-Enabled Thermocouple Readout

Daniel A. Steck Theoretical Division (T-8), MS B285 Los Alamos National Laboratory Los Alamos, NM 87545

29 April 2004

1 Introduction

Capabilities: 1. 8 multiplexed thermocouple inputs. 2. Support for J-type thermocouples, easy conversion to K-type by changing thermocouple connectors and switching to AD595. 3. 12-bit ADC over 5 V range for nominal 0-480◦ range and 0.1◦C resolution; noise rejection will be done in software if necessary by multiple sampling.

4. 100 base-T Ethernet connection for http temperature readout or telnet readout of temperature and network reprogramming of device. 5. 20x2 LCD character display for temperature readout, with software-selectable LED backlight.

2 Hardware Notes 3 Configuration

1. Set up a method for communicating via a terminal over a DB-9 serial connection from your computer. I used minicom v. 2.1, which can be compiled under OS X and run under Terminal.app. Another freeware terminal application that should work without much effort is MacTNC. For the serial port connection, I used the Keyspan High Speed USB Serial Adaptor (USA-19HS); under minicom I configured the connection to use /dev/tty.USA19H191P1.1 (look in /dev once the device is plugged in to see what the proper setting should be). 2. Follow the instructions in the Ethernut Hardware Manual to test the Ethernut board via the serial port and configure its network settings using the BaseMon program. 3. Install binutils (under OS X 10.3.3, I used v. 2.14). As root, the procedure would be something like tar xvzf binutils-2.14.tar.gz; cd binutils-2.14; ./configure --target=avr; make; make install.Ad- ditional information is available at http://www.mit.edu/people/mseeman/resources/macmicro.html. 4. Install avr-gcc (under OS X 10.3.3, I used v. 3.3.2). As root, the procedure would be something like tar xvzf gcc-core-3.3.2.tar.gz; cd gcc-3.3.2; ./configure --target=avr --enable-languages=c; make CC="cc -no-cpp-precomp"; make install. Additional information is available at http://www.mit.edu/people/mseeman/resour 3 CONFIGURATION 2 1 1 1 8 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Qty $19 $160 $7.85 $2.55 $1.75 $7.96 $1.11 $7.18 $1.58 $1.88 $4.10 $3.06 $8.50 $1.32 $0.63 $7.33 $3.07 Unit $10.43 $20.93 Vendor P/N Q300-ND AD594AQ-ND Ethernut Bulk V2 01H0904 SMP-J-M GG-J-20-25 13C1167 25C5739 ADC12130CIWM- ND LM4040BIM3- 5.0CT-ND X109-ND 73-1057-ND PRD360LPW-ND 47F1106 PS-926 172-1016 163-5004 517-1M-1010-064-6 517-1M-1010-014- 12 Vendor Digi-Key Mouser All Electronics Digi-Key Omega Digi-Key Digi-Key Newark ImageCraft Newark Omega Digi-Key Newark Newark Digi-Key Digi-Key Mouser Mouser Mouser Cmaxtemp ◦ C temperature coefficient, ◦ Description with ethernet interface power entry module, SPST switch, fuse SOT-23 PC mount miniature J typenector thermocouple con- J type thermocouple maleJ type connector thermocouple wire, 20 AWG, glassinsulation, braid 25’ spool,thermocouple 482 amplifiercompensation with8 cold channelwide differential junction package multiplexer,quad NO SOIC-28 SPST analog switch, SOIC-16package narrow 12 bit ADC, self-calibrating,5V SOIC-16 micropower shunt voltagetolerance, reference, 100ppm/ 0.2% TTL oscillator, 5.000 MHz LCD character display, 20x2, yellow LEDlight back- bezel for LCD characterSPST display DIP relay, 5V coil 9V, 2.6A regulated switching power supply DC power cable, rightplug, 6” angle, 24 2.1 AWG mmDC power jack, locking PC mount, 2.1ribbon mm, cable right assy, angle 0.1” contact spacing,ductor, 64 6” con- 28 AWG ribbon cable assy, 0.1” contact spacing,ductor, 14 12” con- 28 AWG Part Number AD594AQ 761-18/003 AD-715U-1090 Ethernut 2.0 Rev. A PCC-SMP-J SMP-J-M GG-J-20-25 DG407DW DG412LDY ADC12130CIWM LM4040BIM3-5.0 ECS-100A-050 DMC20261NY-LY- AXE 6303020 W107DIP-1 - - 1M-1010-064-3365- 006.0-00-AB-00-0 1M-1010-014-3365- 012.0-00-AB-00-0 Table 1. Parts list used for sample assembly of thermocouple readout. Prices in USD are current as of April 2004. Manufacturer egnite Software GMBH Omega Omega Omega Analog Devices Vishay Siliconix Vishay Siliconix National Semi- conductor National Semi- conductor ECS Inc. Optrex PRD Plastics Magnecraft APS Qualtek Kobiconn Kobiconn 3M 3M 3 CONFIGURATION 3 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 5 3 5 6 8 Qty Unit $3.60 $2.07 $0.78 $0.84 $1.32 $0.44 $0.65 $1.73 $1.50 $0.09 $0.09 $0.09 $0.09 $2.50 $2.50 $0.65 $0.81 $0.13 $0.13 $0.26 $15.38 Vendor P/N 929665-09-36-ND WM5862-ND WM5872-ND DF15005SDICT- ND 74C3882 P6KE15CACCCT- ND 283-2356-ND 283-2120-ND 13B825 271-121 271-330 271-1K 271-20K 3296W-101-ND 3296W-203-ND 74-199D16V10 74-199D16V22 75- 1C10Z5U103M050B 75- 1C10Z5U104M050B HM253-ND 2203K-ND Vendor Newark Digi-Key Digi-Key Digi-Key Digi-Key Mouser Mouser Mouser Mouser Mouser Mouser Newark Newark Digi-Key Digi-Key Digi-Key Digi-Key Mouser Mouser Digi-Key Digi-Key × 39870-0102 ter- Description Table 1. (continued) 3” F, 50 V monolithic ceramic radial capac- F, 50 V monolithic ceramic radial capac- × µ F, 16 V tantalum radialF, capacitor 16 V tantalum radial capacitor µ µ µ itor, 20% tolerance PC-Tron 1 A fuse, short leads PC-Tron fuse socket, PC mount 72 pin double rowpluggable 0.1” low-profile terminal header block,spacing 2 position,straight header 5 receptacle mm minal for block 1.5 A rectifier bridge, DF-S case 1.5 A adjustible voltage regulator, TO-263 15 V, 600 W transient voltage suppressor 8.2 Ω, 5 W121 thick-film Ω, 1/4 chip W, 1% resistor330 metal-film Ω, resistor 1/4 W, 1%1 metal-film kΩ, resistor 1/4 W, 1%20 metal-film kΩ, resistor 1/4 W, 1%100 metal-film Ω, resistor 25 turn cermet20 trim kΩ, pot 25 turn cermet10 trim pot 22 0.01 0.1 itor, 20% tolerance Styrene 2-piece plastic instrument7.9” case, 11”Aluminum hexlength standoff, 4-40 , 0.5” Part Number P6KE15CA DF15005S-T 1598JSGY TA205PA8R20J 3296W-101 271-1K 271-20K 929665-09-36-I 39870-0102 39870-0702 LM1086CS-ADJ BK/PCS BK/PCC-1 271-121 271-330 3296W-203 199D106X9016C1V1 199D226X9016D1V1 1C10Z5U103M050B 1C10Z5U104M050B 2203 Manufacturer 3M Molex Molex Diodes Inc. National Semi- conductor Littelfuse Inc. Bussmann Bussmann Ohmite Xicon Xicon Xicon Xicon Bourns Bourns Vishay/Sprague Vishay/Sprague Vishay Vishay Hammond Keystone Elec- tronics 3 CONFIGURATION 4

5. Install avr-libc (under OS X 10.3.3, I used v. 1.0.4). As root, the procedure would be something like tar xvzf avr-libc-1.0.4.tar.gz; cd avr-libc-1.0.4; ./doconf; ./domake; ./domake install. Additional information is available at http://www.mit.edu/people/mseeman/resources/macmicro.html. 6. Compile the ethernut software (included in the Ethernut Starter Kit cd). I used v. 3.4.2. The procedure here is: bunzip2 ethernut-3.4.2.tar.bz2; tar xvf ethernut-3.4.2.tar.Thencd ethernut/nut,modify the configure script and comment out the exit 1 statement near the beginnning of the file. Then ./configure and select atmega128 and STK-500 options. Then make; mkdir -p lib/gcc/atmega128; make install. To build the crurom tool, make -C tools/crurom/; mkdir -p tools/linux; ln tools/crurom/cruro tools/linux/. Then build the sample applications: mkdir -p bin/atmega128; make apps apps-install. 4PCBOARD 5

Figure 1: Top PCB silk layer.

4PCBoard 4PCBOARD 6

Figure 2: Top PCB solder mask layer. 4PCBOARD 7

Figure 3: Top PCB copper layer. 4PCBOARD 8

Figure 4: Bottom PCB copper layer (view from top of board). 4PCBOARD 9

Figure 5: Bottom PCB solder mask layer (view from top of board).