OPERATION & MAINTENANCE

MANUEL
FOR

PID TRAINER

1
 PID Controller

Theory :
In industrial applications different types of control loops are used so that process parameters
are easily controlled. The 4 basic parameters, which are required to be controlled, are flow,
temperature, pressure and level. Contribution of process parameters is much high while deciding the
controller performance. Controller performance varies from parameter to parameter. Level
controlling is slow and continuous process so if we use PID controller in order to control the level
then it will be quite sluggish and response of controller will also be sluggish. Hence PID controller is
generally used for controlling the temperature.
When PID controller is designed most of the things are not taken into consideration. Due to
this, limitations arise while operating PID controller. e.g. there is a process in which level is
controlled continuously. Water is passing through a pipe. That water is heated with the help of
heating coil. After some time temperature of the heating coil will be quite high. If user is taking set
of readings then there must be difference of 20 between the two sets. e.g. one has started taking
readings by giving set point value as 50 then nest set should be started at set point value 70.so that
there will be proper overshoots and undershoots. It means process value is high so set value or set
point should be above the process value. But if PID is having certain limited range then it will not
possible to adjust the set point value to be greater than process value. Also due to limitation of range
there is also limitation of set of operations to be carried out. Because we can’t give the set point
value beyond certain range. so there will be limitation on no. Of sets of operations to be carried out.
Also one more drawback is time required to stabilize the response will be large. It will cause
large amount of error in controlling the process. Due to which there is lack of accuracy as well as
precision. To overcome all these problems Neeshionics has manufactured the PID controller. This
PID controller is having better frequency response.
The range of the same instrument is also increased so that it will be possible for user to take
no of sets of readings and study the performance characteristics of P, I, D, PI, PD, PID controller.
Operating temperature range is 0-450ºC.
One more advantage of this PID controller is that process cycle time is very less means it will
take only 5 to 10 minutes to complete single process. This will reduce the percentage of errors
occurring.

2
 This PID is also having provision to generate disturbances. Both positive and negative
disturbances can occur. If disturbances occur after stabilizing the system then controller will check
for the disturbances and will take the proper corrective action to compensate it. This will be the
indication of proper working of PID controller. To generate the disturbances there is switch on the
front panel of PID controller. After checking is done the switch is turned off.
This PID controller is user friendly and also there is provision to interface the PID with PC.
For that serial communication cable like RS232 or RS485 is used. Due to this facility one can see the
system performance on PC. Communication between PID controller and PC is user-friendly
communication. Online trend plotting is also possible.

3
 PID TRAINER
Study of the PID controller, study of various control actions/ modes like On- Off, P, PI, PD &
PID etc. and the performance of all the controllers with effect of min, max & moderate constants. To
study PID trainer using nicholus-ziggler method. To study PID auto tuning. To study the PID
control action against process disturbance for a given process of temperature. Study step response of
all PID control actions / Modes.

Aim: To study the PID controller

a) To study the ON-OFF control action
b) To study the Proportional, Integral & Derivative actions on a given process.
c) To study the effects of P, I & D constants on a given process when the constants
are very LOW, very HIGH & MODERATE.
d) To study the P, PI, PD & PID actions on the given process.
e) To study step response for all above set-ups.
f) To study the PID auto tuning method using Nicholas- Ziegler method.
g) To study the PID corrective action on positive & negative disturbance generated.
h) To study the Real Time On Line Process Trend Plot on PC. (Optional)

Apparatus: 1) PID Trainer

2) Software CD (Optional )

Precautions: 1) Ensure the PID trainer is connected to 230 V AC mains.

2) Ensure No any error detected while self-diagnostic check during power ON.
3) Ensure the Proper mode of control action is selected.
4) Ensure the Proper PID constants are programmed.
5) Ensure the Proper set point is programmed.

Procedure: 1) Connect the PID trainer to 230 V AC mains.

2) Turn ON the mains & observe self-diagnostic tests.
3) Ensure no error while self-diagnostic check.
4) Set appropriate PID constants
5) Set OUT% Output percentage to 100%
6) Set proper Set value

4
 7) Select the controller mode, refer the PID controller mode selection chart:
8) Note the observations
9) Give step change to SV
10) Repeat from step 8

PID controller mode selection:

a) On-Off Control P=I=D=0
b) Proportional control P = xxx (0 – 200%) I = D = 0
c) PI control P=M I = xxx (0 – 3600 Sec) D = 0
d) PD control P=M D = xxx (0 – 900 Sec) I = 0
e) PID control P = I = D = xxx
f) PID control (tuned) P = I = D = M
xxx: Constants
M: Moderate Constants ie P = 30 I = 6 & D = 2

Observation Table: SV = P= I= D=

Sr. SET VALUE TIME PROCESS VALUE

1.

Shut Down Procedure:

1. Turn the cooling system off.
2. Switch off the PID Trainer
3. Remove the PC interface cable if connected

Graph:

Conclusion:

Self-Assessment Questions:

5
 1. What is the disturbance? List the types of disturbances may occur for flow control loop.
2. What do you mean the tuning of PID?
3. What is the difference between auto tuning of PID and the other methods of PID tuning?
4. List the advantages of PID over ON-OFF controller.
5. Can the PID be replaced by any other means? If YES explain how?

FUNCTIONAL FLOW DIAGRAM OF PID TRAINER: -

(Furnace Temperature)

TEMPERATURE
SENSOR
K-TYPE
THERMOCOUPLE
(Temp. sensor input to PID)
PROCESS VALUE
PID

SET VALUE
(Output of PID to T.M.)

THYRISTERISED
MODULE

(T.M. Controls the Heater)

HEATER

(Heating the Muffle Furnace)

MUFFLE
FURNACE FAN

(Fan for cooling or Disturbance)

6
Block Schematic of PID Trainer:

Heater
Thy. Module

OUT

F IN PID
A PV
Controller SV
N TC
Display
Muffle Furnace SET

Keyboard

Transfer Function of PID Trainer :

G(S) = _________K________________ Where : K = 0.024892

S( 1+TP1* S ) TP1 = 19.118

9
PV
PV 10
11
SV
SV
12

SET < ^ V

3 5 6 7

7
Test Report on process control software: -
Fig:- Effect of Proportional control Action.

Fig:-Effect of Derivative Control Action

8
Fig:- Effect of Integral control Action.

9
Fig:- Effect of PID control Action

Fig:- Effect of On- Off control Action

10
Fig:- Effect of Disturbance

11