RTD Pt-100 Signal Conditioning Module

This is the RTD Signal Amplifier part of Temperature Controller or Indicator. The card also contains a relay on-off control circuit.

The Circuits are –

The PCB Boards –

Two Set Point – Display Card – Process Controller

This is the pcb board details of a Two Set Point Controllers for any process, shown here for temperature. For new types of transducers or input types, module card has to be designed or modified. The other cards remain the same.

The cabinet of these process controllers were made of steel for shielding, but the display card would still pickup EMI in some cases. These were more in instances where the Instrument supply was derived from the motor 3-phase supply. Instrumentation Supplies 230V AC must come from a Lighting Circuit of another supply arm, this has to come after conditioning with EMI-RFI filters and Servo Stabilizers or UPS if possible. This way the load spikes-glitches due to turn-on and turn-off of Motors and Heaters. dont act as a feedback to instruments. If line-load regulation is bad and mains voltage unstable, more problems can be expected.

This front panel shielding was done with a semi farady cage, by having a ground plane on the front of PCB, facing operator. This is just the negative of solder mask, but is the copper layer in front, no pth processing, even though it is two layer pcb. The solution worked well.

Display Card - Shield

Proportional Module for Process Controller

When you need a proportional control output, either 4-20mA or Time Proportional On-Off, This module is used. It does a slow PWM control, the cycle time for SSR or Thyristor Banks can be closer to Mains Frequency. The 4-20mA can be used to drive motors for turning valves for fuel or fluid heat control.

Schematics of Module

Board of Module

Thermocouple and Current Input Module

This input module converts J, K Thermocouple and 4-20 mA Inputs to 0-2V Full Scale. These can be used for any voltage/current inputs too. The RTD module can be modified more easily for Voltage inputs. The control output can be On-Off or 4-20 mA/Proportional with another card. The 4-20mA I/O STC1000I is not complete in documentation.

This is a Input Signal Conditioning Card for the Temperature controller. The voltage levels from sensors are either too low or need to be translated in level and span. Then for greater accuracy some linearization methods have to be used for a more precise reading. This also increases the cost. The circuits here do no cover the linearization see others in this and my related pages.

The step or segment linearization can be done by transistor, diode or CMOS switches to accomplish varying attenuation/gain for stages of the curve or voltage levels. In Microcontroller systems it can be done by lookup tables or math.

In some older digital systems without a MCU, the A to D drives the address of an Eprom Array to get a Digital Data for Display, as a linearized Reading. This Corrected Data was in turn made into analog using a D/A and then on to a Chart Recorder. This was a Logic only System of the early days. Microprocessor systems was expensive, power consuming and use to frighten people by getting lost in loops or a short nap.(they have fixed that, make sure you code properly).

Input Module - J and K Thermocouple with 4-20 mA

Input Module – J and K Thermocouple with 4-20 mA

PCB Boards of the Module

Temperature Controller Main Card

This contains the Main card with a Power Supply and Relay Control. On this card is connected the Display ICL7107 – Temperature controller.

The Thermocouple and Control Modules can be plugged into this card, these change the type of control and type of inputs. This way this can be made into any parameter controller with any type of input and output. But it is all set in production, not configurable at site.

So even if you make a 4-20mA output Flow Controller with this, the Main card and Display card remains the same. Only the Modules change. No Connectors are used, to make it vibration resistant.

The PCB Layout is here

Display ICL7107 – Temperature controller

This is the Display Circuit and PCB part of of section Temperature Control.

The above circuit is powered by +5 and -5 from a LM7805 and LM7905 pair. If +/- 12V or +/- 7.5V is used in opamp or digital parts, then use below circuit for the DPM section.

5 V Dual Supply with Zeners

The PCB for above

The PDF Circuit for above Display Card STC1000

Proportional Temperature Controller

Proportional Temperature Controller

This is a Proportional Controller where the setpoint is derived from a Thumbwheel switch.

Proportional Temperature Controller

The conversion of Thumb-wheel Digital Data to Analog mV is similar to R-2R Weighted Resistor Network. In this case it is a 1-2-4-8 Binary Weighted Resistor Network. It has no Digital Components.

You can see an example circuit below for digit weights you just use like 10K-100K-1M etc. There is a problem of procuring 8M Resistors, so use series parallel combinations, avoid open presets. Trimpots can be used but then it raises the BOM cost.

1-2-4-8 Kilo Ohms may load opamp for high output levels. 1-2-4-8 Mega Ohms may be ok in the lowest digit. Greater than 10M designs are possible only in lab, not in commercial or industrial domains.

Binary Weighted Resistor Network

Make such R networks, solder array on thumbwheel, in some thumbwheels remove diodes or other connections. Club all of them, thumbwheels. One opamp will do. Use -2.5 V for positive mV output. The resistors should be close to 0.3% at least.

This Binary Resistor Network can also work with Digital CMOS Chips like CD4029. Use these chips on a separate supply, which is just a LM336 – 5V device. A digital thumb-wheel also can be used.

In this controller you can see a sensor open indication. When the sensor breaks, the temperature controller may continue to turn on the actuators or heaters, It may even Oscillate. So when a high impedance is detected in the sensor input terminals, the output relay is shut off and a LED is turned on to simplify operator’s diagnosis.

Mount the controller a distance away from heaters, ac-drives and vibrating parts. Avoid direct sunlight on controller, fix controller in a sealed control panel. Earth the point where the thermocouple senses heat. Some heaters leak. The machine has to be earthed.