)

Questions:
1. What is the principle of working of capacitive transducer?
2. What is calibration?
3. How capacitive transducer used for displacement measurement?
4. What are the advantages of capacitive transducer?
5. What is the replacement for displacement measurement if capacitive transducer is not there?

6
 EXPERIMENT NO.2

STUDY AND CALIBRATION OF LVDT TRANSDUCER FOR DISPLACEMENT MEASUREMENT

Displacement Measurement by LVDT

7
 INTRODUCTION

The primary object of the INSTRUMENTATION TRAINER is to introduce and to educate electronic instrumentation
systems in a manner sufficiently complete that the students will acquire proper knowledge and the idea about the
transducers and their applications to measure mechanical and terminal quantities. The mechanical quantities include
strain, force, pressure torque displacement, acceleration, frequency, etc. The terminal quantities include temperature
and heat flux.

It is understood that the students will have a conceptual understand of these quantities through exposure of mechanics
or physics courses, such as static’s dynamics, strength of materials or thermodynamics. The students experience in
actually measuring these quantities by conducting experiments, however, will usually be quit limited. It is an objective
of this tutor to introduce methods commonly employed in such measurements and the usage of such electrical
components such as capacitance, resistance, inductance, intensity, etc.

Emphasis in the instrumentation trainer will be directed toward electronic instrumentation systems rather than
mechanical systems. In most cases electronic systems provide better data more accurately completely characterize the
design or process being experimentally evaluated. Also the electronic system provides an electrical out put signal that
can be used for automatic data reduction or for the control of the process. These advantage of the electronic
measurement system over the mechanical measurement system have initiated and sustained trend instrumentation
toward electronic methods.

An attempt is made through these “Instrumentation trainer” to make as easy as possible for the students to learn about
the electronic instrumentation system and various transducers used for the measurement of mechanical component.
The instrumentation tutor panels are design in such a way that block diagrams of the stages of electronic
instrumentation system are clearly pictured on them. This makes the instrumentation tutor self explanatory and also the
best teaching aid for Engineering students.

Since the instrumentation tutors are not instrument as a whole the accuracy of the measurement cannot be claimed. It is
very clear that the instrumentation tutor are only for demonstration purpose and cannot be used for any external
measurement other than conducting experiments.

THEORY

MEASUREMENT OF DISPLACEMENT
Differential transformers on a variable inductance principle, are also used to measure displacement. The most popular
variable inductance transducer for linear displacement measurement is the Linear Variable Differential Transformer (
LVDT ). The LVDT illustrated in the fig. consists of three symmetrically spaced coils would onto an insulated bobbin.
A magnetic core moves through thee bobbin without contact, provides a path for magnetic flux linkage between coils.
The position of the magnetic core controls the mutual between the center or primary coil and with the two outside of
secondary coils.

When an AC carrier excitation is applied to the primary coil, voltages are induced in the two secondary coils that are
wires in a series-opposing circuit. When the core is centered between the two secondary coils, the voltage induces
between the secondary coils are equal but out of phase by 180 0. The voltage in the two coil cancels and the output
voltage will be zero. When the core is moves from the center position, an imbalance in mutual inductance between the
primary coil and the secondary coil occurs and an output voltage develops. The output voltage is a linear function of
the core position as long as the motion of the core is within the operating range of the LVDT.

8
 CIRCUIT EXPLANATION

The circuit can be divided into three parts.

1. Power supply 2. Display 3. Frequency generator &
4. Signal Conditioner

1. POWER SUPPLY

The power supply unit provides power for all the electronic device in the instrument. There are two differential
regulated power supply in the unit.

a) +5V, -5V 250mA too drive digital integrated circuits.

b) +5V, -0 -5V, 250mA to drive linear integrated circuits.
9
2. DISPLAY

The display circuit is basically a 3 ½ digit voltmeter which accepts DC of 200mV for full scale Reading. The display
will be indicated through seven segment bright LED’s.

3. FREQUENCY GENERATOR

The circuit is an IC based (OP AMP) used to generate excitation voltage to the LVDT primary coil. The IC’s use +5V
and -5V and produce a fine square wave of desired frequency. The Voltage can be adjusted using a trim pot. The
square wave is then trimmed by FET, PnP and NpN transistor. Then the Frequency is adjusted by varying the trim pot.
The voltage and frequency is adjusted to 2khz 2 V which is fed to LVDT as an excitation voltage.

4. SIGNAL CONDITIONER

The circuit which processes the output of transducers and presents a fixed DC voltage to the display constitute the
Demodulator and amplifier. Demodulator is a phase sensitive detector and AC amplifier, which gives out DC voltage
which is amplified and fed to summing amplifiers. The output of the summing amplifier is fad to the display.

SPECIFICIATIONS

INDICATOR

* DISPLAY : 3 ½ digit seven segment red LED display of

Rage 200mV for full scale deflection to read +/- 1999 counts
* EXCITATION VOLTAGE : 1000 Hz at IV
* OPERATING TEMPERATURE: +100 c to 550 C
* ZERO ADJUSTMENT : Front panel through Potentiometer
* SENSTIVITY : 0.1 mm
* SYSTEM IN ACCURACY : 1%
* REPEATABILITY : 1%
* CONNECTION : Through 6 core shielded cable with Din
connector.
* FUSE : 250mA fast glow type.

* POWER : 230 V +/- 10%, 50 Hz

SENSOR

* RANGE : +/- 10.0 mm

* EXCITATION VOLTAGE : 1 to 4 kHz at 1 to 4V
* LINEARITY : 1%
* OPERATING TEMPERATURE: : +100c to 550 C
* CONNECTION : Through 6 core shielded cable provided
along with the sensor of 2M length.
* CALIBRATION JIG : Micrometer to 0 to 25 mm length is mounted
on the base.

10
PANEL DETAILS

DISPLAY : 3 ½ Digit LED display of 200mV FSD to

read up to “+/- 1999” counts.
ZERO : Single turn potentiometer to adjust “000”
when the sensor is connected
CAL : Single turn potentiometer to adjust the
calibration point.
CIRCUITRY : Block diagram of the circuit for
displacement indicator. The diagram also shows LVDT block
diagram also.

MOUNTING OF L V D T ON THE CALIBRATION JIG

L V D T has to be mounted perfectly on the calibration Jig. Micrometer should be moved till the micrometer reads 20.0
mm. LVDT should be mounted too the center plate by the two nuts provided. The core of the LVDT should be aligned
with the core of the micrometer. Adjust the core of the LVDT till it touches the micrometer core and lighten the nut.

CONNECTION DETAILS

CONNECTING INSTRUMENT TO MAINS

3 Pin power chord is provided, attached to the instrument. Connect the 3 pin plug to 230V 50Hz socket.
Before connecting ensure that the power On switch is in OFF position.

SENSOR CONNECTION
6 core shielded cable is connected to the LVDT with male connectors of different colors are fixed to each wire.
Connect the male pins to the socket matching the color correctly.

11
 OPERATI NG PROCEDURE

1. Connect the power supply chord at the rear panel to the 230V 50Hz supply. Switch on the instrument by
pressing down the toggle switch. The display glows to indicate the instrument is ON.
2. Allow the instrument in ON position for 10 minutes for initial warm-up.
3. Rotate the micrometer till it reads “20.0”.
4. Adjust the CAL potentiometer at the front panel so that the display reads “10.0”
5. Rotate the core of micrometer till the micrometer reads “10.0” and adjust the ZERO potentiometer till the
display reads “00.0”.
6. Rotate back the micrometer core upto 20.0 and adjust once again CAL Potentiometer till the display read
10.0. Now the instrument is calibrated for +/- 10.0 mm range. As the core of LVDT moves the display reads
the displacement in mm.
7. Rotate the core of the micrometer in steps of 1 or 2 mm and tabulate the readings. The micrometer will show
the exact displacement given to the LVDT core the display will read the displacement sensed by the LVDT.
Tabulate the readings and Plot the graph Actual V/s indicator readings.

EXPERIMENT & TABULAR COLUMN

Measurement of displacement through LVDT is well accepted method in process control instrumentation. In
measurement Repeatability, Linearity. Accuracy are important factors. So the experiment to test the LVDT for all these
factors.
EXPERIMENT is the known displacement is given to the LVDT core through micrometer and the displacement sensed
by the micrometer can be noted down. Graph of Micrometer reading versus LVDT reading can be Plotted. Accuracy
and the linearity of the LVDT can be calculated by the graphs. Repeatability can be calculated by repeating the
experiment 3 to 4 times and tabulating the readings both for ascending and descending of displacement.

TABULAR COLUMN

A B C D E
SL.NO. ACTUAL INDICATR ERROR %
MICROMETER READINGS B.C. ERROR
READINGS LVDT (MM)
(MM)

Questions:
1. What is the principle of working of LVDT?
2. What is calibration?
3. How LVDT used for displacement measurement?
4. What are the advantages of LVDT?
5. What is the replacement for displacement measurement if LVDT is not there?

12
 EXPERIMENT NO.3

STUDY OF RESISTANCE TEMPERATURE DETECTOR FOR TEMPERATURE

MEASUREMENT.

Temperature measurement by RTD

CONTENTS
1. THEORY
2. PANEL DETAILS
3. SPECIFICATIONS
4. OPERATING PROCEDURE

13
Theory

RESISTANCE TERMPERATURE DETECTORS (RTD)

The change in the resistance of metals with temperature provides the basic for a family of temperature measuring
sensors known as resistance temperature detectors. The sensor is simply a conductor fabricated either as a wire would
coil or as a film or foil grid. The change in resistance of the conductor with temperature is given by the expression.

∆R / R0 = λ1 (T-T0) + λ2 (T-T0) 2 + λn (T-T0)n

Where T0 is a reference temperature.
R0 is the resistance at temperature T 0

λ1, λ2,………………… λn are temperature co-efficient of resistance.

Platinum is widely used for sensor fabrication since it is the most stable of all the metals, is the least sensitive to
contamination, and is capable of operating over a very wide range of temperature. The dynamic response of on RTD
depends almost entirely on construction details.

CIRCUIT EXPLANATION

The circuit comprises of three parts.

1. POWER SUPPLY
2. SIGNAL CONDITIONING AND AMPLIFYING
3. ANALOG TO DIGITAL CONVERTER.

1. POWER SUPPLY.
Inbuilt power supply use power to all electronic devices inside the circuitry. High stable regulated Power
supply is used for better performance.
There are three different power supply inside the unit.

+12-0 012 V 500mA to drive digital integrated circuitry.

+5-0—5V 250mA to drive A to D converter.

2. SIGNAL CONDITIONING AND AMPLIFYING

The circuitry comprises of signal conditioner and amplifier. The output of the sensor is amplified to required
level. The Thermocouple gives out directly which is amplified. Thermistor and RTD are connected to the ground
through a resister, and the voltage is applied to the other end of the sensor. The resistance change in the sensor will
gives the mV out put which is amplified and controlled. Analog out put is fad to the ADC.

3. ANALOG TO DIGITAL CONVERTER.

The output from the amplifier is a linearised analog DC voltage. This analog output is converted into digital
output with the help of IC 7107 3.5 digit 200mA. A to D converter. Then it is displayed through seven segmented
LEDs.

PANEL DETAILS

DISPLAY : 3 ½ Digit LED Display of 200 mV FSD.

INITIAL SET : Single turn potentiometer to set Initial Temperature
(Room Temperature)
FINAL TEST : Single turn potentiometer to Calibrate the instrument
(Max. Temperature)
SELECT : 3 Way rotary switch to select RTD, Thermocouple and
Thermister.
14
POWER ON : Rocker switch to control power supply to the
instrument.

CONNECTION DETAILS

POWER : 3 pin mains cable is provided with the instrument.

Connect the 3 pin socket to the instrument at the rear panel and to the AC mains
230v supply.

NOTE : Before connecting ensure the voltage is 230 V and the

Power switch is in off position)

SENSORS : Connect RTD, Thermistor and Thermocouple to the

connector on the rear panel.

OPERATING PROCEDURE

Check connection made and Switch ON the instrument by rocker switch at the front panel.
The display glows to indicate the instrument is ON.
Allow the instrument in ON Position for 10 minutes for initial warm-up.
Pore around 3/4th full of water to the kettle and place sensors and thermometer inside the kettle.
Note down the Initial water temperature from the thermometer.
Select the sensor on which the experiment to be conducted through selection switch on the front panel.
Adjust the Initial set Potentiometer in the front panel till the display reads initial water temperature.
Switch on the kept and wait till the water boils note down the reading inn the thermometer and set Final set
potentiometer till the display reads boiling water temperature.
Remove the sensor from the boiling water immerse it I the cold water. Set the cold water temperature using initial set
potentiometer.
Repeat the process till the display reads exact boiling water and cold water temperature. Change the water in
the kettle with and re heat the water. Now the display starts showing exact temperature raise in the kettle.
Experiment can be repeated for all the three sensors. Temperature in the thermometer and the indicator
readings in steps of 100 C can be tabulated.

EXPERIMENTS AND TABULAR COLUMN-1

EXPERIMENT TO MEASURE TEMPERATURE USING RTD:

Experiment can be conducted on the instrument as per the operating instruction given above for the RTD and and
various parameters like Linearity. Accuracy, Hysteresis etc, can be calculated. The readings can be tabulated and
graphs can be plotted to calculated the above parameters.

TABULAR COLUMN-1

THERMOMETER REARING 0C
SL. RTD
(Actual Temperature) 0
NO C

15
Graphs: Actual reading V/s indicator Reading

EXPERIMENTS AND TABULAR COLUMN – 2

EXPERIMENT TO STUDY THE CHARACTERISTICS OF RTD.

 Remove the YELLOW & GREEN terminals of the sensors from the instrument
 Connect RTD to Ohm-meter to measure ohms.
 Repeat the Experiment 1 but measure the resistance changes of RTD.
 Tabulate the readings in the tabular column given below. Plot the graphs for Temperature change in the
thermometer V/s Change in the millivolt/Resistance

TABULAR COLUMN-1

EXPERIMENT-2

THERMOMETER REARING 0C
SL. RTD
(Actual Temperature) 0
NO C

Questions:

1. What is the principle of RTD?

2. What is calibration?
3. How RTD used for Temperature measurement?
4. What are the advantages RTD?
5. What is the replacement for temperature measurement if RTD is not there?

16
 EXPERIMENT NO.4

CALIBRATION OF THERMOCOUPLE FOR TEMPERATURE MEASUREMENT.

Temperature measurement by THERMOCOUPLE

CONTENTS

1. INTRODUCTION
2. THEORY
3. PANEL DETAILS
4. SPECIFICATIONS
5. OPERATING PROCEDURE

17
 INTRODUCTION

The primary object of the INSTRUMENTATION TAINERS (TEMPERATURE TRAINER) is to introduce

and to educate electronic instrumentation systems in a manner sufficiently complete that the students will acquire
proper knowledge and the idea about the transducers and their applications measure mechanical and thermal quantities.
The mechanical quantities include strain, force, pressure, torque, displacement, acceleration, frequency, etc. The
thermal quantities include temperature and heat flux.
It is understood that the students will have a conceptual understanding of these quantities through exposure of
mechanics or physics courses, such as static’s, dynamics, strength of materials or thermodynamics. The student’s
experience in actually measuring these quantities by conducting experiments, however, will usually be quit limited. It
is an objective of this tutor to introduce methods commonly employed in such measurements and the usage of such
electrical components such as capacitance, resistance, inductance, intensity, etc.,
Emphasis in the instrumentation tutor will be directed toward electronic instrumentation systems rather than
mechanical systems. In most cases electronic systems provide better data more accurately and than mechanical
systems. In most cases electronic systems provide better data more accurately completely characterize the design or
process being experimentally evaluated. Also, the electronic system provides an electrical out put signal that can be
used for automatic data reduction or for the control of the process. These advantage of the electronic measurement
system over the mechanical measurement system have initiated and sustained trend in instrumentation toward
electronic methods.
An attempt is made through these “Instrumentation tutors” to make as easy as possible for the students to
learn about the electronic instrumentation system and various transducers used for the measurement of mechanical
component. The instrumentation tutor panels are design in such a way that the block diagrams of the stages of
electronic instrumentation system are clearly pictured on them. This makes the instrumentation tutor self explanatory
and also the best teaching aid for Engineering students.
Since the instrumentation tutors are not instrument as a whole the accuracy of the measurement cannot be claimed. It is
very clear that the instrumentation tutor are only for demonstration purpose and cannot be used for any external
measurement other than conducting experiments.

1. THERMOCOUPLE

When two dissimilar materials are brought into contact, a potential develops as a result of an effect known as
the “seeback effect”. A Thermocouple is a very simple temperature sensor operates based on the seeback effect, which
results in the generation of a thermoelectric potential when two dissimilar metals are joined together to a junction. The
electric potential of the material accepting electrons becomes negative at the interface, while the potential of the
material providing the electrons become positive. Thus an electric field is established by the flow of electrons across
the interface. When this electric field becomes sufficient to balance the diffusion forces, a state of equilibrium with
respect to electron migration is established. Since the magnitude of the diffusion force is controlled by the temperature
of the thermocouple junction, the electric potential developed at the junction provides a measure of the temperature.

The electric potential is usually measured by introducing a special junction in an electric circuit. The voltage across
terminals M-N can be represented approximately by an empirical equation having the form.

E0 = C1 (T1 – T2) + C2 (T12 – T22)

When C1 and C2 are thermoelectric constants that depend on the material used to form the junction T1 and T2 are
junction temperature.

18
 CIRCUIT EXPLANATION
The circuit comprises of three parts.

1. POWER SUPPLY
2. SIGNAL CONDITIONING AND AMPLIFYING
3. ANALOG TO DIGITAL CONVERTER.

1. POWER SUPPLY.
Inbuilt power supply use power to all electronic devices inside the circuitry. High stable regulated Power
supply is used for better performance.
There are three different power supply inside the unit.

+12-0 012 V 500mA to drive digital integrated circuitry.

+5-0—5V 250mA to drive A to D converter.

2. SIGNAL CONDITIONING AND AMPLIFYING

The circuitry comprises of signal conditioner and amplifier. The output of the sensor is amplified to required
level. The Thermocouple gives out directly which is amplified. Thermistor and RTD are connected to the ground
through a resister, and the voltage is applied to the other end of the sensor. The resistance change in the sensor will
gives the mV out put which is amplified and controlled. Analog out put is fad to the ADC.

3. ANALOG TO DIGITAL CONVERTER.

The output from the amplifier is a linearised analog DC voltage. This analog output is converted into digital
output with the help of IC 7107 3.5 digit 200mA. A to D converter. Then it is displayed through seven segmented
LEDs.

PANEL DETAILS

DISPLAY : 3 ½ Digit LED Display of 200 mV FSD.

INITIAL SET : Single turn potentiometer to set Initial Temperature
(Room Temperature)
FINAL TEST : Single turn potentiometer to Calibrate the instrument
(Max. Temperature)
SELECT : 3 Way rotary switch to select RTD, Thermocouple and
Thermister.
POWER ON : Rocker switch to control power supply to the
instrument.

CONNECTION DETAILS

POWER : 3 pin mains cable is provided with the instrument.

Connect the 3 pin socket to the instrument at the rear panel and to the AC mains
230v supply.

NOTE : Before connecting ensure the voltage is 230 V and the

Power switch is in off position)

SENSORS : Connect RTD, Thermistor and Thermocouple to the

connector on the rear panel.

19
 OPERATING PROCEDURE

Check connection made and Switch ON the instrument by rocker switch at the front panel.
The display glows to indicate the instrument is ON.
Allow the instrument in ON Position for 10 minutes for initial warm-up.
Pore around 3/4th full of water to the kettle and place sensors and thermometer inside the kettle.
Note down the Initial water temperature from the thermometer.
Select the sensor on which the experiment to be conducted through selection switch on the front panel.
Adjust the Initial set Potentiometer in the front panel till the display reads initial water temperature.
Switch on the kept and wait till the water boils note down the reading inn the thermometer and set Final set
potentiometer till the display reads boiling water temperature.
Remove the sensor from the boiling water immerse it I the cold water. Set the cold water temperature using initial set
potentiometer.
Repeat the process till the display reads exact boiling water and cold water temperature. Change the water in the kettle
with and re heat the water. Now the display starts showing exact temperature raise in the kettle.
Experiment can be repeated for all the three sensors. Temperature in the thermometer and the indicator readings in
steps of 100 C can be tabulated.

EXPERIMENT AND TABULAR COLUMN-1

EXPERIMENT TO MEASURE TEMPERATURE USING THERMOCOUPLE. Experiment can be conducted on

the instrument as per the operating instruction given for Thermocouple and various parameters like Linearity.
Accuracy, Hysteresis etc, can be calculated. The readings can be tabulated and graphs can be plotted to calculate the
above parameters.

TABULAR COLUMN-1

EXPERIMENT-1
THERMOMETER REARING
0 THERMOCOUPLE
SL.NO C 0
C
(Actual Temperature)

% Error = Column No. 4 X 100

Max. Load

Graphs: Actual reading V/s indicator Reading

20
 EXPERIMENTS AND TABULAR COLUMN – 2

EXPERIMENT TO STUDY THE CHARACTERISTICS OF THERMOCOUPLE

 Remove the YELLOW & GREEN terminals of the sensors from the instrument
 Connect Thermocouple terminals to a Millivolt meter.
 Repeat the Experiment 1 but measure the thermocouple output through millivolt meter.
 Tabulate the readings in the tabular column given below. Plot the graphs for Temperature change in the
thermometer V/s Change in the millivolt/Resistance

TABULAR COLUMN-1

EXPERIMENT-2
THERMOMETER REARING
0 THERMOCOUPLE
SL.NO C 0
C
(Actual Temperature)

Questions:
1. What is the principle of Thermocouple?
2. What is calibration?
3. How Thermocouple used for Temperature measurement and what is the range of thermocouples?
4. What are the advantages of Thermocouple?

21
 EXPERIMENT NO.5

CALIBRATION OF THERMISTOR FOR TEMPERATURE MEASUREMENT.

Temperature measurement by THERMISTOR

CONTENTS
1. THEORY
2. PANEL DETAILS
3. SPECIFICATIONS
4. OPERATING PROCEDURE
Theory

THERMISTORS.

Temperature – measuring sensor based on the fact that the resistance of a material may change with
temperature is known as a THERMISTOR. Thermostats differ from resistance temperature detectors in that they are
fabricated from semi conducting materials instead of metals. The semi – conducting materials, which include oxides of
copper, cobalt, manganese, nickel and titanium, exhibit very large change in resistance with temperature.

22
Resistance with temperature can be expressed by an equation of the form

Inp = A0 + A1 / T + A2 / T2 + …………. + An / Tn

Where P is the specific resistance of the material.

A1, A2, ……………………….An are material constants.

T is the absolute temperature.

Thermistor have many advantage over other temperature sensors and are widely used in industry. They can be small
and consequently, permit point sensing and rapid response to temperature change. Their high resistance minimizes lead
– wire problems. Their out put is more than 10 times that of a resistance temperature detector. The disadvantages of
thermistor includes non linear out put with temperature and limited range.
Since the instrumentation tutors are not instrument as a whole the accuracy of the measurement cannot be claimed. It is
very clear that the instrumentation tutor are only for demonstration purpose and cannot be used for any external
measurement other than conducting experiments.

CIRCUIT EXPLANATION

The circuit comprises of three parts.

1. POWER SUPPLY
2. SIGNAL CONDITIONING AND AMPLIFYING
3. ANALOG TO DIGITAL CONVERTER.

1. POWER SUPPLY.
Inbuilt power supply use power to all electronic devices inside the circuitry. High stable regulated Power
supply is used for better performance.
There are three different power supply inside the unit.

+12-0 012 V 500mA to drive digital integrated circuitry.

+5-0—5V 250mA to drive A to D converter.

2. SIGNAL CONDITIONING AND AMPLIFYING

The circuitry comprises of signal conditioner and amplifier. The output of the sensor is amplified to required
level. The Thermocouple gives out directly which is amplified. Thermistor and RTD are connected to the ground
through a resister, and the voltage is applied to the other end of the sensor. The resistance change in the sensor will
gives the mV out put which is amplified and controlled. Analog out put is fad to the ADC.

3. ANALOG TO DIGITAL CONVERTER.

The output from the amplifier is a linearised analog DC voltage. This analog output is converted into digital
output with the help of IC 7107 3.5 digit 200mA. A to D converter. Then it is displayed through seven segmented
LEDs.

PANEL DETAILS
DISPLAY : 3 ½ Digit LED Display of 200 mV FSD.
INITIAL SET : Single turn potentiometer to set Initial Temperature
(Room Temperature)
FINAL TEST : Single turn potentiometer to Calibrate the instrument
(Max. Temperature)
SELECT : 3 Way rotary switch to select Thermister.
POWER ON : Rocker switch to control power supply to the
instrument.

23
 CONNECTION DETAILS

POWER : 3 pin mains cable is provided with the instrument.

Connect the 3 pin socket to the instrument at the rear panel and to the AC mains
230v supply.

NOTE : Before connecting ensure the voltage is 230 V and the

Power switch is in off position)

SENSORS : Connect Thermistor to the

connector on the rear panel.

OPERATING PROCEDURE

Check connection made and Switch ON the instrument by rocker switch at the front panel.
The display glows to indicate the instrument is ON.
Allow the instrument in ON Position for 10 minutes for initial warm-up.
Pore around 3/4th full of water to the kettle and place sensors and thermometer inside the kettle.
Note down the Initial water temperature from the thermometer.
Select the sensor on which the experiment to be conducted through selection switch on the front panel.
Adjust the Initial set Potentiometer in the front panel till the display reads initial water temperature.
Switch on the kept and wait till the water boils note down the reading inn the thermometer and set Final set
potentiometer till the display reads boiling water temperature.
Remove the sensor from the boiling water immerse it I the cold water. Set the cold water temperature using initial set
potentiometer.
Repeat the process till the display reads exact boiling water and cold water temperature. Change the water in the kettle
with and re heat the water. Now the display starts showing exact temperature raise in the kettle.
Experiment can be repeated for all the three sensors. Temperature in the thermometer and the indicator readings in
steps of 100 C can be tabulated.

EXPERIMENTS AND TABULAR COLUMN-1

EXPERIMENT TO MEASURE TEMPERATURE USING THERMISTOR:

Experiment can be conducted on the instrument as per the operating instruction given above for Thnermistor and
various parameters like Linearity. Accuracy, Hysteresis etc, can be calculated. The readings can be tabulated and
graphs can be plotted to calculated the above parameters.

TABULAR COLUMN-1

THERMOMETER REARING 0C THERMISTER

SL.
(Actual Temperature)
NO 0
C

Graphs: Actual reading V/s indicator Reading

24
 EXPERIMENTS AND TABULAR COLUMN – 2

EXPERIMENT TO STUDY THE CHARACTERISTICS OF THERMISTER.

 Remove the YELLOW & GREEN terminals of the sensors from the instrument
 Connect Thermistor to Ohm-meter to measure ohms.
 Tabulate the readings in the tabular column given below. Plot the graphs for Temperature change in the
thermometer V/s Change in the millivolt/Resistance

TABULAR COLUMN-1

EXPERIMENT-2

THERMOMETER REARING 0C THERMISTER

SL. 0
C
(Actual Temperature)
NO

Questions:

1. What is the principle of Thermistor?

2. What is calibration?
3. How Thermistor used for Temperature measurement?
4. What are the advantages of Thermistor?
5. What is the replacement for temperature measurement if Thermistor is not there?

25
 EXPERIMENT NO.6

CALIBRATION OF HOT WIRE ANEMOMETER FOR TEMPERATURE

MEASUREMENT.

26
1. FEATURES

* Thermal anemometer, available for very low air velocity measurement.

* Slim probe, ideal for grilles & diffusers.
* Combination of hot wire and standard thermistor, deliver rapid and precise measurements even at
low air velocity value.
* Microprocessor circuit assures maximum possible accuracy, provides special functions and features.
* Super large LCD with dual function meter's display, read the air velocity & temp. at the same time.
* Heavy duty & compact housing case.
* Records Maximum and Minimum readings with recall.
* Data hold.
* Operates from 0O6P DC 9V battery.
* RS 232 PC serial interface.
* The portable anemometer provides fast, accurate readings, with digital readability and the
convenience of a remote probe separately.
* Multi-functions for air t1ow measurement: m/s, km/h, ft/min, knots. mile/h.
* Build in temperature °C, °F of measurement.
* Thermistor sensor for Temp. measurement, fast response time.
* Used the durable, long-lasting components, including a strong, light weight ABS-plastic housing
case.
* Deluxe hard carrying case.
* Applications: Environmental testing, Air conveyors, Flow hoods, Clean rooms, Air velocity, Air
balancing, Fans/motors/blowers, Furnace velocity, Refrigerated case, Paint spray booths.

2. SPECIFICATIONS
2-1 General Specifications

Circuit. Custom one-chip of micro processor LSI circuit

Display * 13 mm (0.5”) Super large LCD display
* Dual function meter’s display
Measurement m/s (meters per second)
km/h (kilometers per hour)
ft/min (feet/per minute)
knote (nautical miles per hour)
mile/h(miles per hour)
Temp – oC, oF.
Data hold.
Sensor Air Velocity:
Structure Tiny glass bead thermistor.
Temperature:
Precision thermistor.
Memory Maximum and Minimum with recall.
Sampling Time Approx. 0.8 sec.
Data output RS 232 PC serial interface.

27
 Operating Temperature 0 0C to 50 0C (32 0F to 122 0F).
Operating Humidity Less than 80% RH.
Power Supply 1.5 V AAA (UM-4) battery x 6 PCs. (Alkaline or heavy
duty type).
Power Supply Approx. DC 30 mA.
Weight 355 g/o0.78 LB.
Dimension Main instrument.
180x72x32 mm (7.1x2.8x1.3 inch)
Telescope Probe.
Round, 12 mm Dia x 280 mm (min. length).
Round, 12 mm Dia x 940 mm (max. length)
Accessories included Instruction manual……………….1 PC.
Telescope Probe………………….1 PC.
Hard carrying case……………….1 PC.

A. Air Velocity
Measurement Range Resolution Accuracy
m/s 0.2-20.0 m/s 0.1 m/s
km/h 0.7 - 72.0 km/h 0.1 km/h ± (5% + 1 d )
Reading or
ft/min 40-3940 ft/min 1 ft/min
± (1%+1d)
mile/h 0.5-44.7 mile/h 0.1 mile/h full scale
knots 0.4-38.8 knots 0.1 knots

Note: m/s - meters per second km/h - kilometers per hour

ft/min - feet/per minute knots - nautical miles per hour
mile/h - miles per hour (international knot)

Remark:
Spec. tested under the environment RF Field Strength less than 3 VIM & frequency less than the 30 MHz only.

28
3. FRONT PANEL DESCRIPTION

Fig. 1
3-1 Display
3-2 Power Off/On Button
3-3 Data Hold Button
0 0
3-4 C/ C
3-5 Memory “Record” Button
3-6 Memory “CALL” Button
3-7 Zero Button
3-8 Unit Button
3-9 Battery Compartment/Cover
3-10 RS232 Output Socket
3-11 Probe Input Socket
3-12 Sensing Head
3-13 Probe Handle 3-14 Probe Plug

29
5) a. Slide the sensor cover to the down position, let the air velocity sensor to
contact the air, refer Fig. 3.
b. Extent the telescope probe to the convenient length, refer Fig.4.

air velocity
sensor
(do not touch by
fingers or tools)

“Sensor cover”
slide to the low
position when
make the
measurement

Probe Handle

Fig. 3
Caution !!! Fig.4

Do not use the fingers or any tools to touch the air velocity sensor, otherwise the meter may happen the
permanent damage.

6) Direction of the sensor head:

There is a mark on the top of the “Sensor Head”, When make the measurement, then this mark
should against the measured wind refer Fig. 6, Fig. 7. When sensor head face against the
measurement air, then the upper display will show the air velocity value. The lower display will
show the temperature value.

Sensor head (side view)

Direction mark
should face the
measured wind.

Probe Handle
Sensor head (top view)
Fig. 6
Direction mark should face the measured wind.

Fig. 7

30
7) Data Hold:
a. During measurement, pushing the “Data Hold Button” (3-3, Fig. 1) will hold the display values
& the LCD will show the “D.H” symbol
b. To cancel the Data Hold function, Press the Data Hold Button once more.

8) Data Record (Max. & Min. reading)

a. The Data Record function displays the maximum & minimum readings. To start the Data
Record function, press the “Record Button” (3-5, Fig. 1) once. “REC” symbol will appear on the
LCD display.
b. With the “REC” symbol indicated on the display
* Push the “CALL Button” (3-6, Fig. 1) once, then the “Max” symbol with the maximum
values recorded will appear on the LCD display.
* Push the “CALL Button” once again, the “Min” symbol with the minimum values recorded
will appear on the LCD display.
* To de-activate the Data Record function, Press the “Record Button” (3-5, Fig. 1) once
again. All associated anunciators will disappear from the display.

9) For quick measurement, follow the procedures shown below:

Main Procedures:

Power * Select the oC or oF Zero

* Determine the display unit
On
Optional measuring procedures:

DATA HOLD MEMORY RECORD

5. RS 232 PC SERIAL INTERFACE
Max. Min.
The instrument features an RS232 output via 3.5 mm “RS232 Output Socket” (3-10,
Fig. 1).

The connector output is a 16 digit data stream which can be utilized to the users’s specific
application.

An RS232 lead with the following connection will be required to link the instrument with the PC
serial input.

Meter PC
(3.5 mm jack plug) (9W ‘D” Connector)

Center Pin…………………………………………………Pin 2
Ground/Shield……………………………………………..Pin 5

The 16 digit stream will be displayed in the following format:

D15 D14 D13 D12 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0

Each digit indicate the following status:

D0 End Word
D1 to D4 Upper Display reading, D1=LSD, D4=MSD
D5 to D8 Lower Display reading, D5 = LSD, D8 = MSD
D9 Decimal Point(DP) for Upper display.
0 = No DP, 1= 1 DP, 2 = 2 DP, 3 = 3 DP
31
 D10 Decimal Point (DP) for lower display
0 = No DP, 1 = 1 DP, 2 = 2 DP, 3 = 3 DP
D11 & D12 Anunuciator for Upper Display
00= No Symbol 07 = mg/L 14=mS
01 = 0C 08 = m/s 15=Lux
0
02 = F 09 = Knots 16=Ft – cd
03= % 10=km/h 17= dB
04= % RH 11=Ft/min 18=mV
05 = % PH 12=mile/h
06=% O 2 13= uS
D13 Anunuciator for Lower Display
0 =No Symbol 1= 0C 2 = 0F
D14 Reading Polarity for the Display
0 = Both upper & lower display value are “+”,
1= Upper “__” Lower “+”
2= Upper “__” Lower “__+
3= Both upper & lower display value are “_”
D15 Start Word
6. BATTERY REPLACEMENT

1) When the left corner of LCD display show “LBT”, it is necessary to replace the battery. However, in
– spec measurement may still be made for several hours after low battery indicator appears before
the instrument become inaccurate.

2) Slide the “Battery Cover” (3-9, Fig. 1) away from the instrument and remove the battery.

3) Install the 1.5 V AAA (UM-4) battery x 6 PCs. Please use the Alkaline of heavy duty type battery.
When install the batteries, then reinstate the battery cover.

32
 EXPERIMENT NO.7
CALIBRATION OF PRESSURE GAUGES

Pressure measurement using Pressure cell

CONTENTS
1. THE INSTRUMENT
2. CIRCUIT EXPLANATION
3. SPECIFICATION
4. PANEL DETAILS
5. CONNECTION DETAIL & OPERATING PROCEDURE

THE INSTRUMENT

UNIQUE Digital pressure measuring setup comprises of pressure indicator and pressure cell with loading system.
Pressure indicator is a strain gauge signal conditioner and amplifier used to measure pressure due to load applied on
the pressure cell. The strain gauge are bonded on the diaphragm and are connected in the form of whetstones bridge. A
foot pump of capacity 7Kg/cm2 is provided to load the Pressure cell UNIQUES Pressure measuring setup in a complete
system which can be used to conduct measurement of pressure applied on the Pressure cell. The pressure indicator is
provided with zero balancing facility through adjustable potentiometer. Digital display will enable to take error free
readings.

The digital indicator comprises of four parts.

1. Power supply 2. Signal conditioning 3. Amplifier
4. Analog and digital converter.
The inbuilt regulated power supply used will provide sufficient power to electronic parts and also excitation voltage to
the strain gauge bridge transducers. The signal conditioner Buffers the output signals of the transducers. Amplifier will
amplifies the buffered output signal to the required level where it is calibrated to required unit. Analog to digital
converter will convert the calibrated analog out put to digital signals and display through LED’s.

33
THEORY:

Transducers that measure force, torque or pressure usually contains an elastic member that converts the quantity to be
measured to a deflection or strain. A deflection sensor or, alternatively, a set of strain gauges can be used to measure
the quantity of interest (force, torque or pressure) indirectly. Characteristics of transducers, such as range, linearity and
sensitivity are determined by the size and shape of the elastic member, the material used in its fabrication.
A wide variety of transducers are commercially available for measuring force. Torque and pressure the different elastic
member employed in the design of these transducer include link, columns, rings, beams, cylinders, tubes, washers,
diaphragms, shear webs and numerous other shapes of special purpose applications. Strain gauges are usually used as
sensors; however linear variable differential transformers (LVDT) and linear potentiometers are some time used for
static or quasistatic measurement.

PRESSURE MEASUREMENT (PRESSURE CELL).

Pressure cells are divisors that convert pressure into electrical signal through a measurement of either displacement
strain or Piezoelectric response. Diaphragm type pressure transducers with strain gauges as sensor is used here for
measurement of pressure.

This type of pressure transducers uses diaphragm as the elastic element. Diaphragms are used for low and middle
pressure ranges. Strain gauges are bonded on the diaphragm and the pressure force is applied to the specimen the
material gets elongated or compressed due to the force applied i.e., the material get strained. The strain incurred by the
specimen depends on the material used and its elastic module. This strain is transferred to the strain gauges bonded on
the material resulting in change in the resistance of the gauge. Since the strain gauges are connected in the form of
whetstones bridge any change in the resistance will imbalance the bridge. The imbalance in the bridge will intern gives
out the output in mV proportional to the change in the resistance of the strain gauge.

CIRCUIT EXPLAN ATION

The circuit comprises of three parts.

1. POWER SUPPLY
2. SIGNAL CONDITIONING AND AMPLIFYING
3. ANALOG TO DIGITAL CONVERTER.

1. POWER SUPPLY:
Inbuilt power supply use power to all electronic devices inside the circuitry. High stable regulated Power
supply is used for better performance
There are two different power supply inside the unit
+12 – 0 -12V 500mA to drive digital integrated circuitary.
+5 – 0 - -5V 250mA to drive A to D converter.

2. SIGNAL CONDITIONING AND AMPLIFYING

Signal conditioner will process the output of transducer and presents a linear DC voltage to the amplifier. This circuit
will also buffers the inputs signal given to the differential amplifier. The operations amplifier is used as a differential
amplifier where the signal gets amplified to required level. The amplifier gives out the analog output.
This output is controlled and calibrated to get the linear to micro strain. This analog output is sed to the A to D
converter.

3. ANALOG TO DIGITAL CONVERTED.

The output from the amplifier is a linearised analog DC voltage. This analog output is converted into digital output
with the help of IC 7107 3.5 digit 200mV A to D converter. Then it is displayed through seven segmented LED’s.

34
 SPECIFICATIONS
MEASUREMENT OF PRESSURE

PRESSURE CELL :

SENSOR : strain gauges bonded on steel diaphragm for

pressure measurement.

TYPE : Diaphragm

RANGE : 10 Kg/cm2
CONNECTION : Through four cure shielded cable with the connector
Attached
EXCITATION : 10V DC
ACCURACY : 1%
LINEARITY : 1%
MAX OVER LOAD : 150%
MECHANICAL
CONNECTION : 1/4 INCH BSP thread.

INDICATOR:
DISPLAY : 3 ½ digit seven segment LED display is used for the
indicator of 200mV full scale deflection to read +/- 1999’
EXCITATION : 10 V DC
ACCURACY : 1%
TARE : Front panel zero adjustment through Potentiometer
POWER SUPPLY : 230 V +/- 10% 50 Hz

35
 CONNECTION DETAILS

POWER : 3 pin mains cable is provided with the instrument.

Connect the 3 pin socket to the instrument at the rear panel and to the AC mains
230v supply.

NOTE : Before connecting ensure the voltage is 230 V and the Power switch is in
off position.

SENSOR : Connect one end of the cable attached with connector to

the sensor and the other end to the instrument. While connecting match the colors
of the wires with the connectors.

36
 OPERATING PROCEDURE

* Check connection made and switch ON the instrument by rocker switch at the front panel. The display glows
to indicate the instrument is ON.
* Allow the instrument in ON Position for 10 minutes for initial warm-up.
* Adjust the Potentiometer in the front panel till the display reads “000”
* Apply pressure on the sensor using the loading arrangement provided.
* The instrument reads the pressure coming on the sensor and display through LED. Readings can be tabulated
and % error of the instrument, linearity can be calculated.

EXPERIMENTS AND TABULAR COLUMN

Experiments can be conducted on the instrument as per the Operating Instruction

given and various parameters like Linearity. Accuracy, Hysteresis etc of the Pressure indicator can be calculated. The
readings can be tabulated and graphs can be plotted to calculate the above parameters.

TABULAR COLUMN

EXPERIMENT-1

1 2 3 4 5
SL.NO. ACTUAL INDICATOR 3-2 ERROR % ERROR
PRESSURE READING
Kg cm2 Kg/cm2

ColumnNo.4
% Error = X 100
MaxLoad
Graphs: Actual reading V/s indicator Reading

SPECIMEN READINGS

EXPERIMENT-1
1 2 3 4 5
SL.NO. ACTUAL INDICATOR 3-2 ERROR % ERROR
PRESSURE READING
Kg/cm2 Kg/cm2
1 1.0 0.9 -0.1
2 2.0 2.0 0
3 3.0 3.0 0
4 4.0 4.0 0
5 5.0 5.1 0.1
6 6.0 6.1 0.1
7 7.0 7.1 0.1

37
 EXPERIMENT NO. 8
CALIBRATION OF STRAIN GAUGE FOR TEMPERATURE MEASUREMENT.

CONTENTS

1. INTRODUCTION
2. SPECIFICATION
3. CANTILIVER BEAM DIAGRAM
4. CONNECTION DETAILS
5. OPERATING PROCEDURE

SPECIFICATION

DISPLAY RANGE : 31/2 digit RED LED display of 200 mV

FSD to read up to +/- 1999 micro strain.
GAUGE FACTOR SETTING : 2.1
BALANCE : Potentiometer to set zero on the panel
BRIDGE EXCITATION : 12V DC
BRIDGE CONFIGURATIONS : Full Bridge
MAX. LOAD : 1 Kg
POWER : 230 V+/- 10% at 50Hz with perfect
Grounding

38
All specification nominal or typical at 230 C unless noted.

CANTILEVER BEAM SPECIFICATION

MATERIAL : Stainless Steel

BEAM THICKNESS (1) : 0.25 Cm
BEAM WIDTH (b) : 2.8 Cms
BEAM LENGTH (Actual) : 22 Cms
YOUNGS MODULUS (ε) : 2X106 Kg / cm2
STRAIN GAUGE : Foil type gauge
GAUGE LENGTH (F) : 5 mm
GAUGE RESISTANCE (R) : 300 Ohms
GAUGE FACTOR (g) : 2.01

INTRODUCTION

The primary object of the INSTRUMENTATION TRAINER is to introduce and to educate electronic instrumentation
systems in a manner sufficiently complete that the students will acquire proper knowledge and the idea about the
transducers and their applications to measure mechanical and terminal quantities. The mechanical quantities include
strain, force, pressure torque, displacement, acceleration frequency, etc. The terminal quantities include temperature
and heat flux.

It is understood that the students will have a conceptual understanding of these quantities through exposure of
mechanics or physics courses, such as static’s, dynamics, strength of materials or thermodynamics. The students
experience in actually measuring these quantities by conducting experiments, however, will usually the quit limited. It
is an objective of this tutor to introduce methods commonly employed in such measurements and the usage of such
electrical components such as capacitance, resistance, intensity, etc.

Emphasis in the instrumentation trainer will be directed toward electronic instrumentation systems rather than
mechanical systems. In most cases electronic systems provide better data more accurately and completely characterize
the design or process being experimentally evaluation. Also the electronics system provides an electrical out put signal
that can be used for automatic data reduction or for the control of the process. These advantage of the electronic
measurement system over the mechanical measurement system have initiated and sustained trend in instrumentation
toward electronic methods.

An attempt is made through these “Instrumentation trainer” to make as easy as possible for the students to learn about
the electronic instrumentation system and various transducers used for the measurement of mechanical component.
The instrumentation tutor panels are design in such a way that the block diagrams of the stages of electronic
instrumentation system are clearly pictured on them. This makes the instrumentation tutor self-explanatory and also the
best teaching aid for Engineering students.

Since the instrumentation tutors are not instruments as a whole the accuracy of the measurement cannot be claimed. It
is very clear that the instrumentation tutor are only for demonstration purpose and cannot be used for any external
measurement other than conducting experiments.

THE ELECTRONIC INSTRUMENTATION SYSTEM.

The complete electronic instrumentation system usually contains six sub systems or elements.

39
The TRANSDUCER is a devise that convert a change in the mechanical or thermal quantity being measured into a
change of an electrical quantity. Example strain gauges bonded in to an specimen, gives out electrical out put by
changing its resistance when material is strained.

SIGNAL
TRANSDUCER CONDITIONER AMPLIFIER RECORDER

POWER SUPPLY DATA

PROCESSOR

The POWER SUPPLY provides the energy to drive the Transducers, example differential transformer, which is a
transducer used to measure displacement required an AC voltage supply to excite the coil.

SIGNAL CONDITIONERS are electronic circuits the convert, compensate, or manipulate the out put from in to a
more usable electronic quantity. Example the whetstone bridge used in the strain transducer converts the change in
resistance. AR to a change in the resistance AE.

AMPLIFIERS are required in the system when the voltage out put from the transducer signal conditioner combination
is small. Amplifiers with game of 10 to 1000 are used to increase their signals to levels they are compatible with the
voltage – measuring devices.

RECORDERS are voltage measuring devices that are used to display the measurement in a form that can be read and
interpreted Digital/Analog voltmeters are often used to measure static voltages.

DATA PROCESSORS are used to convert the out put signals from the instrument system into data that can be easily
interpreted by the Engineer. Data processors are usually employed where large amount of data are being collected and
manual reduction of these data would be too time consuming and costly.

THE INSTRUMENT

UNIQUE Digital strain measuring setup comprises of Strain Indicator and Cantilever Beam setup strain Indicator is a
strain gauge signal conditioner and amplifier used to measure strain due to load applied on the cantilever beam. The
strain gauge are bonded on the cantilever beam and are connected in the form of whetstones bridge. A pan and weights
upto 1 Kg is provided to load the cantilever beam. Unique strain measuring setup is a compete system which can be
used to conduct measurement on strain gauge. The strain indicator is provided with zero balancing facility through
adjustable potentiometer. Digital display will enable to take error free readings.

The digital indicator comprises of four parts.

1. Power supply 2. Signal conditioning
3. Amplifier 4. Analog and digital converter.

The inbuilt regulated power supply used will provide sufficient power is electronics parts and also excitation voltage to
the strain gauge bridge transducers. The signal conditioners Buffers the output signals of the transducers. Amplifier
will amplifies the buffered output signal to the required level where it is calibrated to required unit. Analog to digital
converter will convert the calibrated analog output to digital signals and display through LED’s.

40
THEORY BEHIND IT

When a material is subjected to any external load, there will be small change in the mechanical properties of the
material. The mechanical property may be, change in the thickness of the material or change in the length depending
on the nature of load applied to the material. This change in mechanical properties will remain till the load is released.
The change in the property is called strain in the material or the material get strained. So the material is mechanically
strained this strain is defined as. The ratio between change in the mechanical property to the original property. Suppose
a beam of length L is subjected to a tensile load of P Kg the material gets elongated by a length of □1. So according to
the definition strain S is give by

S = □1/L …………Eq 1

Since the change in the length of the material is very small it is difficult to measure □1. So the strain is always read in
terms of micro strain. Since it is difficult to measure the length Resistance strain gauges are used to measure strain in
the material directly. Strain gauges are bonded directly on the material using special adhesives. As the material get
strained due to load applied, the resistance of the strain changes proportional to the applied. This change in resistance
is used to convert mechanical property in to electrical signal which can be easily measured and stored nor analysis.

The change in the resistance of the strain gauge depends on the sensitivity of the strain gauge. The sensitivity of strain
gauges is usually expressed in terms of a gauge factor Sg where Sg is given as

∆R/R = Sg …………Eq 1

Where □is Strain in the direction of the gauge length.

The output □R / R of a strain gauge is usually converter in to voltage signal with a Whetstones bridge, If a single gauge
is used in one arm of whetstones bridge and equal but fixed resistors is used in the other arms, the output voltage is

Eo = Ei / 4 (□Rg/Rg) ……………….Eq 3.

Substituting Eq2 into Eq3 gives

Eo = Ei 1 / 4 (Ei Sg □) ……………….Eq 3.

……. Eq 4
The input voltage is controlled by the gauge size (the power it can dissipate) and the initial resistance of the gauge. As
a result, the output voltage Eo usually ranges between 1 to 10 □ V/micro units of strain.

41
42
 OPERATING PROCEDURE

 Check connection made and Switch ON the instrument by toggle switch at the back of the box. The display
glows to indicate the instrument is ON.
 Allow the instrument in ON Position for 10 minutes for initial warm-up.
 Adjust the ZERO Potentiometer on the panel till the display roads ‘ OOP’.
 Apply load on the sensor using the loading arrangement provided in steps of 100g upto 1 Kg.
 The instrument display exact microstrain strained by the cantilever beam.
 Note down the readings in the tabular column. Percentage error in the readings. Hysteresic and Accuracy of
the instrument can be calculated by comparing with the theoretical values.

Specimen Calculation For Cantilever Beam

S=(6pl) BT2E

P = Load applied in Kg (1 Kg) – 0.2 kg

L = Effective length of the beam in Cms. (22 Cms)
B = Width of the beam (2.8 Cms)
T = Thickness of the beam (0.25 Cm)
E = Young’s modulus (2X106)
S = Micro strain

Then the micro strain for the above can be calculated as follows.

6 X 1X 22
S =
2.8 X 0.25 X (2 X 10 6 )
S = 3.77 X 10 4
S = 377 micro strain

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 EXPERIMENT NO.9

STUDY AND CALIBRATION OF PHOTO AND MAGNETIC SPEED PICKUPS FOR THE
MEASUREMENT OF SPEED

Speed Measurement by Stroboscope

Aim: To measure the Speed by an optical method called as Stroboscope.

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Introduction:
Theory:
Apparatus:

1. Xenon Flash Lamp

2. Adjustable Motor
3. Marked Rotating Wheel
4. Stand for set up
5. Power Supply

Procedure:

1. Check the connections of the equipment.

2. Select the mode of operation on Xenon flash lamp (Hi/lo).
3. Make a mark on the rotating wheel.
4. Now switch on the Xenon flash lamp and adjust that the light exactly projected on the rotating wheel.
5. Adjust the speed of the motor such that ONE STATIONARY mark is visible on the wheel. Note down the
reading in the tabular column.
6. Now adjust the sped of the motor such that Two Stationary marks are visible and note the readings.
7. Similarly for Three and more marks and note the readings.

Tabular column:
S.No No. of images Reading on the Frequency
Xenon Flash
Lamp

Questions:

1. What is the Principle of Stroboscope?

2. What are the applications of Stroboscope?
3. Specifications of Stroboscope?
4. What are the Applications of Stroboscope?
5. What are the advantages and disadvantages of Stroboscope?

45
 EXPERIMENT NO.10
STUDY AND CALIBRATION OF A ROTAOMETER FOR FLOW MEASUREMENT.

ROTAMETER

The obstruction is a float that rises in a vertical tapered column. The lifting force and thus the distance to
which the float rises in the column is proportional to the flow rate. The lifting force is produced by the differential
pressure that exists across the float, because it is a restriction in the flow. This type of sensor is used for both liquids
and gases. A moving vane flow meter has a vane target-immersed in the flow region, which will be roted out of the
flow as the flow velocity increases. The angle of the vane is a measure of the flow rate.

FLOW CONTROL SYSTEM

TURBINE METER:

The turbine flow meter consists of a multi-bladed rotor that is supported centrally in the pipe along which the flow
occurs. The fluid results in rotation of the rotor. The angular velocity bring approximately proportional to the flow rate.
The rate of revolution of the rotor can be determined using a magnetic pick-up. The pulses are counted and so the
number of revolutions of the rotor can be determined.

FLOW CONTROL SYSTEM

Control & Operations:

1. Press flow: This is a D.P.D.T Switch to set the required flow rate.
2. Flow Control: This is a potentiometer to set the flow rate.

Operation:

1. Connect the turbine flow sensor with indicator marked as flow sensor input.
2. Connect the two pin of the motor to the instrument.
3. Now vary the flow control potentiometer to any required set level.
Note: While controlling the flow make sure the pointer in Rotometer floats.
4. Compare the Rotameter reading and digital reading with set reading.
5. Take reading for different set of flows rate.
6. Plot the graph of Rotameter Reading with Digital Indicator Reading.

Description Rotometer:

The air source is centrifugal blower which controlled by the set valve of flow of air measured in L.P.M. The
flow is measured directly on the rotameter. The turbine flow meter senses the flow rate and through microprocessor
based signal conditioner. The flow is measure din digital form and acts us a set point controller also.

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Tabular Column

Sl.No. Set Flow in L.P.M. Rotameter Digital Reading Error Between

Reading in L.P.M. Rotameter & Digital
reading

Note: The range of Flow is 30 L.P.M. to 100 L.P.M.

Indicator Reading

Rotameter Reading

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DISPLAY SYSTEM

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