PROJECT

Mi
REPORT

Temperature Controlled
System
Mini Project
Kunal Ray

Manish Kumar

2009

DEPARTMENT OF INSTRUMENTATION
Mini Project Report – Temperature Controlled System

DESIGN OF TEMPERATURE CONTROLLED

SYSTEM

A Mini Project Report

Submitted To the Faculty Of The

Department of Instrumentation

Cochin University of Science And Technology

Towards partial fulfillment of the requirements for the Degree of B.Tech.

In Instrumentation Engineering

By

Kunal Ray

&

Manish Kumar

Approved By:

Mrs. Suniya V. S.

&

Mr. Anwar Sadath

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Acknowledgement

We would like to express our heart-felt gratitude to our project guides Mrs. Suniya
V. S. and Mr. Anwar Sadath for their unflinching support and guidance towards
the completion of this project. It is due to their kind support and timely advice that
this project has been able to see the light of the day.

Furthermore, our sincere thanks go to our Head of Department Dr. K. N.

Madhusodanan, who not only very kindly allowed us to make use of all the
excellent facilities in the Department, be it the workshop or the various
laboratories, but also channelized our resources in the right direction through
periodic mentoring.

We would also like to express our thanks to our Laboratory In-Charge Mr. Gopi
Menon for his constant backing and exceptional guidance.

Lastly, we would like to express our heartfelt gratitude to all our batchmates from
the class of 2010, who not only provided moral support but also helped us in every
way possible such that the project was completed in time and in a smooth manner.

Kunal Ray

Manish Kumar

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TABLE OF CONTENTS

Introduction……...………………………………………………………………05

Part I – Physical Arrangement…...…………………………………………….06

Part II – Circuit Requirements………………………………………………...11

Part III – Working………………………………………………………………21

Conclusion………………………………………………………………………25

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Introduction: Temperature is a physical property of a system that underlies the

common notions of hot and cold; something that feels hotter generally has the
higher temperature. Temperature is one of the principal parameters
of thermodynamics. If no net heat flow occurs between two objects, the objects
have the same temperature; otherwise heat flows from the hotter object to the
colder object. This is the content of the zeroth law of thermodynamics.

Temperature control finds varied uses in our everyday lives. Be it common room
coolers, air-conditioners or large industrial devices like boilers; the ability to
control temperature has not only improved our everyday lifestyle but has also
aided in almost all industrial processes. In short, the capability of humans of
controlling the physical parameters around them such as temperature have been
instrumental in their all round growth.

In this project, a temperature controller has been introduced which works in a

controlled environment. It is basically an ON-OFF controller which works
according to the value of the temperature. In other words, when the temperature
exceeds or is less than the set point value of temperature, corrective action is taken
to rectify it.

The project report given here is divided into three parts, where the first two parts
discuss the physical arrangements and the circuit requirements of the project giving
a detailed description of all the components used; and the third part gives a
thorough explanation of the working of the apparatus and how is it able to qualify
as a temperature controlled system.

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Mini Project Report – Temperature Controlled System

PART I

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Mini Project Report – Temperature Controlled System

Physical Arrangement:

A block diagram explaining the operation and physical structure of the project is
shown below:

The components used in order to create the physical controlled environment for the
project are as follows:

 12V/0.25A DC Brushless Fans (2 nos.)

 Nichrome wire wounded heater – 500Ω (1nos.)
 LM35 Temperature sensor (1 nos.)
 Tin Container (1 nos.)
 Glass lid.

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A detailed description of the components has been explained below:

12V DC Brushless Fans: The fans used for this project are of the DC Brushless
type. The cross-sectional diagram and the specifications are provided below –

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The specifications of the fan, as obtained from the manufacturer are as follows:

1. Voltage – 12
2. Current – 0.25
3. Power – 3.0
4. RPM – 3010
5. Air Flow (CFM) – 38.6
6. Pressure (inches) – 0.160
7. Noise (dB/A) – 34.4
8. Weight (gm) – 86

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Nickel-Chromium Strip Heater: A nickel-chromium (nichrome) heater of room

temperature resistance 500Ω has been used. A cross-sectional for the same is
shown –

When connected to a 230V AC power supply with a 5A current supply, the heater
is capable of reaching temperatures up to 120ºC. It is ideal for the project given its
ability to attain high temperatures in relatively low time intervals.

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PART II

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Circuit Requirements: The circuit employs the following components. A brief

description of every such component is given along with their specifications to
facilitate understanding.

 CA3130 Comparator (1nos.): A schematic of the CA3130

comparator is shown below.

Pin Out Diagram

The CA3130 series circuits operate at supply voltages ranging from
5V to 16V (±2.5V to ±8V). They can be phase compensated with a
single external capacitor, and have terminals for adjustment of offset
voltage for applications requiring offset-null capability. Terminals
provisions are also made to permit strobing of the output stage.

Absolute Maximum Ratings:

1. DC Supply Voltage (Between V+ And V- Terminals) . . . . .16V
2. Differential Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . .8V
3. DC Input Voltage . . . . . . . . . . . . . . . . . .(V+ +8V) to (V- -0.5V)
4. Input-Terminal Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1mA
5. Output Short-Circuit Duration (Note 1) . . . . . . . . . . . Indefinite
6. Operating Conditions Temperature Range . . . . . -50ºC to 125ºC

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A schematic diagram for the CA3130/3130A comparator is given below:

Explanation:

Input Stage: The circuit of the CA3130 is shown in the schematic diagram.
It consists of a differential-input stage using PMOS field-effect transistors
(Q6, Q7) working into a mirror-pair of bipolar transistors (Q9, Q10)
functioning as load resistors together with resistors R3 through R6. The
mirror-pair transistors also function as a differential-to single-ended

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converter to provide base drive to the second stage bipolar transistor (Q11).
Offset nulling, when desired, can be effected by connecting a 100,000Ω
potentiometer across Terminals 1 and 5 and the potentiometer slider arm to
Terminal 4.
Cascade-connected PMOS transistors Q2, Q4 are the constant-current source
for the input stage. The biasing circuit for the constant-current source is
subsequently described. The small diodes D5 through D8 provide gate-oxide
protection against high-voltage transients, including static electricity during
handling for Q6 and Q7.
Output Stage: The output stage consists of a drain-loaded inverting
amplifier using CMOS transistors operating in the Class A mode. When
operating into very high resistance loads, the output can be swung within
milli-volts of either supply rail. Because the output stage is a drain-loaded
amplifier, its gain is dependent upon the load impedance. The transfer
characteristics of the output stage for a load returned to the negative supply
rail are shown in the figure. Typical op amp loads are readily driven by the
output stage. Because large signal excursions are non-linear, requiring
feedback for good waveform reproduction, transient delays may be
encountered. As a voltage follower, the amplifier can achieve 0.01%
accuracy levels, including the negative supply rail.

 LM 35 Temperature Sensor (1nos.): The LM35 series are precision

integrated-circuit temperature sensors, whose output voltage is
linearly proportional to the Celsius (Centigrade) temperature. The
LM35 thus has an advantage over linear temperature sensors
calibrated in ° Kelvin, as the user is not required to subtract a large
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constant voltage from its output to obtain convenient Centigrade

scaling. The LM35 does not require any external calibration or
trimming to provide typical accuracies of ±1⁄4°C at room temperature
and ±3⁄4°C over a full −55 to +150°C temperature range. Low cost is
assured by trimming and calibration at the wafer level. The LM35’s
low output impedance, linear output, and precise inherent calibration
make interfacing to readout or control circuitry especially easy. It can
be used with single power supplies, or with plus and minus supplies.
As it draws only 60 μA from its supply, it has very low self-heating,
less than 0.1°C in still air. The LM35 is rated to operate over a −55° to
+150°C temperature range, while the LM35C is rated for a −40° to
+110°C range (−10° with improved accuracy).

Connection Schematic – LM35.

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A LM 35 temperature sensor provides extremely dependable

measurement of temperature, which can be observed using a multi-
meter with the help of basic calibration.

 IC7806-3pin voltage regulators (1nos.): These voltage regulators are

monolithic integrated circuits designed as fixed–voltage regulators for
a wide variety of applications including local, on–card regulation.
These regulators employ internal current limiting, thermal shutdown,
and safe–area compensation. With adequate heat sinking they can
deliver output currents in excess of 1.0 A. Although designed
primarily as a fixed voltage regulator, these devices can be used with
external components to obtain adjustable voltages and currents. The
pin diagram for the IC is shown as follows:

The standard method for connecting a 7806 voltage regulator is shown

below:

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The IC7806 used in this project provides a 6V output voltage, which

is used to drive all the different components like the comparator,
temperature sensor and the TIP122 which is explained below. Hence,
it provides a regulated output voltage maintained at 6V.

 TIP122 Darlington (1nos.): A TIP122 is an NPN epitaxial

Darlington transistor. In electronics the Darlington transistor (often
called a Darlington pair) is a compound structure consisting of two
bipolar transistors (either integrated or separated devices) connected
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in such a way that the current amplified by the first transistor is

amplified further by the second one. This configuration gives a much
higher current gain (written β, hfe, or hFE) than each transistor taken
separately and, in the case of integrated devices, can take less space
than two individual transistors because they can use
a shared collector. Integrated Darlington pairs come packaged in
transistor-like packages. A TIP122 along with its equivalent circuit
diagram is shown below:

A Darlington pair behaves like a single transistor with a high current

gain (approximately the product of the gains of the two transistors). In
fact, integrated devices have three leads (B, C and E), broadly
equivalent to those of a standard transistor.
A general relation between the compound current gain and the
individual gains is given by:

If β1 and β2 are high enough (hundreds), this relation can be

approximated with:

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 6V Relay (1nos.): A relay is an electrically operated switch. Electric

current through the coil of the relay creates a magnetic field which
attracts a lever and changes the switch contacts. The coil current can
be on or off so relays have two switch positions and they are double-
throw (changeover) switches. A photograph of the relay used in the
project is given below –

A simple electromagnetic relay, such as the one taken from a

car in the first picture, is an adaptation of an electromagnet. It consists
of a coil of wire surrounding a soft iron core, an iron yoke, which
provides a low reluctance path for magnetic flux, a movable
iron armature and a set, or sets, of contacts; two in the relay pictured.
The armature is hinged to the yoke and mechanically linked to a
moving contact or contacts. It is held in place by a spring so that when
the relay is de-energized there is an air gap in the magnetic circuit. In
this condition, one of the two sets of contacts in the relay pictured is
closed, and the other set is open.
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When an electric current is passed through the coil, the

resulting magnetic field attracts the armature and the consequent
movement of the movable contact or contacts either makes or breaks a
connection with a fixed contact. If the set of contacts was closed when
the relay was de-energized, then the movement opens the contacts and
breaks the connection, and vice versa if the contacts were open. When
the current to the coil is switched off, the armature is returned by a
force, approximately half as strong as the magnetic force, to its
relaxed position. A figure showing a typical relay operation is shown
below –

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PART III

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Working: The circuit diagram for the temperature controlled system using all the
above described components is shown below followed by an elaborate explanation.

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In the figure above,

R1 = 1.2KΩ

R2= 10KΩ

R3=12KΩ

R4=5.6KΩ

R5= 10KΩ Potentiometer

R6= 680Ω

And

C1 = 47µF

C2= 1µF

C3 = 0.1µF

The working of the temperature controlled system is relatively easy to understand.

In the project, the set point temperature is controlled by varying the potentiometer.
This is manifested as the voltage output (in mV) of the potentiometer. At the same
time, the output from the LM35 gives the ambient temperature in terms of mV.

The output of the LM35 is given to the pin no. 3 (non – inverting) of the
comparator. At the same time, the set point voltage is provided to the pin no. 2
(inverting) of the comparator. Initially, when the LM35 output is lower as
compared to the set point, the output as displayed by the pin 6 of the comparator
remains low. As soon as the LM35 output exceeds the set point value, the output
pin 6 of the comparator becomes high and this drives the Darlington pair TIP122
which in turn drives the relay.
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Simultaneously, the relay, in the normally closed position, is connected in such a

manner that the heating coil is connected to the mains i.e. 230V AC. Therefore, the
heater warms the surrounding air and the ambient temperature inside the container
increases. As soon as the ambient temperature becomes more than the set point
temperature, the comparator output through the Darlington pair drives the relay
into the normally open position which drives the 12V DC brushless fans. The two
fans, one acting as blower and the other as exhaust, work together to reduce the
ambient temperature, thereby bringing it below the set point value at which, the
heater once again gets switched on and the temperature starts increasing. This
process of ON – OFF control continues and the ambient temperature is controlled
and maintained as close to the set point value as physically possible.

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Conclusion: Temperature control is a process in which change of temperature of

a space (and objects collectively therewith in) is measured or otherwise detected,
and the passage of heat energy into or out of the space is adjusted to achieve a
desired average temperature.

In this project, a simple yet effective method to control the ambient temperature of
a closed space is discussed. This method can be further improved to deal with
bigger areas like rooms etc. Temperature control finds usage in our households and
industries. Whether we realize it or not, more often than not, almost all the
electronic and electrical devices that we use have some method or the other to
control temperature.

We hope that the method discussed here finds use in some industrial application
and justifies our endeavour.

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