U1 CD4541 is a Timer with Long Duration Ability. This timer is started by a low pulse from earlier circuit, when the temperature goes above setpoint, a low state is at U2A inputs, this starts the timer. The timer output goes high after a preset time. U2C-D Flip flop is power on reset via cap C7. Even a manual ‘reset’ is used if required. This alarm toggle is ‘set’ when The temperature remains high even after the preset time period of U1.
Timer and Counter Modules – del90002
A digital counter monitors the number of times a process goes beyond a certain temperature limit over a long cycle of time. This circuit has a Analog Timer and Digital Counter. The Analog timer turns on an Alarm if the Temperature Limit transition is very long.
Here 4052 is used as an analog multiplexer, U3A TL062 opamp is wired as a 1mA Constant Current Source. It pumps 1mA into U2 4052 pin 13 X . Depending on BCD code on inputs A, B of 4052 the current is routed to any one of the four RTD 100E, whose one end is connected to X0-X3. The current then flows to GND thru the Platinum 100E resistance. The Y0-Y3 monitors the mV developed on RTD in tandem with X0-X3 positions. Like a ganged rotary switch. The Output mV at Y is the mV of Active Channel as selected by the BCD of 4029.
RTD Pt-100 Four Point Alarm – del90001
The BCD is provided by 4029 counter which is clocked by a 555. U5A cancels out the 100E mV (1mA * 100E) of a cold RTD and Amplifies the differential mV. This output of U5A is in proportion with measured temperature. U5B compares the mV that was obtained with a preset mV of POT1, which is a user setting called setpoint. The difference is amplified by U5B which is saturated by U3B comparator which adds a little hysteresis too. R7-C2 further dampen and slow the response. This finally drives Q2 to provide a Logic Signal indicating if temperature is below or above setpoint.
Four points in a Closed Loop Temperature Control System is Monitored and a Alarm set to go off when the temperature goes beyond the set limit.
Here is a 4-20 mA In/Out Analog Mux with Cascade option. This is a simple circuit i designed to make a Automation System within a budget.
Mixed Circuits Analog with Digital
This takes 4-20mA from many Transmitters and gives out just one 4-20 mA output. The Mux is done with a digital byte or word. This is a slow scanner as process is slow, that way many analog inputs can be multiplexed and sent into one analog input of a D/A. In near real time systems a faster mux could be used or mux totally avoided. This was made in some numbers, so the pcb is better than others.
4-20mA Multiplexer Circuit – pdf
Here is an ancestor of the product in the earlier post. It is a Process Scanner and Indicator. There was no control, but there were individual alarms for each channel.
This is a original design of mine, obsolete now due to size and technology. The inspiration of the product concept was from a Omega Catalog Item. Even today i use the Omega catalog for inspiration, but i do not design complete products, only circuit sections.
The Omega catalog was introduced to me by the MD of a firm i worked in as a R&D Engineer in my young engineer like days. He used to call me and show a catalog product and ask me if i could build something like that. I would then design it working both at home and office, sometimes even in the night, it was just the enthusiasm or creating something new.
I even built the first Pneumatic Tyre Inflater with the help of the CNC director for that firm, this product won a national award in the nineties. I left the firm on a trivial issue which i never disclosed. It was Exhibition time, many new products were not complete, they asked me to make Mockup Dummy Instruments for demonstration only, overnight. I ran away.
Read more about Control Instruments at my pages here
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.
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.
These are the circuits and boards of a Mini Temperature Transmitter for a Platinum hundred ohms temperature Sensor.
RTD-3W-Transmitter Circuit. See my Transmitter Application Note for this.
The customer wanted a two wire system, this needs low power opamps which were ten times the price. If this transmitter works at 3mA it could have been two wire. Those parts were in short supply and the budget of customer was low. So i made it with regular opamps but three wire. The customer was satisfied as he got a cost effective solution. But now the situation of markets and products are different.
If you need to transmit the temperature from a high voltage area or toxic environment. You will need to hermetically seal the transmitters, convert the Voltage to frequency, frequency to IR LED flashes or RF. This can be then remotely monitored. Then the transmitter has to be battery-solar operated, low power too. ICL7135 is a simple solution. It has a serial output that can be used to Drive IR Leds. Remotely sense these flashes in a Micro-controller and you have a reading. You may be able to use optic-fibers too. Where volatile liquids are present so that the risks of sparks can be eliminated.
The PNGs of PCB is 600dpi 16 color. It is to be scaled appropriately.
This is the same Mini RTD Pt-100 Transmitter but in its case. Encapsulated in epoxy, hermetically sealed against harsh industrial environment. This will work well even near fumes of Ammonia with no corrosion. But not near vapors which can be ignited by sparking as terminals are still open. The side view shows zero and full scale ten turn bourns trimpots heads, for calibration. After cal it can be sealed with RTV compound.
This was a Heater which was custom built for a CRT manufacturer, It comprised of many Tubular finned heaters. And probably a big fan that worked at high temperatures. This was used in a Heating Chamber which aged or tested CRT monitors. It had a temperature controller, a remote indicator. Learn about CRT here Cathode-Ray Tube .