DESIGN AND CONSTRUCTION OF AN AUTOMATIC CHANGE OVER SWITCH

UGOCHUKWU IZUELUMBA

2004/18891 EE

A Project Submitted To The Department Of Electrical AndComputer

Engineering,Federai University Of Technology - Minna.

DESIGN AND CONSTRUCTION OF A MICROCONTROLLER BASED SINGLE-

PHASED AUTOMATIC CHANGEOVER

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DECLARATION

Declaration by the Student

This research proposal is my original work and has not been presented for an award in

any other institution. Any production of this work is prohibited without prior permission

from the researcher or The Catholic University of Eastern Africa.

AMOS

BED/GC/323/13/14

SIGNATURE: ……………………………DATE: …………………………………….

Declaration by the supervisor

This proposal has been submitted for examination with my approval as the University

supervisor.

MR. NICHOLAS MWAURA

SIGNATURE: …………………………… DATE: …………………………………….

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ACKNOWLEDGEMENT

First and foremost I would like to thank my Almighty God for fundamental strength and

good health which has enabled me to reach this far. Secondly I am very grateful to my

Supervisor Mr. Nicholas Mwaura who tirelessly offered valuable pieces of advice and

extremely became helpful in the development of this study. His corrections, guidance and

encouraging remarks have greatly motivated me. He has enriched me with the necessary

skills. I’m really grateful to him. I am also greatly indebted to the persons and the

institution that made the write up of this research proposal possible.

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Abstract
The main aim of any electric power supply in the world is to provide uninterrupted power
supply at all times to all its consumers. Although, in developing countries like Nigeria,
the electric power generated to meet the demands of the growing consumers of electricity
is insufficient, hence power instability or outage. Power instability and outage in general
does not promote development in the public and private sector of the country’s economy.
The investors do not feel secure to come into a country with constant power failure.
These limit the development of industries, in addition, there are processes that cannot be
interrupted because of their importance for instance, surgery operation in hospitals,
transfer of money between banks and lots more. Power instability and outage in Nigeria
creates a need for alternative source of power to backup the mains supply. A
microcontroller-based automatic power changeover finds a wide application scope
wherever the reliability of electrical supply from the utilities is low and it is used in areas
wherever continuity of power supply is necessary, for switching to an alternative source
from main supply and vice versa. This project is a design and construction of a
microcontroller-based automatic power changeover, that means the automatic changeover
switch will change to an alternative power supply (generator), and back to the main
supply when it is restored. The purpose of this project is to maintain constant supply to
the main circuit that is being supplied by making-up for the time lapse or delay that
usually accompanies the manual switching from one source to another.

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DEDICATION

I dedicate this project to Almighty God for the wisdom, understanding, knowledge and

strength to write this project.

I also dedicate this project to my lovely family, Sir & Lady (Dr.) I.V.Obi’s family for

their love, support, advice and intense sacrifice throughout my study in the University.

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CHAPTER ONE

INTRODUCTION

1.1 INTRODUTORY CONCEPTS

MICROCONTROLLER

Microcontroller is a small computer on a single integrated circuit containing processor

core, memory and programmable input/output peripherals, also designed for embedded

applications in contrast to the microprocessor used in personal computers or other general

purpose applications

 ELECTRIC POWER

This is the rate at which electric energy is transferred by an electric circuit. Electric

power can be produces by electric generators; can also be produced by other sources such

as electric batteries. The Standard International Unit (S.I. Unit) of power is the Watt

which is one joule per second.

 MAINS POWER SUPPLY

Also known as the public power supply is the general purpose alternating current (A.C.)

electric power supply. In Nigeria, it is the PHCN (Power Holding Company of Nigeria)

that generates and dissipates the public power supply.

 STANDBY GENERATOR

This is a back-up electric system that operates manually or automatically. Within seconds

of utility outage an automatic transfer switch senses the power loss and commands the

generator to start, and then transfer the electrical loads to the generator.

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  AUTOMATIC POWER CHANGE-OVER

This is an electrical mechanism that changes from one power source to another, for

instance from public power supply to a standby generator and vice versa. It switches off

the generator set after alerting you and switches over to the public power supply when

there is light.

 TRANSFER SWITCH

This is electrical switch that switches a load between two sources either from mains

power supply to a standby generator or vice versa. Some switches are manual, while

others are automatic and switch power when they sense that one source has lost or gained

power.

 RELAY

It is an electrically operated switch. Many relay use an electromagnet to mechanically

operate a switch. Relays are used to control circuit by a low power signal or where

several circuits must be controlled by one signal.

1.2 BACKGROUND OF THE STUDY

The mention of electricity and its technological advancement in the field of

Electrical/Computer Engineering has enlarged its application in various ways hitherto

considered impossible. Life seems miserable without electricity. A new home cannot be

described as modern if it not connected to electricity supply. This is because most of the

items required for making life comfortable in a house function with electricity. For

instance, the lighting of homes, heating or cooking, pumping of water, operating of such

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appliances as fans, radio sets and televisions, desktops, laptops are powered by

electricity.

In Nigeria today, the inadequate availability of electricity supply has made her citizens to

seek alternative and independent means of power supply. This has resulted in individuals

buying wind turbines, solar panels, generating sets of all descriptions, power inverters

and so on, in an effort to provide alternative electricity supply for private use. The use of

alternative power supply unavoidably requires a means of selecting which power source

to be used as at when required.

With advancements in technology, the computer system has become an integral part of

the scientific life. The development of software integrated hardware (intelligent

hardware) like the microprocessors and microcontrollers has made real time

instrumentation controls and measurement to become more accurate, precise and timely.

In addition, the processing of calculations and programs among other advantages are

faster and better handled. This project, therefore, is intended to design and build a system

device that is interfaced with a microcontroller programmed for phase-voltage monitoring

selection and generator starting processes.

1.3 OBJECTIVES OF THE STUDY

The major aim of this work is to exploit the ubiquitous microcontroller facilities in

bringing about automation of the changeover process. One of the most critical needs of

embedded systems is to reduce power consumption, space and time and this is achieved

in this work.

The purpose of this work is to provide a very affordable means of automatically

switching between the alternative power supply systems and the utility power supply

8
without human intervention. It has been observed over the years that power instability has

caused companies to lose millions of naira each time there is power failure, as a result of

the time lag between power failures and when the power is restored. This is evident in

hospitals, airports, banks, telecommunication companies, breweries, cold rooms, and

abattoirs to mention but a few.

This system is designated to proffer solution to the shortcomings of the already existing

manual changeovers by performing power swap from public power to generators

automatically and vice versa. The devised system has the ability to eliminate the stress

and to reduce time lag of manually switching on the generator where there is public

power failure.

1.4 SCOPE AND LIMITATION OF THE STUDY

The project is to design and construct at a prototype level an intelligent switching device

that will toggle between a single-phased public power supply and a self starting

generator. The level of the design will be simple enough for a local technician to

understand, particularly during an opportunity to effect repairs. This automatic

changeover unit can be operated in single phase system.

Moreover the size and captivity of the unit will depend upon the load for which it will be

used. The unit is portable, easy, convenient and safe to install.

1.5 STATEMENT OF THE PROBLEM

From various surveys in the industrial sector of Nigeria, it was generally noticed that

industries are vulnerable to long and short interruptions (that are considered “reliability

issues”, in the power system analysis).

The single-phased automatic changeover switch to design is a complete system with

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various sub-systems and components arranged and linked to function primarily as a

means of manipulating the supply of electrical power to any desired load.

A changeover switch can be generally described as a device that allows the conversion

from one power source to another (for example, supply from PHCN to supply from a

standby generator). The switching obtainable from the changeover switch is usually

manual, that is the user has to move a lever to change from one source to another. This is

usually associated with time wasting as well as some health hazards like electric shock

and trauma.

In order to eliminate this human intervention as well as introduce speed and precision in

the changeover operation there is need for an automatic changeover switch. This is

typically a switching system whose function is based on the predetermined configuration

unit. It selects the available power source without intervention of the user to ensure the

availability of supply at the desired times provided from one source to another can only

be achieved by device or a system that determines when the change should actually take

place and which source to be given preferences to supply the load. This brings about the

need for a unique control system.

The basic problem to be addressed here is how to connect two different sources of

electrical power simultaneously to a single unit (the automatic changeover switch) that

can serve as a link between these power sources and the load or network. Moreover,

preference is given to the power source such that one source supplies the load at a time

and when the first (mains) source fails, the link immediately connects the second

(generator) source to the load.

1.6 JUSTIFICATION OF THE STUDY

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Considering the high frequency at which the public utility power fluctuates, users in their

various homes and offices always require to temporarily stop work to go to their

changeover switch box and toggle it as many times as the power fails or get the power

restored. They are also expected to go to their generators and turn off as often as the

public power supply fails.

Constructing a phase/generator intelligent switching system (automatic changeover

system with a microcontroller) that can toggle automatically and then off the generating

set, will reduce the time and energy spent in changing over from time to time. This will

allow the user more time and concentration to attend the task at hand, the user will, in

addition enjoy long term steady and uninterrupted supply of power. It has the following

advantages;

 It minimizes damages lives/equipment since it has its own monitoring system and

its switching requires no human contact with the switch, thus eliminating human

error.

 It reduces its changeover timing to the minimum due to its fast response to power

outage.

 It maintains high quality of service through its fast and prompt response.

1.7 SIGNIFICANCE OF THE WORK

This work serves the purpose of saving the electrical appliances in a household and

offices from power fluctuation-related damages which could be occasioned by

overloading of unprotected changeover switches. Such a device protects electrical

appliances from possible harmful effects of voltage sag. It provides an average user the

comfort of enjoying the use of electrical appliances at home and offices without the

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interruption of work and switching over between the public power source and alternative

power source. Convenience of not having to walk all the way to the alternative power

supply source to turn it off or on is also provided.

It can also create entrepreneurship opportunity for our teeming unemployed youths of the

country owing to the large number of people that use alternative power supply that seek

automatic changeover from the public power supply to the alternative power supply.

1.8 ORGANISATION OF THE WORK

The entire project is arranged in sections to allow proper report presentation and

understanding. The first chapter: the introduction; defines some important concepts on

the project and gives a brief description of the problems in the society which results in the

need for an intelligent switching system. This contains also the objectives, scope and

limitations of the project implementation. The second chapter is the review of related

literature which describes briefly the history and various types of automatic changeovers

as well as the review of some major components used in the construction of the project.

Chapter three throws light on the design details, calculations of the component values in

the design and description of how the circuit works. The implementation and testing of

the project is contained in chapter four. The conclusion, summary of findings and

recommendation for further studies on the project completes the write-up for chapter five.

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CHAPTER TWO

2.0 LITERATURE REVIEW

2.1 REVIEW OF RELATED LITERATURE

Robert Dowuona (2008) found out that emergency power systems were used as early as

World War II on naval ships. In combat, a ship may lose the function of its steam engines

which powers the steam-driven turbines for the generator. In such a case, one more diesel

engines are used to drive backup generators. Early changeover switches relied on manual

operation: two switches would be placed horizontally in line and the “ON” position

facing each other, a rod placed in between, in order to operate the changeover switch, one

source must be turned off, the rod moved to the other side and the other turned on.

With technological advancement globally, maintaining the power quality and a steady

energy supply are the major requirements the electricity consumers are demanding for.

This is because many electrically powered and voltage-sensitive devices like advanced

system control, automation precise manufacturing techniques, continuous data processing

require uninterrupted power supply. For some of these devices, a temporary disruption or

sudden surge of power can cause scrambled data, a frozen mouse, interrupted

communication system crashes and equipment failures. Consequent upon this, there is

urgent need to have alternative power supply is expected to come into operation

immediately there is power seizure from the mains power supply. An efficient steady

supply of power is therefore of tremendous advantage both in terms of cost and

efficiency.

With adequate power supply base of the nation at the moment, it is almost impossible to

supply electricity to consumers at all times. The unreliable public power supply has led

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many to the alternative power supply sources. In Nigeria today, the use of generators to

power businesses and machines have become the norm. According to the Director-

General of Centre for Management Development, Dr. KabirUsman that Nigeria has the

highest number of standby generators in Africa, averaging to every 2.5 people has at least

one standby generator. He also pointed out that about 60million Nigerians spend

1.6trillion naira on generators annually. Many generators are in use; while some are

manually started others are automatically activated.

To ensure the continuity of power supply, many commercial industrial facilities depend

on both utility service and onsite generation (generator set). Because of the growing

complexity of electrical systems, it becomes imperative to give attention to power supply

reliability and stability. Over the years many approaches have been adopted in

configuring changeover systems, some of them are discussed below

i. Manually Controlled Changeover

ii. Sequential Logic Controlled Changeover

iii. Microprocessor-based Controlled Changeover

2.2 MANUALLY CONTROLLED CHANGE-OVER

According to Jonathan (2007), manual changeover switch system still remains the oldest

changeover switch box used by majority of the electricity consumers. Manual changeover

switch box separates the source between a generator and public supply. Whenever there

is power failure, change-over is done manually by an individual and the same happens

when the public power is restored. This is usually accompanied by a loud noise and

electrical sparks.

2.2.1 LIMITATIONS OF MANUAL CHANGEOVER SYSTEM

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 i. Manual changeover is time wasting whenever there is power failure

ii. It is strenuous to operate because a lot of energy is required

iii. It causes device process or product damage

iv. It has the potential to cause fire outbreak

v. It is usually accompanied by a lot of noise which may sometimes be

psychologically destabilizing.

vi. Maintenance is more frequent because the changeover action causes tear and

wear. (Mbaocha, 2012)

2.3 SEQUENTIAL LOGIC-CONTROLLED CHANGEOVER (SLC)

In sequential logic control of power selection, sequential digital circuits are used to effect

the detection and control of the supplied power. Sequential logic control approach

involves only an automatic violation of the public power source in the event of power

failure, but the generator activation to supply alternative power is done manually. In

effect the sequential logic control is more efficient then the manual control (Shanmuhka

and Ramesh, 2013).

Katz and Boriello (2005), the main advantage of the sequential logic control power

changeover switch is its simplicity.

2.3.1 DISADVANTAGES OF SEQUENTIAL LOGIC CONTROL SYSTEM

i. The main possible clock rate is determined by the slowest logic path in the circuit,

otherwise known as the critical path. Every logical calculation, from the simplest

to the most complex must be complete in one clock cycle, so logic paths that

complete their calculations quickly are idle much of time, waiting for the next

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 clock pulse. (Katz et al (2005).

ii. The clock signal must be distributed to every flip-flop in the circuit. As the clock

is usually a high frequency signal, this distribution consumes a relatively large

amount of power and dissipates much heat. Even the flip-flop that is doing

nothing consumes a small amount of power, thereby generating waste heat in the

chip. (Katz and Boriello, 2005).

2.4 MICROPROCESSOR-BASED CONTROL

The microprocessor-based control operates control operates through a central processing

unit programmed in a software-implemented format and stored in memory; Random

Access Memory (RAM) and/or Read Only Memory (ROM) subsequently used to effect

controls in real time.

There are two aspects of microprocessor control namely

i. Microcontroller-Based Controls and

ii. Computer-Based Controls

2.4.1 MICROCONTROLLER BASED CONTROLS

In microcontroller-based controls, microcomputers are employed with the resulting

systems described as embedded. It gets information like data status from sensors and then

issues control commands to actuators. One distinguishing feature of the embedded system

from other real-time system is that they are only executing task relative to a fixed and

well-defined work load. They do not provide any development environment; they are

low-level programmed (Mbaocha, 2012).

2.4.2 COMPUTER-BASED CONTROLS

The computer-based control operates through a computer system employed in a multi-

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machine-distributed computing environment. Other feature known as real-time software,

extensions are provided for programming languages and protocols enabling, such systems

to be programmed and checked. These systems are programmed to override the operating

system mechanism to control directly the hardware. They are high level language

programmed.

This project however is designed and implemented as a microprocessor-based controlled

system specifically using the microcontroller as its basic component. It is a dedicated

embedded system.

2.5 DESCRIPTION OF THE NEW SYSTEM

In view of the limitation of above previous changeover systems, this project proposes and

implements a changeover system that drastically reduced the shortcomings, the noise,

arching, tear and wear, stress and time wasting associated with manual switch box and

sequential logic control are eliminated totally by the introduction of solid state relay.

Digital components are used to make the work more reliable, unlike the previously

existing ones that make use of circuit breakers. Also PIC16F84 microcontroller was also

incorporated to help improve the speed of automation. The system is controlled by a

software program embedded in the microcontroller. This work I handy and portable

compared to the bulky work previously done, it has also some important features like an

indicator light to indicate the presence of public power source and over voltage and under

voltage monitoring. Economically, this project is of affordable cost because of the use of

integrated circuits (ICs) in place of discrete components.

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2.6 RELATED COMPONENTS IN THE SYSTEM DESIGN

There is a great deal to designing a process control voltage changeover system than just

selecting the appropriate interconnecting components and developing the software. There

is the need therefore for a review of the technical terms, process and related components.

2.6.1 SWITCH

A switch is an electrical component that can break an electrical circuit, interrupting the

current or diverting it from one conductor to another. Also can be used to select and ‘ON’

or ‘OFF’ state of a system. In a power system the ‘ON’ state represents power flow while

the ‘OFF’ state represents the otherwise situation. Switches are commonly used in power

electrical circuitry (Theraja, B.L and Theraja, A.K, 2000).

The various switching systems used in power systems include.

i. MANUAL SWITCHING

Where a cut-out (an electrical connector device) is used to approximately interconnect

and select down the voltage phases by manually plugging in a removable fused connector

from one base to the other depending on the one with power. This conventional approach

is usually employed in homes often than in industries.

ii. MECHANICAL SWITCHING

Mechanical switching involves using some sort of mechanism for closing and opening a

part of current flow. A typical example is the gang switch used in isolating supply lines.

iii. ELECTROMECHANICAL SWITCHING

Electromechanical switching is a form of switching which integrates electrical and

18
suitable mechanism for power flow. In this case, power is supplied to the mechanism

using solenoids to activate the switching mechanism.

iv. AUTOMATIC SWITCHING

Automatic switches are those switches that are activated in response to any change in

system characteristics (current or voltage). It usually employs relay for detection of

change in system characteristics after which a corresponding switching is activated

immediately.

v. MICRPROCESSOR CONTROLLED SWITCHING

In the case of microprocessor controlled switching a microprocessor chip is software

programmed and stored in its memory unit to b interfaced between the available power

source and the connected loads.

2.6.2 SWITCH GEAR

A switch gear is the combinations of electrical disconnect switches, fuses or circuit

breakers used to control, protect and isolate electrical equipment. Switch gear is used to

both de-energise equipment to allow work to be done and to clear faults downstream. The

tumbler switch with ordinary fuse is the simplest form of switch gear and is used to

control and protect electrical installations and other equipment in homes. This type of

component is important because it is directly linked to the reliability of the electric supply

(Ahmed, Mohammed and Agusiobi, 2006).

However, such switch gear cannot be used profitably in high voltage systems

2.6.3 RELAYS

A relay is an electrically operated switch that has two major parts – coil unit and the

contact unit. Current flowing through the coil of the relay creates a magnetic field which

19
attracts a lever and changes the switch contact positions.

Relays have two switching positions – the normally closed and the normally open. There

is no electrical connection between the coil unit and the contact switching position when

energized. The link is only magnetic and mechanical. The operational principle of the

relay is basically like that of a switch controlled by electromagnetic force. This magnetic

force is generated by flow of current through a coil in the relay. The relay opens or closes

a circuit when current through the coil is started or stopped. The circuit symbol of a relay

is shown in fig: 1.1 below

Fig: 2.1: Circuit symbol of a relay

2.6.4 TRANSFORMERS

A transformer consists of a laminated iron core wound with two coils – the primary and

the secondary. The primary coil is connected to a source of alternating voltage which

builds up a changing magnetic field setting up a similar type of AC voltage at the

secondary. This is done through mutual inductance between the coils by magnetic flux

linkage. When the number of turns in the primary is more than that of the secondary, it is

called a step-down transformer. It is called a step-up transformer when the reverse is the

case (Therajah et al, 2000). Step-down transformer was used in this project to transform

the high voltage to a low voltage output.

The figure 2.2 below shows schematic diagram of an iron-core step-down transformer.

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Figure 2.2: schematic diagram of an iron-core transformer

2.6.5 μA741 OPERATIONAL AMPLIFIER (OP-AMP)

The μA741 IC is an operational amplifier that has two input terminals, otherwise known

as inverting and non-inverting input. It amplifies only the difference between two signals

applied at the input terminals. It can be also used as a voltage comparator for two

different inputs. It has a high input impedance, high voltage gain and low output

impedance. It has a total of 8 pins as shown in figure 2.3

The pin terminals and designated assignment are contained in table 2

TABLE 2.1: PIN ASSIGNMENTS OF μA741 OP-AMP

PIN ASSIGNMENT

1 Offset Null

2 Inverting Input

3 Non-inverting Input

4 Negative Power Supply

5 Offset Null

6 Output

7 Positive Power Supply

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 8 Not Connected

2.6.6 PERIPHERAL INTERFACE CONTROLLER (PIC16F84)

PIC16F84 is a peripheral interface controller with many functional units. It carries out

adequate functional controls as interfacing device between sets of electronic circuitry. It

belongs to the peripheral interface controller-microchip technology device and has the

following characteristic features.

i. HIGH PERFORMANCE CPU FEATURES

 It has only 35 single-word instructions except to learn

 All instructions are single-cycle except for program branches which are two-

cycles

 Operating speed: DC – 20MHz clock input

DC – 200 ns instruction cycle

 1024 words of program memory

 68 bytes of Data RAM

 64 bytes of Data EEPROM

 14-bit wide instruction words

 8-bit wide data bytes

 15 special function hardware registers

 Eight-level deep hardware stack

 Direct, indirect and relative addressing modes

 Four interrupt sources:

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  External RB0/INT pin

 TMRO timer overflow

 PORTB<7:4> interrupt-on-change

 Data EEPROM write complete

ii. PERIPHERAL FEATURES

 13 input/output pins with direction control

 High current sink/source for direct LED drive

o 25mA sink maximum per pin

o 25mA source maximum per pin

 TMRO: 8-bit timer/counter with 8bit programmable prescaler.

iii. SPECIAL MICROCONTROLLER FEARTURE

 10,000 erase/write cycles enhanced FLASH program memory

 10,000,000 typical erase/write cycles EEPROM Data memory

 EEPROM Data Retention > 40 years

 In-Circuit Serial Programming – via two pins

 Power-on Reset (POR), Power Up Timer (PWRT)

 Watchdog timer with its own On-chip RC Oscillator for reliable operation

 Code protection

 Power saving SLEEP mode

 Selectable Oscillator options

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iv. ENHANCED TECHNOLOGY

 Low power, high speed technology

 Fully static design

 Wide Operating voltage range of

o Commercial: 2V to 5.5V

o Industrial: 2V to 5.5V

 Low power consumption of less than 2mA at 5V, 4MHz or 15mA at 2V, 32KHz

(retrieved from

http://www.microchip.com/downloads/en/DeviceDoc/39630C.pdf)

In summary, there are two memory blocks in the PIC16F84. These are the program

memory and the data memory. Each block has its own bus, so that access to each block

can occur during the same oscillator cycle. The data memory can further be broken down

into the general purpose RAM and the Special Function Registers (SFRs). The operations

of the SFRs that control the “core” are described here. The SFRs used to control

peripheral modular are described here in the section discussing each individual peripheral

module. The data memory area also contains that data EEPROM memory. This memory

is not directly mapped into the data memory, but id indirectly mapped. That is, an indirect

address pointer specifies the address of the data EEPROM memory to read/write. The 64

bytes of data EEPROM memory have the address range 0H – 3H. The reset vector is at

0000H, while the interrupt vector is at 0004H. The first 1k x 14(0000H – 03FFH) are

physically implemented.

Table 2.2: PIN ASSIGNMENT OF PIC16F84

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PIN ASSIGNMENT

1 RA2Input/Output Port A

2 RA3Input/Output Port A

3 RA4 Timer Port A

4 MCLR Mortar Clear

5 Vss Ground

6 RB0/INT Interrupt Port B

7 RB1Input/Output Port B

8 RB2Input/Output Port B

9 RB3Input/Output Port B

10 RB4Input/Output Port B

11 RB5Input/Output Port B

12 RB6Input/Output Port B

13 RB7Input/Output Port B

14 VDD

15 OSC2/CLK OUT

16 OSC1/CLK IN

17 RA0Input/Output Port A

18 RA1Input/Output Port A

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CHAPTER THREE

3.0 THE SYSTEM DESIGN, ANALYSIS AND METHODOLOGY

Systems Analysisis the process of investigation of a system’s operation with a view to

changing it to new requirements or improving its current working.

The analysis stage is the front-end phase of the development process of microcontroller-

based systems. This phase constitutes an essential step of the development process and

one of the critical issues that determines the quality of the final product.The analysis

phase sets the stage for the whole project. The necessary groundwork for understanding

what the project is all about is completed in this phase. We take the strong position that

the more effort you put into planning, the smoother the rest of the project will go and the

better the quality will be of your final product.

The total design and development of any microcontroller based system typically involves

three. Phases. They are as follows

 Hardware design and development

 Software design and development

 Prototype implementation and diagnostic testing

Details of the procedure working principles of the various stages are briefly described.

The hardware part consist of the biscuit details, design and calculation of various

components used in the work including the values of the ones assumed too. While the

26
software part is mainly the programming implementation on the PIC. Summary details

are contained in the flowchart block diagram as show below in all, a total of twelve

(12)geometrical block shapes were assembled together to achieve the complete design.

Fig3.1: Block Diagram Of The Micro-Controller Based System

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3.1 Hardware Design And Analysis

The complete project work was sectionally achieved in five (5) units they are:

 The power supply unit

 The voltage reference/variable unit

 The comparator unit

 The microcontroller unit

 The switching unit

There can be briefly seen in the block diagram of figure 3.2 below

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Figure 3.2:Block Diagram Of The Complete Design

3.2 THE POWER SUPPLY UNIT

The power supply unit has a step down transformer. T1 that reduces the high input

voltage of 240v to as low as 12v output. It also has a bridge rectifies that converts the low

A.C to an equivalent D.C output, though still pulsating in nature. A Low pass filter

connected immediately after the rectifies helps to reduce the A.C content bringing out a

cleaner increased D.C output. There is a light emitting diode (LED) D5, connected in

series with a resistor and both in parallel with the output D.C to help indicate the process

is working as designed.

3.2.1 DERIVATION OF VALUES

in a design of this nature, some values are decided (assumed) for the smooth working of

the components as well as purposeful result to be realised. In this value derivations the

assumed ones are stated wherever used.

The voltage measured at the output of the step-down is A.C and in root mean square

value (r.m.s). The required D.C needed for the design is 12v i.e VDC=12v

using the formular

The input frequency is 50hz. This is do

ubled

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at the secondary output as seen below

Figure 3.3 Wave Form Of The A.C Input/Output

the peak inverse voltage of the diodes is dependent on the vmax of the power unit.

any value greater than 18.86v as real inverse voltage of the diode will do for the design.

Diodes in4002 has piv of 100v, hence was chosen for the work

In the calculation of the capacitor value, the total load resistance and the expected

minimum ripple content were chosen as

RL= 400Ω = Load Resistance

Ripple Voltage, Vr=10mV

Capacitor C,≥

=0.000361 Farad

C≥361µf

Standard value is used 1000µf, i.e C1= C2= C3= 1000µf

The indicator circuit has a total of 12v connected to it

Vs=VR1 + VLED

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the forward biased voltage of the LED is 2V with an operating current of

20mA

.:Vs=VR1 + 2

Where Vs= 12

12 = VR1 +2

VR1= 12 -2

VR1=10

VR1=ILED ×r1

R1=

=500Ω

Standard value of the resistor chosen was 560Ω

R1=560Ω

The ic voltage regulator (ic2 7805) has a positive output voltage of 5v even when the

input to the ic is 12v or more this output is connected to the micro controller that

requirers 5v as the maximum voltage supply. The biscuit diagram is shown below figure

3.4

FIGURE 3.4 CIRCUIT CONNECTION OF THE POWER SUPPLY UNI

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3.3 THE REFERENCE/VARIABLE VOLTAGE UNIT

this unit provides the required two voltage values one fixed and the other variable, which

are both eventually fed to the comparator unit. It is built around two voltage divides

circuits comprising of zener diodes and resistors. The variable voltage is taken across

resistor r2, serially connected with a zener diode d6 of valu 4.7v.

The fixed voltage is comebued out of the zener diode D7 with value of 6v. The two

resistors r2 and r3 are of the same value of 1.8kΩ

R2= R3=1.8kΩ

D6 = 4.7v

D7 = 6v

the two voltage values are only possible when the supply input is 220v. The circuit

comebuino is shown below.

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Figure 3.5:Circuit Connection Of The Reference/Variable Voltage Unit

3.4 THE COMPARATOR UNIT

the comparator is an operational amplifier integrated biscuit of LM741 connected to

produce an output value of high (1) or low (0) when the difference between the two

outputs is positive a high output will be produced; but when the difference is negative, a

low output will be produced. At a voltage of 220v source input, the voltage value at pin 3

of the comparator op-amp is 6v. The one at pin 2 is 7.3v, the resultant output will be low

(0) because the difference is negative

i.e 6v -7.3v=-1.3v

But when the supply voltage goes very low to about 190v or below, the voltage at pin 2

reduces far below that of fixed value pin 2 (6v). This results to a positive high output(1)

at pin 6 of the comparator op-amp. The op-amp requires both positive and negative

voltage sources (+12 and -12v) from power supply to function.

The circuit diagram is shown in figure 3.6 below.

Figure 3.6:Circuit Connection Of The Comparator Unit.

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3.5 THE MICRO CONTROLLER UNIT

The micro controller unit has three major components

 IC3 =PIC16F84

 C3-C4=27PF ceramic capacitor

 Xtal=Crystal Oscillator (4mhz)

The micro controller used, pic 16f84 has a total number of 18 external pin terminals, only

eight terminals were physically implemented. Pin 14 is for the power supply (+5v)

The microcontroller used, P1C16F84 has a total number of 18 external pin terminals,

only eight terminals were physically implemented. Pin 14 is for the power supply (+5v)

and pin5 is grounded. The IC has two ports, port A and port B. Port A which houses the

input data and port B for bringing out the output data. At port A, pin 1 and 2 are used for

the input data destination while at port B, pins 8 and 9 are connected as output terminals.

The configuration of the micro controller is at a frequency of 4MHz made possible

through the use of external oscillator a crystal oscillator connected between pin 15 and

16. The two terminals of the crystal oscillator are grounded from each side with a non -

polarized capacitor C3 and C4. The table 3.1 below shows the pin types, their

assignments as well as designated names.

NO PIN NAME PIN NUMBER PIN TYPE PIN DESCRIPTION

Oscillator crystal input/exeternal

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 1 OSCI/CLK IN 15 I clock source input

2 OSCI/CLK OUT 16 O Oscillator crystal output

3 RA2 1 I Plot A, Input 1

4 RA3 2 I Plot A, Input 2

5 RB2 8 O Plot B, Output 1

6 RB3 9 O Plot B, Output 2

7 VOD 14 P Positive Supply Source

8 VSS 5 P Ground Terminals

LEGEND

I=Input

O=Output

P=Power

The system software development starts with problem specification and design of a

suitable flow chart as shown in figure below. This is to accomplish very easily the design

task and implement the specifications. A successful structured flow chart will ensure

good flow of signal. This is done before the implementation of the program writing in a

low level assembly language was used in implementing the program writing of this

project.

35
The programmers language was used to transfer the written program into the chip. In

other words, the programmers language was used to convert the assembly language into

machine code for the actual consumption of the chip (PIC16F84). One logic set up is that

once pin 1 is high, pin 8 output terminal is programmed to be high too when pin 2

terminal is high, pin 9 output terminal will be high as well. The circuit connection is as

shown in the figure below.

The program is made up of the main program and the delay sub routine. A list of

assembly system program could be seen in the appendix attached at the ending part of

chapter five, but the main program flow chart is shown below in figure 3.8

Figure 3.8: Program Flow Chart for the Microcontroller IC

Any of the two transistors Q1 or Q2 can be biased into conduction thereby grounding the

relay to be energized. This causes an automatic switch over to the GEN or generator

supply from the PHCN source. The only time the phcn source is constantly to the load is

36
when the two transistors are at off positions and that happens when the supply is

available, at the same time up to the standard value require for the A.C load. The

complete circuit diagram is shown in the figure 3.10 below.

CHAPTER FOUR

4.0 IMPLEMENTATION AND TESTING

37
The implementation of this project was carried out in stages, starting from bread-

boarding, veroboarding up to the final stage of arrangement and packaging even the

soldering exercise was carefully and skillfully carried out to avoid damage of the

components.

Primarily, it was in three parts – the software programming, the hardware assembling and

the combination of both parts as one unit on a veroboard.

4.1 SOFTWARE IMPLEMENTATION

The type of programming language used was a low level assembly language due to its

machine oriented ability and its electronic circuit friendliness. The peripheral interface

microcontroller chosen and used is the PIC16F84, the input/output data setting of the

microcontroller was software/program instruction based. MPLAB software (a software

program that runs on a PC to develop application for microchip microcontrollers and

digital signal controllers) was installed in a high definitive dual core HP system unit. This

made an easy access and running of a micro plan text assembler – MPASMWIN (an

executable file that helps in programming a microcontroller chip with assembly program)

that has already been installed in the system. With the flowchart established earlier on

during the design process, inputting of data was not as difficult as envisaged.

After the data writing and formatting on the system software, it was run on the

MPASMWIN text assembler for error-free confirmatory test. When it was confirmed

error-free, the program was now burn into microcontroller integrated circuit (IC) that is

used in the project which is PIC16F84.

4.2 BREADBOARDING AND VEROBOARDING ASSEMBLY

38
Breadboarding is simply a stage when all the electronic hardware components including

the PIC16F84 are carefully assembled on a construction base using the designed circuit

diagram as a guide. When this has been carried out, the initial results gotten were not as

expected. For instance, the reference voltages were adequately confirmed as inputs to the

comparator integrated circuits (ICs), but there was no output coming out from them, even

when there was noticeable power presence from the input public supply. A correction

was immediately effected by changing all the voltage reference components – the zener

diodes of D6 and D7(Chapter three circuit diagram).

The circuit was powered again. This time there was output voltages as inputs (high and

low values) to the comparators and with the presence of the input voltage to the

comparator, expected outputs were measured at their outputs. Thus a successful transfer

of assembled components from breadboard to veroboard was done with the desired result

gotten.

4.3 METHOD OF TESTING

The following stages of testing were carried out in the testing process

STAGE I:

An input supply of 220V was connected to the circuit, the output of the comparator was

measured to give zero (0) value, the pin terminal of the PIC16F84 was also low. As a

result the switching circuit transistor was at cut-off, but the voltage at pin1 of the

controller was high, making it produce low output at its pin8 terminal.

STAGE II:

39
Input voltage was reduced to a lower value by the variation of the potentiometer. The

comparator output went high, transistor Q2got biased becausethe pin9 of the

microcontroller went up. This caused relay A to energise, closing up on the generator to

come ON.

STAGE III:

When there was no output supply at all from PHCN pin1 and pin8 terminals of IC 3 went

high and low respectively causing transistor Q1 to be switched into saturation mode. Thus

the relay once again got energized as a result the generator is switched ON once again.

The implication is that the generator only came ON when either the public supply was

very low or not available at all.

4.4 CASING AND PACKAGING

This project is a prototype set target, therefore set of 100 watts bulbs, A.C voltage

powered, were connected to the output load.

The veroboard containing the soldered components is housed inside a rectangular shaped

box. All the external switches, the A.C bulb, circuit breakers and the cut-out fuses were

mounted externally on the box. Care was taken during all connections; the rectangular

box was made from a good quality plywood, painted with a high quality colour paint.

4.5 ACHIEVEMENTS

A design of this nature is a peculiar one, but effort was put in here to checkmate and

mitigate the effect of low voltage supply, since all other changeover devices only switch

over to generator when the supply is absent. This design does not only automatically

40
change over to generator as input supply to the load, but through the intelligence of the

programmed microcontroller, switch over to the generator at a time the supply is

dangerously low. This benefit will be useful in industries whose heavy and expensive

A.C machines are in use. After all, low voltage supply affects the machine windings more

than high voltages due to internal overheating.

CHAPTER FIVE

 CONCLUSION AND RECOMMENDATION

41
CONCLUSION

After a research work and findings on the existing changeover devices through the use of

cut-out fuses, a normal switching system and even automatic coil-energised changeovers,

a step-further was taken to put in place active component monitors to provide as input

data to a microcontroller software programmed chip in controlling the time and method

of switching over to a standby generator once there is low or no supply from public

power supply. It makes the design highly sensitive to avoid damaging effect of low

voltage in particular or instant changeover to the alternative source for a continous supply

to the load uninterrupted.

PROBLEMS ENCOUNTERED

 There was problem of inconsistent power supply during the design stages. This

caused mostly the delays as well as unstable data values, more so when the device

was power input based.

 Cost financing of the project seriously affected the progress of the work.

 Sourcing for components was also a constraining factor as it led to going to

distant cities such as Lagos and Portharcourt in order to purchase some major

components of the project.

 RECOMMENDATIONS

 The level of this project achieved is only at a prototype level and is therefore

unsafe for installation as a household device except the various power ratings of

42
 the components are upgraded.

 System design of the project can be enhanced for a multi-phase based input

instead of the single-phased input.

 All connections at various stages of the circuit design should be carefully re-

examined before the introduction of the high input voltages. This can be

disastrous if ignored

REFERENCES

Ahmed, M.S, Mohammed, A.S and Agusiobo O.B (2006): Development of Single

Phased Automatic Changeover Switch: African Union Journal, Vol.10, No.1. pp

43
 68 – 74.

Amos, S.W.; and James, M. 1981. Principles of transistor circuit: Introduction to the

design of amplifiers, receivers and digital circuits, 6th ed., Hartnolls Ltd.,

Bodmin, UK.

‘Automatic transfer switch’ retrieved from http//:www.wikipedia.com. July 15,

2011Katz, R and Boriello, G (2005): Contemporary Logic Design. 2nd

edition.Prentice Hall, Italy.Pp 445 – 589.

Kolo, J.G (2007). Design and Construction of an automatic Power Changeover Switch:

African Union Journal, Vol.2, No.11, pp113 – 118 (October, 2007).

L.S. Ezema, B.U. Peter, O.O. Harris (2012):Design Of Automatic Change Over Switch

With Generator Control Mechanism.Electrical Power and Electronic

Development Department, Projects Development Institute (PRODA), Enugu:

Natural and Applied Science, Vol.3, No.3. November, 2012. Pp 125 – 130.

Microcontrollerfeatures retrieved from

http://www.microchip.com/downloads/en/DeviceDoc/39630C.pdf)

Mbaocha C. (2012): Smart Phase Changeover Switch Using AT89C52 Microcontroller:

Journal of Electrical and Electronics Engineering Vol.1; Issue 3: pp 31 – 34.

Nwafor, C.M, Mbonu E.S, and Uzedhe G. (2012): Cost Effective Approach to

Implementing Changeover Systems: Academic Research International; Vol.2,

No.2

44
Robert Dowuona-Owoo (2008). Design and Construction of Three phase Automatic

Transfer Switch: A Thesis presented at Regent University College of Science and

Technology Ghana

ShanmukhaNagaraj& Ramesh S. (2013): Programmable Logic Controlled Circuits:

International Journal of Research in Engineering & Technology Vol.1, Issue 2,

July, 2013; pp 111 – 116.

Theraja, B.L and Therajah, A.K(2000). Electrical Technology.S.Chand and Company

Limited.New Delhi, 1999.

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