Theory- Electronics and Instrumentation

Learning electronics in theory by studying books is the conventional way, this method may help in History and Maths. Maths needs a paper and pencil for practicals and history needs a well equipped Library. In these modern times, the web has made access to wide range of learning information easy, which is true Knowledge Empowerment. The greatest gift a Child can get from the Parents or School, is Knowledge.

Electronics Theory and Tutorials  

Process Control Instruments - These are some instruments i manufactured when i used to run my own industrial automation business.



Now many Virtual Electronics Workbench Software and Interactive Tutors are available, these aid learning. We have to design, build and apply some electronic ideas in 3D Hardware, for complimenting the Book, Academic or Web learning.

Practical and Theoretical study in electronics has to be in Tandem, this is possible only when Industry works with Universities to create real talent and skills in students. The applied technology is evolving, hence the academic education must be relevant when the student gets into his first job.

• Industrial Process Control Applications
• Process Control Instrumentation
• Instruction Manuals - Control Panels
• Test & Measurement Instruments
• Tutorials on Basics and Instrumentation
• Tutorials on Digital Electronics

The Evolution of Temperature Control

A closed loop controller is the heart of an Industrial Automation System. Right from an On-Off Hysteresis Controller to a Auto Tune PID Controller, we find solutions of different complexities. Each solution might suit a particular system; depending on the requirements of Ease-of-use, Cost and Process Type.

• Industrial Process Control Applications
• Process Control Instrumentation

A PC based multiplexed scanner controller with data-acquisition cards and I/O Cards can be solution for Laboratory or Research. This is used when real time control is not required or where the control failure will not lead to damage or loss.

A PLC or Microcontroller based controller should be used with a Analog Controller Protection or Over temperature Trip-Alarm.

Electromagnetic Relays and SSR

Solid State Relays - These designs were improvements i made on the Application Notes of Motorola Semiconductor (freescale) and Thomson CSF (stmicro) Thyristor Data. The parts are still available, now made by other firms. You can also find similar equivalents.

Solid State Relays - SSR

They are called SSR as there are made of semiconductors and have no moving parts to wear out. They do generate heat depending on load and switching. Thyristors are used in most as they are rugged, mosfets and IGBT may also be used for various applications.



In this section you will find SSR designs and PCB layouts which you can study. These were made and sold by me years ago. So the PCB layouts have gone thru some revisions and they worked quite well.

• DC Load DC Control Solid State Relay.
• DC-AC Solid State Relay or SSR.
• NO AC Load SSR with DC control.
• PCB AC Load SSR with DC control.
• NC AC Load SSR with DC control.
• AC-AC Solid State Relay or SSR.

Electrical Control Panel Wiring

Control panels are a part of industrial automation. It contains many DIN standard instruments both in the front panel and inside back rails along with the wiring. They are called panel mounting and rail mounting. Cable management is a Science in these equipment.

Just like rackmounts hold big instruments or computers, control panels small or big have to hold DIN Instruments, switches and annunciators to make it easy for the operator. The maintenance work also is simple from the backside. It can be kept near the machinery which it controls.



Some Control panels go into Control Rooms at a distance away or at a greater height from the shop floor. This way they can monitor and give instructions while managing a larger process like processing of chemicals and at the same time safeguarding the instrumentation and computers with controlled environments.

Some example circuits of panels here Electrical Control Panel Wiring

delabs Technologies

Temperature Measurement and Control

Temperature Controller 48-96 - A 1/8 DIN Indicating Temperature Controller. This is a Analog Controller built around ICL7107.

Temperature Measurement and Control

This is a 48-96 DIN Temperature Controller, it is mains operated, it is in a Industrial Plastic Housing. It is not meant for very harsh environments. Suitable for Control Panels in Control Rooms. It has a accuracy and linearity of 0.5%. It had options of on-off or time proportional control



J and K Thermocouple with 4-20 mA

Temperature is the most common process parameter, Pressure seems to be next. Flow, Humidity, Strain, Torque, Level, RPM, Distance and many more follow.

When a physical parameter let us say distance is measured, we first need a sensor that converts it into electrical values, digital, pulses(events/limit) or analog. The sensor used for length is a Linear encoder and it creates the electrical information for the DRO to Display.

Mixed Circuits Analog with Digital

Digital Interface to Analog Circuits is an example of Mixed Signal Design. Generating Digital Control Signals from the Analog sections in instruments is also done by Mixed Signal Circuit.

A/D Convertors and D/A Convertors are like Mixed Signal Chips. A Digital Potentiometer that controls an analog signal amplitude with a digital byte or word, figures in Mixed Design Circuit.

Analog Designs have to handle Linear Signals, Like 2.03 V and 35.3812 mA. Waveforms of all shapes from Straight Line DC Levels to the Jittery and Multi-Frequency Audio Waveforms.

Mixed Circuits Analog with Digital

350 MHz Mixed Signal Oscilloscope HMO3524 by HAMEG Instruments

Mixed Signal IC or ASIC are chips that are mainly Digital on the Core but have peripheral I/O within the chip to interface with the real world outside, over Analog Signals. Sensors and Actuators use signals in the analog language. The CPU with its Math Power, speaks Digital Words, its behavior thus can be patterned by a Software Program.

Fluid or Water Level with Reed Relays

Some Circuits on above pages are..

• Voltage to pulse converter using opamps
• Analog Section of 8751 based flowmeter
• Voltage to pulse converter impulse counter
• 16 channel analog multiplexer
• 8 channel analog mux with sample hold
• Digital Control for 8 channel analog mux

Basic Electrical Circuits

Electrical Engineering encompasses Everything in Electronics. Communications, Computers etc. are further specializations of Electronics. So it is best to Identify Electrical Circuits with Electrical Designs which excludes Active Devices. It can include Electronic Products in the form of wireable modules.

• Electrical Control Panel Wiring
• Circuits using only  discrete devices
• Electronic Tables and Charts
• Mains Voltage and Power Circuits

So House and Factory wiring, Appliances like Ovens, Toasters, Power Generation and management; all these are electrical. Motors, Generators, Connectors, Relays, Contacters and Circuit Breakers are Electrical Components.

See a diagram i made for a Sequential Process Control Unit, custom built for Vacuum Impregnation;



A Radio or Power Inverter is Electronic. When an Inverter or Electronic AC-DC Motor Drive is used in a Control panel or Power Supply system, that integration is shown as an Electrical Circuit. I feel Simple Consumer Electronic Circuits using Diodes, Transistors, SCR, Capacitors and Resistors can also be taken under electrical circuits; when they are used in Mains-Power or Household Appliances. Solar Energy related circuits also can be studied under Electrical Power Circuits.

In Electronics RF-Microwave and Communications is a specialization area, Computer Hardware, Software, Internet form another major domain. Networking and Wireless data communication overlaps both the above.

Power Electronics and Instrumentation are fundamental domains needed for many. Industrial Automation with Process Control Instrumentation is unique, but is supported by the fundamental domains. Many more finer areas like Robotics and Medical Electronics have a much sharper focus.

Basic Electrical Circuits - delabs

delabs Technologies

Embedded Microcontroller Systems

Analog devices like transistors and diodes lead to opamps and analog computing. This takes more parts but with fast devices can be real time. Then came Logic and Digital Circuits, here also big systems will take too many parts. A very Old hp Logic Analyzer instrument, could be HP1607A, had more than five large PCBs, Toggle Switches and numerous 74Fxx TTL Chips. I tried to revive it, it could not be fully restored.

Embedded Microcontroller - delabs

Then came the solution the Microprocessor. Here the entire system goes into the firmware and a Hardware Tool Set in the Microprocessor made up of Logic and Math is sequentially used to perform the same operation that would require innumerable Gates in a plain hardware digital circuit. But as it performs the operations one after another, it takes time and is defined by the CPU Clock Speed.



When the External RAM and EPROM and other peripheral devices moved into the main package, MicroController were born. When more external devices merged with the MicroController. It formed a nearly complete computer, this is known as the SOC.

• 80C51, SBC, Firmware and Circuits.
• Microcomputer Circuits in Process Control.
• Interface 80C51-80C31-89C51 to ICL7135.
• 80C39-8749 MCS-48 Examples and code.