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 Op-Amps

OP07: Ultralow Offset Voltage Operational Amplifier

Both the output are identical but opposite polarity. Only low offset opamp can make this possible. We also have to consider temperature stability, environment, emi and thermoelectric emf when working with micro-volts.

Ensure the opamp circuit including the 1% resistors are away from power electronic circuits like output drivers and power supplies. A hot Mosfet close to a 1% resistor will need Sherlock Homes to fix your design, which is flawless. The layout was kaput.

The Measured Value and The Setpoint are two inputs to a Control System. The Measured Value is the Amplified input of a Transducer or Sensor for some Parameter that needs to be controlled. It could be Pressure or Temperature…etc.

The Setpoint is the User Defined Input using a Potentiometer, Thumbwheel, EPROM or Flash Value. This is the value at which the process has to be maintained for that parameter.

Analog PID control using OpAmps

Industrial Process Control Circuits

The difference of these two is the Error, this is the input for this PID Analog Computation Stage. The three Opamps are configured as Proportional, Integrator and Differentiator Amps.  The Addition or Summation of these Values is the PID Control Output.(These days it is Math in the Firmware on a MCU, DSP or Software Application in SCADA)

This Analog PID Control Output can now be translated to a 4-20 mA Control Signal, that means 0-100% of power to the Actuator, which could be a Heater, Pump, Fan, Motor using AC/DC Drives. It could be a Steam Valve, Pneumatic or Hydraulic Motorized/Solenoids. The Actuator Size/Array must be right for the Process, a tiny fan cannot cool a Large Furnace, a small solenoid valve cannot fill a Big Tank. An effective Proportional or PID  control depends on choosing or designing the Sensor, Actuator and System Environment prudently.

The Auto Reset is needed to ensure the Integrator does not dampen the Process so much that it fails to even raise to the Process value fast enough (Diffrentiator). So in the Proportional Band the Integrator is Active.

If the Setpoint is 1000 deg C, the proportional band is 10%. The Raise of temperature till 950 deg is Undampended. After that Integrator is called in by the Window Comparator made of two opamps, the integrator prevents OverShoot, Undershoot, Ringing and Oscillations.

The PID control output can also be a Time Proportional Output like PWM. With a large cycle time of 20 or More seconds. Like 2 Seconds on and 18 Seconds off for 10% Control.Fast Cycle times may be needed for small systems with less inertia.

The input impedance of this module is very high, if U1 is OP07 it is in mega ohms, use CA3140 or LF356 fet input opamps to get 1 tera ohm input impedance, but for high gains OP07 is better as it is ultra low offset, this is a good amplifier for sensor outputs, as in a DC Circuit.

Non-Inverting Opamp Interactive Simulation

Non-Inverting Amplifier - Op-Amp Circuits

Vout = Vin * (Rf + Ri) / Ri

The Spice in Analog Design

The zener diodes protect the opamp inputs, R1 limits current during high voltage inputs and R1 and C1 form a filter to remove ac components C1 should be a plastic type as ceramic and electrolytic caps are leaky. A large C1 will slow the response time, the sum of Ri + Rf should be greater than 5k so that output is not loaded. also do not connect output to voltages more than vcc/vdd it will blow Opamp.

This is a Test arrangement for Leakage Testing of Diodes on Reverse Bias. The leakage current indicates the ability of the diode to withstand higher voltages. An AutoTransformer or Variac can be used to vary the test voltage. Even Plastic capacitors can be tested for leakage this way.

High Resistance Indicator – del50004

Diode Reverse Bias Leakage Tester

Safety Precautions –
Use a Isolation 1:1 transformer for safety. This circuit has to be enclosed in a insulated cabinet. A Jig or Acrylic Safety Plate with clamp can be used to connect the diode. The voltage is only applied as long as a Mains two way push switch is pressed. This adds to the safety.

Build a DMM or Digital Multi Meter

Caution Instruction –
Use this with Low voltages like 24V AC for Learning. Do not Use it with High Voltage AC. If you are learning, first work with other circuits using batteries or Low Voltage Mains Adapters.

Here is the circuit of a Op-Amp based Square Wave Generator. One of the main application of this is in a Simple PWM circuit and Triangle Opamp Oscillator. The Slope of the Triangle wave is compared with a DC Level to derive a pulse width or On-Time proportional to a Voltage.

Op-amp Oscillator delabs

This On-Time proportional to voltage is for a fixed oscillation rate based on C2-C3 and R15. The C2-C3 form a Unpolarized cap, This type is also used in crossover networks in speaker boxes. This is because, a plastic 4.7 uF (2 * 10uF series) is big and costlier, but a plastic cap is very stable and closer to an ideal cap.

Square and Triangle Opamp Oscillator

First you need to know that most opamps in such circuits can give a square wave, but very few can swing to the rails (+/-5). For designing take 75% of Vcc. CA3130 is one that can swing to rails like a CMOS gate.

Op Amp Triangle-Wave Generator

Assuming the swing of output is around +/- 4V, the pin 10 + input will be at +/- 2V. When the cap is discharged at 0 V, let us take that the output is +, the cap charges to a little above +2, – input becomes dominant, so output swings negative. This discharges the cap to 0 and then charges it negatively upto -2. This in turn flips the output to + as pin 10 turns dominant. Hence this continues as a oscillation, with a nice triangle across the cap for the PWM comparator.

Dominant means more +, 0 is positive compared to -2V. Also -2.5 is negative compared to -2.2.

The gain of U1 can be controlled by a digital binary 1248 nibble at ABC. The gain at digital 000 is unity or 1 and the gain at various stages are set by 4051.

Precision Attenuator with Digital Control – delabs

There are eight different gains as the steps of gain resistor network is chosen by 4051. The on resistance of 4051 channel around 100E gets added to U1 pin 2 internal impedance.

Digital gain control of Opamp

Auto ranging 4-1/2 Digit Digital Voltmeter – delabs

You can use separate resistor networks with trimpots for each channel if you require but keep the networks total burden on U1 pin 6 to around 10K, not less than than. You can use this to set the gain of a amplifier with the help of a microcontroller.

This circuit changes the gain of opamp U1B in four steps or segments. It can be used to get a linear output from most transducers to 1% levels.U1A is a amplifying buffer use it to boost the signal to the required level.
Linearizing Circuit for Thermocouples

The resistor values i have put are for an imaginary transducer, you have to design them. The buffered input signal is compared to reference switching points by LM339.

Temperature Measurement and Control

LM339 changes the gain resistors of U1B thru the mux switch 4066. JP1 to JP4 can select either amplification or attenuation of signal. The resistor switched by 4066 can be across R1 or R2 based on JP1 to JP4.

You may have to input transducer values into a spreadsheet and draw a graph. Then divide the graph into 5 segments and deduce the switch points and gain.

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.

Analog Level by BCD Thumbwheel Switch

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.

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