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Analog Level by BCD Thumbwheel Switch

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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Battery Level LED Indicator

This LED Indicator uses a LM339, a quad comparator. LM339 can work on single or dual supplies, it has a open collector output that can drive 15mA, low power consumption. The circuit is an untested design but it should work.

Mains Voltage and Power Circuits – Similar circuits for Mains Voltage Monitoring.

There are many better circuits in the various circuit archives i have linked on the front page, you just have to look around. When you measure the open circuit voltage of a battery with a high impedance DMM (10M), the value may be a bit misleading. Apply a dummy load to bleed the battery a bit so that proper readings can be taken on Load. The load below is a 100 ohms wire-wound fusible ceramic resistor which will heat a bit when you test 12V batteries.
Battery Level LED Indicator

Theory of Operation.

R16 a 5W ceramic wire wound bleeder or dummy load. R15 is a part of an attenuator for obtaining ranges. D2 is a protection clamp diode. R10-D1 forms the 5V reference for comparators. Then an attenuator obtains 1.2, 1.4, 1.6, 1.8 V steps for each comparator. This circuit is similar to Audio Level meter or VU meter circuit.

Comparators in Interface Circuits

The comparator compares the battery sample voltage to the fixed reference step. If ‘+’ pin is more positive than ‘-‘, or is ‘+’ is more dominant, then output goes floating ‘open collector’, so No LED light . But if ‘-‘ is more dominant the output transistor of comparator goes low impedance or saturates or turns ‘ON’. But only spec current can be switched, do not compare with electrical switch ‘ON’. Also on a dual supply 0V is more dominant or positive compared with -12V, even though it appears -12V is a big number. The direction of current is what decides, all measurements are relative.

Thermocouple Amplifier Standard

Thermocouple is the most common sensor in Industrial Temperature Measurement. The Signal Conditioning involves Cold Junction Compensation and High Gain DC Amplification. The output of a Themocouple is in millivolts.

The OP07 is a low offset 75uV opamp, here it is used to amplify the output of a Thermocouple, the gain of this stage is high. The zeners are to protect any high voltage at input zapping the opamp.

Thermocouple Amplifier Standard

The Resistor R6 limits the current. The zeners should be low leakage or use clamping pull-up and pull-down diodes to +5 and -5 respectively.

The RC low-pass filter formed by R6 and C2 reduce the mains hum or 50 Hz pickup of long thermocouple cables laid close to high current heater wiring. R1 is a offset null use or add if required. R11 is gain control of OP07. The TL072 is a FET input opamp used here as a summing amp.

Blind Dial Proportional Temperature Controller

Adding one more inverting amp with some gain to the output of this circuit can give you a 1-5V suitable for ADC or PC analog I/O cards. C1 also serves to filter, it is an integrator here. It suppresses EMI and RFI from motors, contacters etc., R13 sets an output value for 0mV input.

Voltage to Current Source 4-20 mA

The 0-1V to 4-20 mA Converter published earlier is a current sink, Here is a circuit that is a voltage to current converter but with a current source.

Voltage to Current Source 4-20 mA

You can use a LM358 or LM324. The first opamp is a Voltage to Current with a sink output. That current creates a varying voltage w.r.t the 12V DC supply, this varying voltage is mirrored by the second opamp across the source output resistor. This way a constant current is obtained with a sourcing output. The control elements are small signal high gain transistors. Any suitable equivalent can be used. Even the opamp can be chosen by the precision and application you want.

In this form of feedback. way to understand …. “Op-Amp drives the output to maintain both inputs at the same level” and also the “Output takes the polarity of the dominant input” and lastly “dominant means, more positive”. +5 is more Dominant than +3 or 0 or -2. Then -3 is more dominant than -12. See which is more positive.

Long distance of current loop may need higher voltage and lower source resistor value. Then the output transistor needs to change, if you use 24V DC then that voltage should not reach opamp. Design needs to foresee all possibilities of I/O troubles, as these are wired by a customer, mistakes happen. Hence, Industrial Designs have to be rugged.

0-1V to 4-20 mA Converter

This two opamp circuit converts analog voltage signals to current (sink) signals in a proportional manner. Current signals are more immune to noise and cross talk, hence long wires can be used. Voltage Signal to Current Signal Analog Converter.

Ensure +5/-5 dual supply for chip TL062 IC3. Gnd is common ps ground, let grounds radiate from ground plane in one side of PCB. R3-R8 is an attenuator that may need to be designed or modified.

0-1V to 4-20 mA Converter

In output R23 is for protection from shorting of +5V supply, R23 can also go to an unregulated or external. supply upto 24V DC which is referenced to this circuits gnd. More voltage more distance.

Q2 is the current control device, and R22 50E is the shunt for taking a sample of current. 4-20mA in the output (provided suitable load is connected) means 200mV- 1000mV across 50E shunt. This is fed to close loop control system of IC3a inverting pin.

An opamp on this type of feedback tries to drive the output in such a way, so as to maintain both the inputs at same level.

Mini RTD Pt-100 Three Wire Transmitter

If there is 1V at pin 3 and no current is flowing pin 2 is at 0V so output goes positive and drives Q2. this results in a flow of current till a 1V builds across shunt, if it exceeds then output of opamp falls This reduces drive to transistor and hence current reduces. That is the part of V to I conversion with open collector output.

Now we need 200mV to 1000mV to get 4-20mA 4mA is good for 0 as low level measurements are more noise prone. that is the reason 4mA and not 0mA.

Now we need to convert 0-2 V to 0.2 – 1.0 V using IC3B. R14 is a representation of that 200mV offset set by R16 pot. the opamp IC3B adds both the input and this offset to get 200mV to 1000mV. for that the opamp IC3B is an analog computer, summer, subtracter. Try to now calculate the values for that.

Simple Mains Voltage monitor

This Circuit helps in the monitoring of mains supply voltage. It does not use a isolation step down transformer. This has to be constructed only by skilled people with knowledge of safety requirements.

C1 0.47uF can be brought down to 0.22uF for low LED currents, use high efficiency ultra bright LEDs.C1 should be 440V AC or 630V DC plastic axial yellow, polyester, polycarbonate, polypropylene, metalized film.

R3-R6-R9-R14-R18 resistor divider determines the LED turn on or threshold switch points, 10M for hysteresis.

Mains Voltage and Power Circuits

Adjust R16 preset with a log Plastic tweaker to get the led D2 to turn on when input voltage is at 220V AC. This has to be done after PCB is put in a sealed fire-retardant-plastic or epoxy box. drill a hole in box for plastic tweaker.

LM324 – Low Power Quad Operational Amplifier

This Circuit is Not a Tested Design. It is an Idea for study
Simple Mains Voltage monitor LM324
Warning : This Circuit is Mains Operated without Isolation Transformer and will give lethal electric shock if touched when the circuit is turned on. Test circuit only with DC 9V Bench Power Supply to try it out. Do not use 230V AC.

Simple Thermocouple Amplifier

The OP07 is in a non inverting amplifier so as not load the mV of thermocouple, the zeners are to protect circuit if junction contacts heaters or the earth gets broken.

Thermocouple and Pt-100 RTD

The RC is to filter out 50Hz pick up in thermocouple wires if near heater wiring and also reduces reading jumps when high current three phase contacter operates.

Simple Thermocouple Amplifier

The Pull-up 10M is when a Thermocouple breaks the output of circuit will be max. This is open sensor protection, in case Thermocouple breaks, Required only in industrial temperature controllers for protection. This means it will be 3.5V which should make you turn off the heater in software.

J and K Thermocouple with 4-20 mA

The other opamp is for further amplification as OP07 is set to around 30 gain and offset has to be adjusted with R9. If OP07 is kept in > 100 gain it may be difficult to adjust offset of 75uV. If you need very high gain in the first stage use some instrumentation amplifier or chopper stabilized amplifier. I am not very sure. This is the very basic Thermocouple Amplifier used as a front end signal conditioning in Process Control.