delabs (Page 21)

Product Design - Industrial Automation and Instrumentation. -

This is a Low cost controller, Analog Dial Temperature Controller. It is also called Blind Controller. This essentially means Open Loop, just control the fuel or energy input to the system to regulate heat. This is not a Blind Controller that way, it only cannot display the temperature value, that could be another reason it is called blind.

Dial cyclic timers were used to control heat, these were purely mechanical clockwork devices. They could regulate well, when the material flow (liquid) is constant and mains power is regulated. But when the job to be heated, varies in quantity, control temperature is close to ambient or when a precise control is required; closed loop controllers are used. Even a thermostat is like closed loop, as the bimetallic sensor is temperature dependent. But not good enough.

Blind Temperature Controller

This controller is closed loop, precision controller, only the digital display of temperature is absent. Fine one deg variations may not be easy in this.

Blind Temperature Controller

PCB Boards for Blind Controller –

Discussions –

This is the Photo of a RTD 3-W Mains Powered Temperature 4-20mA Transmitter. The Circuits and PCB are here

RTD PT100 Transmitter and Multiplexer.

From Soldermans Basic Electronics

Now with new Technologies like Zigbee and Modbus, We can classify Transmitters as shown below. The Measured Parameter Temperature, Flow or Events Has to reach an Intelligent Data Storage and Analysis System. It may just be an Human Operator who jots the data on a Notepad and Turns a Few Dials based on his Experience or an embedded controller. It could even be a Computer Network or a Web Application used by many, like Monitoring the Weather Attributes.

  • Analog Transmitters – Like 4-20mA Loop.
  • Electrically Isolated Analog Transmitters.
  • Transmitters that need to be Intrinsically Safe.
  • Digital Transmitters and Optical Interface.
  • Wireless Transmitters and TCP-IP.

The job of the transmitter is to take the weak analog measured parameter information from sensor, be close to it, amplify, clean, linearize the signal if required and send strong – error free data over a long distance to an operator or system.

When you have to buffer and invert the polarity of mV input levels. This is the circuit you can use, as OP07 has uV offset. R9 and R10 can be 100K 1% MFR or better. Use a symmetrical dual supply.

Dual Polarity Analog Output

OP07: Ultralow Offset Voltage Operational Amplifier

The proximity switch can work for a wide range of power, from 8v to 18v DC, D3 protects reverse power supply connections, and U1 regulates the supply to +5v , -5v is derived from U2 555 oscillator which serves dual purpose.

Circuit Operation

Part of – InfraRed LED Flasher for Optical Switch

The infra red diode D2 detector gets the reflected light from LED and some ambient light, The forward voltage drop of D2 will vary with the amount of light falling on it. Ambient light causes a DC component and the pulsing light from D1 causes an AC component.

Proximity Switch - Driver Supply

The capacitor C6 blocks DC and only transfers AC pulses if any to opamp amplifier U3A whose gain is set by R18, D9 rectifies the pulses to DC and this DC voltage is used by opamp comparator U3B which drives Q1 through Q2 for an open collector output for relays. LED D7 turns on when relay Output is high.

R14 and R13 can be replaced with potentiometer for threshold adjustment if required.

Testing
Connect 12v DC supply to +V and GND Ports, Connect a relay coil Between OUT and GND Ports, you can use the relay contacts as you require to turn on a lamp, heater, fan or motor.

If all connections are ok and ICs are working you should see a +5V at U3 pin8 VCC and around -4 to -5 at U3 pin4 VDD.

See also – Mixed and Interface Circuits

Optical Proximity Switch - Detector

Construction

The Optic switch can be used for both reflecting detection (retro reflective) or obstacle detection. The mechanical construction will decide this, for obstacle detection the diodes D1 and D2 could be put in two different tubes and can be kept far apart 2mts+ and both should be exactly opposite each other, any obstacle like a passing person will be detected.

To make a retro reflective proximity switch this circuit is ideal, it can be housed in a cylindrical 30mm by 70mm metal unit with m30 threads and nuts for mounting, both D1 and D2 have to be fitted in the front of this tube on a plastic plug optically insulated from each other yet beside each other.

A Center tap 50Hz Step Down Transformer with two diodes is used to get a train of Positive Sine Pulses at 100Hz which is applied to Q6 base via R51. 2N2646 is a unijunction transistor(UJT) in a TO-18 metal package. The control voltage or voltage proportional to error is fed to R56-Q3, The UJT drives a pulse transformer which provides isolation from the Load which the SCR bridge is controlling. This phase angle control gives a near Linear closed loop control for a SCR bridge which may be used in Electroplating or a Preregulator of a big power supply.

2N2646 based Voltage controlled SCR Pulser

A Two Point Process Controller or Temperature Controller would look like this. When a High-Low Alarm Protection for uC based Controller was needed the same was modified and used.

Sometimes uC based instruments just forget and that can be costly, the watchdog timer has solved this problem. In Industrial Process Control we cannot take any chances, so a two tier or even three tier protection is required, especially so if the Job or Raw material being processed is expensive. So Real Time Analog Trip + uC Controller is safe. Then you can still have Electro Mechanical Devices for Extra protection against Fire or Meltdown.

Two Setpoint Temperature Controller

Temperature is the most common process parameter, Pressure seems to be next. Flow, Level, RPM, Distance and many more follow.

When a physical parameter let us say distance is measured, we first need a sensor that converts it into electrical values, digital or analog. The sensor used for length is a Linear encoder and it creates the electrical information for the DRO to Display.

Now many sensors like a strain gauge produce very low and weak signals and some are non-linear. So the signals undergo Amplifying, Temperature compensation and Linearizing together called Signal Conditioning. This stage outputs some standard values like 4-20mA, 0-10 V, 1-5V, or even directly digital or wireless in the new technologies. Even when a digital interfacing standard is used, amplification and some signal conditioning is required at sensor end. Compensation and Linearizing can be better done with a uC using Math or Look up Tables.

When you have many different parameters then it is better to use process controllers with a 4-20mA input standard. Then the inventory of controllers can be reused for any process.

It is always better to use sensor-end transmitters to get 4-20mA to your Controller, Recorder or SCADA System.Weak signals are corrupted by noise and dont travel long wire distance. Junction EMF at joints and terminal blocks add to errors. These are overcome by the 4-20mA signal that has the juice and punch to transmit the data over the shop floor to the control panel rooms.

Read more here Temperature Measurement and Control

This is an Application note i used to give with my ssr – app012.pdf – Ananth

Diagram of SSR 5000 DC 3-30 Control / 230V AC N.O. @ 3A.

This is a Thyristor Based Normally Open 230V Switch that can be turned on / off at a fast rate. This switches at Zero Crossover . Use 5V DC for Best Results.

PCB SSR Wiring

  • No moving parts hence no wear and tear.
  • Dissipates Heat when in On Condition 5 Watts @ 3 Amps.
  • Mount with adequate Air Ventilation for 3 Amps.
  • Dissipation is 1.4 Watts per Amp thru Load.
  • Input to Output is optically isolated 1kV.
  • This one is DC 3-30 Control AC 230V N.O. Output.
  • Off state snubber Leakage is around 1 mA.

Notes –

The Termination’s of High Current Lines going to Load must be very tight and crimped. Loose contacts will Spark and cause Fire.

Fast Blow Fuse is to be used. Use a 2 Amps Fuse with Holder in the Hot Line.