HANOI UNIVERSITY OF SCIENCE AND TECHNOLOGY

SCHOOL OF ELECTRICAL AND ELECTRONIC ENGINEERING

DEPARTMENT OF AUTOMATION ENGINEERING

PROJECT REPORT

TEMPERATURE CONTROLLER
Group 8: Do Duc Toan 20212422
Le Anh Tu 20212426
Duong Quoc Tuan 20212427

Instructor: MSc. Chu Duc Viet

Hanoi, 10/2024
WEEK 1 Report
 Function for users:
 Users can monitor temperature.
 Allow users to choose working modes and reset working modes:
 Select Heat/Cool
 Lowest and highest heat settings
 Select and modify the temperature value the user wants to set.
 Have several control methods: ON/OFF, PID control
 Connect the thermostat to an external device for industrial purpose
 From these above functions, we proposed some controller features for the device:
 Setting: Buttons/penal keys to select modes or set/reset operation mode
 Function: Can control and adjust the temperature users set
 Indicator: Screen for displaying the current temperature and the current
mode of the controller, system status (on/off) and operating mode
 Protection: Alarm/warning for users
 Communication: Port to connect/communicate with external devices such
as computers, thermostats

 Specifications:

Unit Specification
24VDC
Power supply voltage
Temperature input: 1
K, J, T, E (Thermocouple); RTD
Analog input: 1
Current input: 4 to 20 mA
Voltage input: 0 to 5 VDC
Digital input: 2
Input High: 15-30 VDC
Low: 0-5 VDC

Output Analog output: 1

 linear current output 4-20
mA;
Digital output: 2
  Relay output: 24VDC;
 Voltage output:
12VDC±20% (NPN) (for
driving SSR);
Buttons to select: 4
Input interface
Setpoints and Mode

11-segment digital display to

display temperature value, Mode,
Output interface (display)
State (ON/OFF) and the Set-value

PID control or ON/OFF control

Controlling method

(RS-485) or USB-serial conversion

Communication cable

Protection Isolation between I/O and μC

 Reference controller: OMRON E5CD

  Solution design:
1. Power supply
 Requirements:
- Supply 24VDC
- Able to reduce voltage to 5VDC and 3V3/DC
- Isolation
 Solution:

a. Convert to 24V to 5V

 Using IC buck converter LM2524D:

- Input voltage: 8V-40V/DC
- Output current max: 2A
- Output voltage: 5VDC
- Operating temperature: -40°C to 125°C

b. Convert to 24V to 3V3

 Using IC buck converter LM2596HVS:

- Input voltage: 4.75V to 40VDC
- Output current max: 3A
- Output voltage: 3V3 DC
- Operating temperature: -40°C to 125°C

2. Input
1. Temperature sensor input
 Requirements:
 Able to detect temperature with small deviation.
 Two differential channels to take input signal from Thermocouple (TC) and RTD.
 Low noise ADC for Small-Signal Sensors.
 Isolation with MCU

 Solution:
 Using LTC2986
1. Thermocouple support:
a. Support many types of thermocouples
b. Cold Junction Compensation
c. High temperature resolution
2. RTD support:
a. Can connect Pt100, Pt500, Pt1000
b. Support 2-wire, 3-wire and 4-wire
 3. SPI communications
4. 24-bit Sigma Delta ADC
5. Be able to integrate with external isolators

2. Analog input
 Requirement:
o Voltage input 0-5VDC and current input in the range 4-20mA.
o Convert signal and reduce noise
 Solution

2.1 Current Signal Processing (4-20mA)

 Requirements:
- Convert the 4-20mA current signal into a voltage compatible with the ADC (0-3.3V or 0-
5V).
- Protect the signal from noise and voltage surges.
 Device Selection:
▫ Shunt Resistor:
- Resistor Value: 250Ω, 0.1% (precision resistor).
- Function: Converts the 4-20mA current into a 1-5VDC voltage.
- Reason for Selection: A high-precision resistor ensures accurate
current-to-voltage conversion, minimizing conversion errors.

▫ Signal Amplifier:
- Device: INA333 (Texas Instruments).
- Type: Instrumentation Amplifier.
- Function: +) Amplifies the 1-5V voltage signal from the shunt resistor to match the ADC
range if necessary.
+) Reduces noise from the environment for cleaner signal processing.
▫ RC Filter:
- Function: Filters out high-frequency noise from the 1-5V signal, ensuring a stable input for
the ADC.
 ▫ ESD and Surge Protection:
- Device: TVS Diode (Transient Voltage Suppressor) – SMBJ5.0A.
- Function: Protects the signal from voltage surges that could damage the ADC or the
amplifier.
- Reason for selection: The 5V clamping voltage effectively shields the circuit from harmful
transients while maintaining signal integrity.

2.2 Voltage Signal Processing (0-5VDC)

 Requirements:
- Transmit a clean 0-5V voltage signal to the ADC without attenuation or noise.
 Device Selection:
▫ Signal Amplifier: INA826
 Role: Amplifies or buffers the 0-5V signal to improve accuracy during ADC
conversion.

▫ RC Filter:
 Role: Removes high-frequency noise, especially ripples from the power supply or
environmental interference.

▫ ESD and Surge Protection: SMBJ5.0A

- Clamping Voltage: 6.4V max at 10A pulse current.
- Breakdown Voltage: 5V min
- Type: Unidirectional.
Role: Protects the signal from voltage surges with a clamping voltage compatible with the
maximum 5V signal.

 ADC: ADS7038
o Resolution: 12 bits
o 0-5V
o SPI Interface

3. Digital inputs

 Requirements
 Isolation with MCU
 ESD protection
 Range:
 High: 15-30 VDC
 Low: 0-5 VDC
  Solutions
 Isolator: Optocoupler PC817
 To isolate high-voltage digital input from sensitive microcontroller
circuitry
 ESD protection: BZX84C15
 Ensures only signals above 15V are treated as HIGH logic levels.
 Protects the comparator or isolator from overvoltage.
 Current Limiting for Optocoupler: MAX22017
 Voltage Threshold Detection: MAX22017
 Detects input logic levels from 15-30V as HIGH and 0-5V as LOW.

3. Output
a. Analog output

 Requirement:
- The circuit is isolated with MCU
- Output current: 4-20mA
- Can protect high voltage, low voltage and static electricity.
 Solution:
- DAC121S101: A 12-bit DAC supporting 0–5V output voltage, ideal for precise
digital-to-analog signal conversion
- XTR117: A dedicated IC for converting voltage signals to 4–20mA current, ensuring
high accuracy and reliability
- ADUM1311: A digital isolation IC with multiple channels, specifically designed for
isolating SPI and other digital signals between the MCU and the circuit
- Use standard diodes and TVS diodes to protect the circuit against high voltage, low
voltage, and static electricity, ensuring system safety and durability

b. Digital output

 Requirement:
 High light intensity in industrial environment
 Large range input voltage/current for designing
 Isolation with MCU
 Solution:

1. Relay output

Isolation (Separating Control Circuit from Load):

 Optocoupler (Photocoupler): PC817

 Reason for selection: +For low control current and isolation between the microcontroller
+ It is simple to use, cost-effective, and compatible with 3.3V or
5V MCU logic levels.

 IC ULN2803: +Amplifies the current and voltage from the PC817's output to drive the
relay coil.
+Each channel can handle a maximum current of 500mA and a voltage of up to
50V.
+Includes an integrated flyback diode for relay protection
 Reason for selection:
- Simple to use and ideal for driving 24VDC relays.
- Supports multiple channels (8 channels), allowing control of multiple relays.
- Compatible with 3.3V or 5V logic signals from the MCU.
 Relay 24VDC: Omron G2R-1-E
 Coil Voltage: 24VDC.
 Coil Current: 21.6mA (compatible with ULN2803).
 Contact Rating: 10A/250VAC or 10A/30VDC.
 Contact Type: SPDT (Single Pole Double Throw).
 Compact size: ideal for control circuits

 Protection diode: 1N4007 diode --> High-current diode suitable for 24VDC
relays.
 Maximum current: 1A.
 Reverse voltage: 1000V

2. Voltage Output (NPN, 12VDC ±20%):

 Optocoupler PC817: For low control current and isolation between the microcontroller
 Relay/MOSFET Driver IC: ULN2083 --> To drive SSR NPN 12VDC±20%

4. Display and Buttons

 4 physical buttons
 Requirement: - simplest of debounce
- debounce signal in both direct and inverse directions: filter bounces in
both rising and falling edges
- use logic device with hysteresis input such as Schmitt trigger inverter.

 Display: Kingbright SA52-11GWA

 11 segment LED display suitable for display requirement
  Drive IC: MAX7219 (LED Matrix/7-Segment Driver)
 Supports up to 8 digits (8x7-segment or 8x11-segment) control.
 Simple SPI communication
 Built-in current limiter helps protect LEDs.

5. Communication
 Requirement:
- Haft Duplex
- Able to operate in harsh industrial environment.
 Choose RS485:
 Cable Type: Multi-drop ->Supports multiple devices connected on the same
communication line.
 Number of Devices: Up to 32 transmitters and 32 receivers can be connected in a
network.
 Communication Type: Supports both half-duplex and full-duplex communication
modes.
 Maximum Distance: - Maximum cable length of 4000 feet (1200 meters).
- Data rate of 100 Kbps at maximum distance.
 Signal Type: - Balanced differential signal -> Ensures better noise immunity and
reliable data transmission in harsh environments.
 Environmental Suitability: - RS485 is well-suited for industrial environments, with
robust performance in areas with high electrical noise.
 IC to drive RS485: Using IC MAX22028:
- Isolated RS485 transceiver, configurable as half duplex
- Baud rate: 2.5 Mbps
- Supply Voltage:
+VDDA: 1.71V ~ 5.5V/DC
+VDDB: 4.75V ~ 5.25V/DC

6. Microcontroller
 Requirements:
1. Temperature and Sensor Inputs: 8 pins.
a. 4 pins for SPI communication with LTC2986.
b. 2 pins for differential RTD/thermocouple channels.
c. 2 pins for SPI input isolation.
2. Analog Inputs: 2 pins.
a. 1 pin for voltage input (0-5V).
b. 1 pin for current input (4-20mA).
3. Digital Inputs: 2 pins.
 a. 1 pin for detecting high/low digital signals.
b. 1 pin for interfacing with an optocoupler.
4. Analog Outputs: 5 pins.
a. 4 pins for SPI communication with DAC121S101.
b. 1 pin for current control via XTR117.
5. Digital Outputs: 3 pins.
a. 2 pins for relay control via ULN2803.
b. 1 pin for SSR control via ULN2083.
6. Display: 6 pins for SPI communication with MAX7219.
7. RS-485 Communication: 4 pins for UART with isolation
8. Power Supply and Ground: 2 pins.

Grand total: 32 pins