BCD Thumbwheel Switch is used to input-set data in digital form, this can be read by digital circuits, uC and uP systems and PLC-SCADA Interfaces.
Temperature Measurement and Control
In the early transition of analog to digital, before uP became acceptable, Digital systems without uP were made, it even had printers, RAM and displays. The uP systems were coming in, uC had not yet come and uP systems had to still win the confidence of the Prudent Industrial Design Engineer.
The drawbacks of uP based systems used in Computers, in those days were.
- Power Consumption was very high, needed SMPS.
- Many chips, a CPU had a Retinue of many chips.
- Large Board, Double or Multi Sided due to Bus.
- Fussy, Hangs on minor Power Glitches or Resets.
- Needs Firmware Development and Tight Testing.
- Investment in all these areas, Tools and Manpower.
These made Industrial Automation with uP a challenge. CMOS digital and mixed devices and custom application devices were more easy to implement and affordable.
The coming of Low power CMOS uC changed everything and embedded systems became smaller and robust. These were packable in DIN standard and DIN Rail Mounting enclosures.
Coming back to inputting digital data. CMOS uC and Ni-Cd Battery backed up RAM with keyboards made thumb-wheels and other methods less attractive for digital data inputs. Then the Li-Ion Battery, Flash Memory in Combination with Application Specific uC and SOC have made inputting, retaining digital data very easy and affordable.
These are the circuits and boards of a Mini Temperature Transmitter for a Platinum hundred ohms temperature Sensor. Has a 4-20mA sink output. Current Loop can be used for multiple instruments.
Mini RTD Pt-100 Three Wire Transmitter
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.
RTD Mains Power Transmitter
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.
I don’t remember if this circuit worked properly. But a few were made and i might not have shown the modifications that were done to make it work. This was meant to be a portable, low cost, insulation tester for an electrician. If you try it out and debug it it may work well.
High Resistance Insulation Materials
A negative voltage is derived by shifting gnd with two diodes, i feel this did not work very well. Two pins of CD4028 pins are also used to boost the reference to get two extra ranges as 4051 has a 100E on resistance.
The 555 clock makes 4029 counter count. But the clock can be clamped to gnd by a TL062 window comparator. The clock is frozen when the input value to comparator pin 5-2 is within a lower limit and upper limit “window” pin 3-6.
The 4029 counter BCD is decoded to decimal by 4028 which drives the LEDs, keep LED drive within 3mA or chip will be loaded. Use high efficiency extra-bright LEDs.
The 4029 BCD also controls a shunt resistor array with CMOS switches 4051. The voltage across shunt is a sample of leakage current. This is compared in the window comparator to freeze the Clock and LED display to give a reading of the leakage current or Insulation Resistance.
Neon Light Flasher was made by me when i was young, it was even published in a magazine, i think it will work, it was used on a very old huge ornamental valve philips stereo system in the remote speakers.
Home Made Circuits
Recently i captured this circuit in eagle to publish online, it seems to have a small design error. It worked well for many years. The step-down transformer is used as a step-up here. The secondary winding was around 50mA so the resistance was protecting the 2N2222. (SL100 was used in the original one). C1 and R3 may need tweaking to get the desired adjustment range in R2.
The voltage across the speaker is fed to C1-Gnd, which blocks DC component. R1, R2, R3 form a threshold bias for T1. 2N2222 chops the 12V DC in tune with the music.
Basics of Electronics
The chopped DC current flowing in the 12V winding of TR1 is stepped up into AC pulses over 100V, this lights the Neon in flashes synchronizing in real-time with the beats. Known Issues – It does not perform well at low Bass like 20Hz.