PERMANENT SWITCH BOARD

MONITORING USING EMBEDDED WEB

SERVER

CONTENTS
CHAPTER PAGE
TITLE
NO. NO.

1 ABSTRACT 3
2 INTRODUCTION 4
3 BLOCK DIAGRAM 5
4 BLOCK DIAGRAM DESCRIPTION 6
4.1 ABOUT MICROCONTROLLER 6
4.2 LIQUID CRYSTAL DISPLAY 30
4.3 VOLTAGE MEASUREMENT 32
4.4 RELAY 33
4.4 ALARM 34
5 OVERALL CIRCUIT DIAGRAM 35
6 OVERALL CIRCUIT DIAGRAM DESCRIPTION 36
6.1 POWER SUPPLY CIRCUIT 36
6.2 MICROCONTROLLER CIRCUIT 41
6.3 VOLATGE MEASURMENT CIRCUIT 42
6.4 ALARM 44
6.5 RS232 46

1
7 PCB DESIGN 49
7.1 INTRODUCTION 49
7.2 SOFTWARE 49
7.3 MANUFACTURING 49
7.4 PANELISATION 50
7.5 PLATING 50
7.6 ETCHING 50
7.7 SOLDER MASK 50
7.8 HOT AIR LEVELING 51
8 SOFTWARE TOOLS 52
8.1 KEILC COMPILER 53
8.2 SIMULATOR 53
9 ADVANTAGES 54
10 APPLICATIONS 54
11 CONCLUSION 55
12 REFERENCES 56

2
1. ABSTRACT

The proposed paper discusses the realization of a

system prototype able to perform a permanent monitoring of a switchboard in
order to allow the manufacturer the complete management of all the measurable
quantities in the switchboard, specially the sensed voltage for each line. The
main purpose is to prevent any fault that can affect the switchboard and provide
an instant alarming if anomalous values are revealed. The significant aspect of
our prototype is the internetworking between several standard network protocols.
In fact, the acquisition network sends the acquired data using the EIA 485
serial protocol. These data are then collected into an embedded web server ad-
hoc developed. The server can be connected to the Internet in a wired and/or
wireless way using the IEEE 802.3 (Ethernet) and the IEEE 802.11 (Wi-Fi)
protocols.Finally, the web server uses standard TCP/IP protocols, such as
HTTP to manage the web pages and SMTP to dispatch automatic alarm
notifications via e-mails

3
2. INTRODUCTION

Present industry is increasingly shifting towards automation. Two

principle components of today’s industrial automations are programmable
controllers and robots. In order to aid the tedious work and to serve the
mankind, today there is a general tendency to develop an intelligent
operation.

The proposed system “PERMANENT SWITCH BOARD

MONITORING USING EMBEDDED WEB SERVER” is designed and
developed to accomplish the various tasks in an adverse environment of an
industry. The intelligent machine is loaded with several units such as voltage
measurement, LCD, microcontroller, and alarm which synchronously work
with the help of a start-of-the-art PIC microcontroller. This project is an owe
to the technical advancement. This prototype system can be applied
effectively and efficiently in an expanded dimension to fit for the
requirement of industrial, research and commercial applications.

Microcontroller is the heart of the device which handles all the sub
devices connected across it. We have used as microcontroller. It has flash
type reprogrammable memory. It has some peripheral devices to play this
project perform. It also provides sufficient power to inbuilt peripheral
devices. We need not give individually to all devices. The peripheral devices
also activates as low power operation mode. These are the advantages are
appear here.

4
3. BLOCK DIAGRAM

5
4. BLOCK DIAGRAM DESCRIPTION

4. 1 MICROCONTROLLER

2.1 CONCEPTS OF MICROCONTROLLER:

Microcontroller is a
general purpose device, which integrates a number of the components of a
microprocessor system on to single chip. It has inbuilt CPU, memory and
peripherals to make it as a mini computer. A microcontroller combines on to the
same microchip:

The CPU core

Memory(both ROM and RAM)

Some parallel digital i/o

Microcontrollers will combine other devices such as:

A timer module to allow the microcontroller to perform tasks for certain
time periods.

A serial i/o port to allow data to flow between the controller and other
devices such as a PIC or another microcontroller.

An ADC to allow the microcontroller to accept analogue input data for
processing.

Microcontrollers are :

Smaller in size

Consumes less power

Inexpensive

Micro controller is a stand alone unit ,which can perform functions

on its own without any requirement for additional hardware like i/o ports and
external memory.

6
The heart of the microcontroller is the CPU core. In the past, this has traditionally
been based on a 8-bit microprocessor unit. For example Motorola uses a basic
6800 microprocessor core in their 6805/6808 microcontroller devices.
In the recent years, microcontrollers have
been developed around specifically designed CPU cores, for example the
microchip PIC range of microcontrollers.

2.2 INTRODUCTION TO PIC :

The microcontroller that has been used for
this project is from PIC series. PIC microcontroller is the first RISC based
microcontroller fabricated in CMOS (complimentary metal oxide semiconductor)
that uses separate bus for instruction and data allowing simultaneous access of
program and data memory.
The main advantage of CMOS and RISC
combination is low power consumption resulting in a very small chip size with a
small pin count. The main advantage of CMOS is that it has immunity to noise
than other fabrication techniques.

PIC (16F877) :
Various microcontrollers offer different kinds
of memories. EEPROM, EPROM, FLASH etc. are some of the memories of
which FLASH is the most recently developed. Technology that is used in
pic16F877 is flash technology, so that data is retained even when the power is
switched off. Easy Programming and Erasing are other features of PIC 16F877.

PIC START PLUS PROGRAMMER :

The PIC start plus development system from
microchip technology provides the product development engineer with a highly
flexible low cost microcontroller design tool set for all microchip PIC micro
devices. The picstart plus development system includes PIC start plus
development programmer and mplab ide.

7
 The PIC start plus programmer gives the product developer
ability to program user software in to any of the supported microcontrollers. The
PIC start plus software running under mplab provides for full interactive control
over the programmer.

2.3 SPECIAL FEATURES OF PIC MICROCONTROLLER :

CORE FEATURES :
• High-performance RISC CPU
• Only 35 single word instructions to learn
• All single cycle instructions except for program branches which are two cycle
• Operating speed: DC - 20 MHz clock input
DC - 200 ns instruction cycle
• Up to 8K x 14 words of Flash Program Memory,
Up to 368 x 8 bytes of Data Memory (RAM)
Up to 256 x 8 bytes of EEPROM data memory
• Pin out compatible to the PIC16C73/74/76/77
• Interrupt capability (up to 14 internal/external
• Eight level deep hardware stack
• Direct, indirect, and relative addressing modes
• Power-on Reset (POR)
• Power-up Timer (PWRT) and Oscillator Start-up Timer (OST)
• Watchdog Timer (WDT) with its own on-chip RC Oscillator for reliable
operation
• Programmable code-protection
• Power saving SLEEP mode
• Selectable oscillator options
• Low-power, high-speed CMOS EPROM/EEPROM technology
• Fully static design
• In-Circuit Serial Programming (ICSP) via two pins
• Only single 5V source needed for programming capability
• In-Circuit Debugging via two pins

8
 • Processor read/write access to program memory
• Wide operating voltage range: 2.5V to 5.5V
• High Sink/Source Current: 25 mA
• Commercial and Industrial temperature ranges
• Low-power consumption:
< 2mA typical @ 5V, 4 MHz
20mA typical @ 3V, 32 kHz
< 1mA typical standby current

PERIPHERAL FEATURES :
• Timer0: 8-bit timer/counter with 8-bit prescaler
• Timer1: 16-bit timer/counter with prescaler, can be incremented during sleep
via external crystal/clock
• Timer2: 8-bit timer/counter with 8-bit period register, prescaler and postscaler
• Two Capture, Compare, PWM modules
Capture is 16-bit, max resolution is 12.5 ns,
Compare is 16-bit, max resolution is 200 ns,
PWM max. resolution is 10-bit
• 10-bit multi-channel Analog-to-Digital converter
• Synchronous Serial Port (SSP) with SPI. (Master Mode) and I2C.
(Master/Slave)
• Universal Synchronous Asynchronous Receiver Transmitter (USART/SCI)
with
9- bit address detection.
• Brown-out detection circuitry for Brown-out Reset (BOR)

9
2.4 ARCHITECTURE OF PIC 16F877 :
The complete architecture of
PIC 16F877 is shown in the fig 2.1. Table 2.1 gives details about the
specifications of PIC 16F877. Fig 2.2 shows the complete pin diagram of the IC
PIC 16F877.
FIG 2.1 ARCHITECTURE OF PIC 16F877

10
 TABLE 2.1 SPECIFICATIONS

DATA DATA EEPROM

DEVICE PROGRAM FLASH
MEMORY
PIC
8K 368 Bytes 256 Bytes
16F877

FIG 2.2 PIN DIAGRAM OF PIC 16F877

TABLE 2.2 PIN OUT DESCRIPTION

11
Legend: I = input O = output I/O = input/output P = power
— = Not used TTL = TTL input ST = Schmitt Trigger input
Note
1. This buffer is a Schmitt Trigger input when configured as an external interrupt
2. This buffer is a Schmitt Trigger input when used in serial programming mode.
3. This buffer is a Schmitt Trigger input when configured as general purpose I/O
and a TTL
input when used in the Parallel Slave Port mode (for interfacing to a
microprocessor bus).

12
4. This buffer is a Schmitt Trigger input when configured in RC oscillator mode
and a
CMOS input otherwise.

Legend: I = input O = output I/O = input/output P = power

— = Not used TTL = TTL input ST = Schmitt Trigger input
Note :
1. This buffer is a Schmitt Trigger input when configured as an external interrupt.
2. This buffer is a Schmitt Trigger input when used in serial programming mode.

13
3. This buffer is a Schmitt Trigger input when configured as general purpose I/O
and a TTL
input when used in the Parallel Slave Port mode (for interfacing to a
microprocessor bus).
4. This buffer is a Schmitt Trigger input when configured in RC oscillator mode
and a
CMOS input otherwise.

2.5 I/O PORTS :

Some pins for these I/O ports are multiplexed with an
alternate function for the peripheral features on the device. In general, when a
peripheral is enabled, that pin may not be used as a general purpose I/O pin.
Additional Information on I/O ports may be found in the IC
micro™ Mid-Range Reference Manual,

PORTA AND THE TRISA REGISTER :

PORTA is a 6-bit wide bi-directional port. The corresponding
data direction register is TRISA. Setting a TRISA bit (=1) will make the
corresponding PORTA pin an input, i.e., put the corresponding output driver in a
Hi-impedance mode. Clearing a TRISA bit (=0) will make the corresponding
PORTA pin an output, i.e., put the contents of the output latch on the selected
pin. Reading the PORTA register reads the status of the
pins whereas writing to it will write to the port latch. All write operations are read-
modify-write operations. Therefore a write to a port implies that the port pins are
read; this value is modified, and then written to the port data latch. Pin RA4 is
multiplexed with the Timer0 module clock input to become the RA4/T0CKI pin.
The RA4/T0CKI pin is a Schmitt Trigger input and an open drain output. All other
RA port pins have TTL input levels and full CMOS output drivers. Other PORTA
pins are multiplexed with analog inputs and analog VREF input. The operation of
each pin is selected by clearing/setting the control bits in the ADCON1 register
(A/D Control Register1).

14
 The TRISA register controls the direction of the RA pins, even when they
are being used as analog inputs. The user must ensure the bits in the TRISA
register are maintained set when using them as analog inputs.

TABLE 2.3 PORT A FUNCTION

Legend: TTL = TTL input, ST = Schmitt Trigger input

TABLE 2.4 SUMMARY OF REGISTERS ASSOCIATED WITH PORTA

Legend: x = unknown, u = unchanged, - = unimplemented locations

read as '0'. Shaded cells are not used by PORTA.

PORTB AND TRISB REGISTER :

PORTB is an 8-bit wide bi-directional

port. The corresponding data direction register is TRISB. Setting a TRISB bit (=1)
will make the corresponding PORTB pin an input, i.e., put the corresponding
output driver in a hi-impedance mode. Clearing a TRISB bit (=0) will make the
corresponding PORTB pin an output, i.e., put the contents of the output latch on

15
the selected pin. Three pins of PORTB are multiplexed with the Low Voltage
Programming function; RB3/PGM, RB6/PGC and RB7/PGD. The alternate
functions of these pins are described in the Special Features Section. Each of
the PORTB pins has a weak internal pull-up. A single control bit can turn on all
the pull-ups.
This is performed by clearing bit RBPU
(OPTION_REG<7>). The weak pull-up is automatically turned off when the port
pin is configured as an output. The pull-ups are disabled on a Power-on Reset.

Four of PORT B’s pins, RB7:RB4, have an interrupt

on change feature. Only pins configured as inputs can cause this interrupt to
occur (i.e. any RB7:RB4 pin configured as an output is excluded from the
interrupt on change comparison). The input pins (of RB7:RB4) are compared with
the old value latched on the last read of PORTB. The “mismatch” outputs of
RB7:RB4 are OR’ed together to generate the RB Port Change Interrupt with flag
bit RBIF (INTCON<0>). This interrupt can wake the device from SLEEP. The
user, in the interrupt service routine, can clear the interrupt in the following
manner:
a) Any read or write of PORTB. This will end the mismatch condition.
b) Clear flag bit RBIF. A mismatch condition will continue to set flag
bit RBIF. Reading PORTB will end the mismatch condition, and allow flag bit
RBIF to be cleared. The interrupt on change feature is recommended for wake-
up on key depression operation and operations where PORTB is only used for
the interrupt on change feature. Polling of PORTB is not recommended while
using the interrupt on change feature. This interrupt on mismatch feature,
together with software configurable pull-ups on these four pins, allow easy
interface to a keypad and make it possible for wake-up on key depression

16
 TABLE 2.5 PORT B FUNCTIONS

TABLE 2.6 SUMMARY OF REGISTERS ASSOCIATED WITH PORTB

PORTC AND THE TRISC REGISTER :

PORTC is an 8-bit wide bi-directional
port. The corresponding data direction register is TRISC. Setting a TRISC bit
(=1) will make the corresponding PORTC pin an input, i.e., put the corresponding
output driver in a hi-impedance mode. Clearing a TRISC bit (=0) will make the
corresponding PORTC pin an output, i.e., put the contents of the output latch on

17
the selected pin. PORTC is multiplexed with several peripheral functions.
PORTC pins have Schmitt Trigger input buffers.

When the I2C module is enabled,

the PORTC (3:4) pins can be configured with normal I2C levels or with SMBUS
levels by using the CKE bit (SSPSTAT <6>). When enabling peripheral functions,
care should be taken in defining TRIS bits for each PORTC pin. Some
peripherals override the TRIS bit to make a pin an output, while other peripherals
override the TRIS bit to make a pin an input. Since the TRIS bit override is in
effect while the peripheral is enabled, read-modify write instructions (BSF, BCF,
XORWF) with TRISC as destination should be avoided. The user should refer to
the corresponding peripheral section for the correct TRIS bit settings.

TABLE 2.7 PORTC FUNCTIONS

18
 TABLE 2.8 SUMMARY OF REGISTERS ASSOCIATED WITH PORTC

PORTD AND TRISD REGISTERS :

This section is not applicable to the 28-
pin devices. PORTD is an 8-bit port with Schmitt Trigger input buffers. Each pin
is individually configurable as an input or output. PORTD can be configured as
an 8-bit wide microprocessor Port (parallel slave port) by setting control bit
PSPMODE (TRISE<4>). In this mode, the input buffers are TTL.

TABLE 2.9 PORTD FUNCTIONS

TABLE 2.10 SUMMARY OF REGISTERS ASSOCIATED WITH PORTD

19
PORTE AND TRISE REGISTER :
PORTE has three pins RE0/RD/AN5,
RE1/WR/AN6 and RE2/CS/AN7, which are individually configurable as inputs or
outputs. These pins have Schmitt Trigger input buffers.
The PORTE pins become control inputs for the
microprocessor port when bit PSPMODE (TRISE<4>) is set. In this mode, the
user must make sure that the TRISE<2:0> bits are set (pins are configured as
digital inputs). Ensure ADCON1 is configured for digital I/O. In this mode the
input buffers are TTL.
PORTE pins are multiplexed with analog
inputs. When selected as an analog input, these pins will read as '0's. TRISE
controls the direction of the RE pins, even when they are being used as analog
inputs. The user must make sure to keep the pins configured as inputs when
using them as analog inputs.

20
 TABLE 2.11 PORTE FUNCTIONS

TABLE 2.12 SUMMARY OF REGISTERS ASSOCIATED WITH PORTE

2.6 MEMORY ORGANISATION :

There are three memory blocks in each
of the PIC16F877 MUC’s. The program memory and Data Memory have
separate buses so that concurrent access can occur.

PROGRAM MEMORY ORGANISATION :

The PIC16f877 devices have a 13-bit
program counter capable of addressing 8K *14 words of FLASH program
memory. Accessing a location above the physically implemented address will
cause a wraparound.

21
The RESET vector is at 0000h and the interrupt vector is at 0004h.

DATA MEMORY ORGANISTION :

The data memory is partitioned into
multiple banks which contain the General Purpose Registers and the special
functions Registers. Bits RP1 (STATUS<6) and RP0 (STATUS<5>) are the bank
selected bits.
RP1:RP0 Banks
00 0
01 1
10 2
11 3

Each bank extends up to 7Fh (1238

bytes). The lower locations of each bank are reserved for the Special Function
Registers. Above the Special Function Registers are General Purpose
Registers, implemented as static RAM. All implemented banks contain special
function registers. Some frequently used special function registers from one
bank may be mirrored in another bank for code reduction and quicker access.

22
PIC16F877 REGISTER FILE MAP

23
GENERAL PURPOSE REGISTER FILE :
The register file can be accessed either
directly or indirectly through the File Selected Register (FSR). There are some
Special Function Registers used by the CPU and peripheral modules for
controlling the desired operation of the device. These registers are implemented
as static RAM. The Special Function Registers can be classified into two sets;
core (CPU) and peripheral. Those registers associated with the core functions.

2.7 INSTRUCTION SET SUMMARY :

Each PIC 16f877 instruction is a 14-bit
word, divided into an OPCODE which specifies the instruction type and one or
more operand which further specify the operation of the instruction. The
PIC16F877 instruction set summary in Table 2.13 lists byte-oriented, bit-
oriented, and literal and control operations. It shows the opcode Field
descriptions.

TABLE 2.13 OPCODE FIELD DESCRIPTIONS

24
 For byte-oriented instructions, ‘f’
represents a file register designator and ’d’ represents a destination designator.
The file register designator specifies which file register is to be used by the
instruction. The destination designator specified where the result of the
operation is to be placed. If ‘d’ is zero, the result is placed in the w register. If ‘d’
is one, the result is placed in the file register specified in the instruction.

For bit-oriented instructions, ‘b’

represents a bit field designator which selects the number of the bit affected by
the operation, which ‘f’ represents the address of the file in which the bits is
located. For literal and control operations, ‘k’ represents an eight or eleven bit
constant or literal value.

The instruction set is highly orthogonal and is grouped into three basic
categories:
• Byte-oriented operations
• Bit-oriented operations
• Literal and control operations
All instructions are executed within one
single instruction cycle, unless a conditional test is true or the program counter is
changed as a result of an instruction. In this case, the execution takes two
instruction cycles with the second cycle executed as a NOP. One instruction
cycle consists of four oscillator periods. Thus, for an oscillator frequency of 4
MHz, the normal instruction execution time is 1 ms. If a conditional test is true or
the program counter is changed as a result of an instruction, then the instruction
execution time is 2 ms.

25
 TABLE 2.14 16F877 INSTRUCTION SET

GENERAL FORMAT FOR INSTRUCTIONS :

26
27
APPLICATIONS OF MICROCONTROLLERS

Microcontrollers are designed for use in sophisticated real time

applications such as

1. Industrial Control

2. Instrumentation and

3. Intelligent computer peripherals

They are used in industrial applications to control

• Motor

• Robotics

• Discrete and continuous process control

• In missile guidance and control

• In medical instrumentation

• Oscilloscopes

• Telecommunication

• Automobiles

• For Scanning a keyboard

• Driving an LCD

• For Frequency measurements

• Period Measurements

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4.2 LIQUID CRYSTAL DISPLAY (LCD)

Liquid crystal displays (LCD’s) have materials, which combine the

properties of both liquids and crystals. Rather than having a melting point, they
have a temperature range within which the molecules are almost as mobile as
they would be in a liquid, but are grouped together in an ordered form similar to a
crystal.
An LCD consists of two glass panels, with the liquid crystal material sand
witched in between them. The inner surface of the glass plates are coated with
transparent electrodes which define the character, symbols or patterns to be
displayed polymeric layers are present in between the electrodes and the liquid
crystal, which makes the liquid crystal molecules to maintain a defined orientation
angle.
One each polarizes are pasted outside the two glass panels. These
polarizes would rotate the light rays passing through them to a definite angle, in a
particular direction. When the LCD is in the off state, light rays are rotated by the
two polarizes and the liquid crystal, such that the light rays come out of the LCD
without any orientation, and hence the LCD appears transparent.
When sufficient voltage is applied to the electrodes, the liquid crystal
molecules would be aligned in a specific direction. The light rays passing through
the LCD would be rotated by the polarizes, which would result in activating /
highlighting the desired characters. The LCD’s are lightweight with only a few
millimeters thickness. Since the LCD’s consume less power, they are compatible
with low power electronic circuits, and can be powered for long durations.
The LCD does not generate light and so light is needed to read the
display. By using backlighting, reading is possible in the dark. The LCD’s have
long life and a wide operating temperature range. Changing the display size or
the layout size is relatively simple which makes the LCD’s more customers
friendly.
The LCDs used exclusively in watches, calculators and measuring
instruments are the simple seven-segment displays, having a limited amount of

29
numeric data. The recent advances in technology have resulted in better
legibility, more information displaying capability and a wider temperature range.
These have resulted in the LCDs being extensively used in telecommunications
and entertainment electronics. The LCDs have even started replacing the
cathode ray tubes (CRTs) used for the display of text and graphics, and also in
small TV applications.
Crystalonics dot–matrix (alphanumeric) liquid crystal displays are
available in TN, STN types, with or without backlight. The use of C-MOS LCD
controller and driver ICs result in low power consumption. These modules can be
interfaced with a 4-bit or 8-bit microprocessor /Micro controller.
• The built-in controller IC has the following features:
• Correspond to high speed MPU interface (2MHz)
• 80 x 8 bit display RAM (80 Characters max)
• 9,920-bit character generator ROM for a total of 240 character fonts. 208
character fonts (5 x 8 dots) 32 character fonts (5 x 10 dots)
• 64 x 8 bit character generator RAM 8 character generator RAM 8 character
fonts (5 x 8 dots) 4 characters fonts (5 x 10 dots)
• Programmable duty cycles
• 1/8 – for one line of 5 x 8 dots with cursor
• 1/11 – for one line of 5 x 10 dots with cursor
• 1/16 – for one line of 5 x 8 dots with cursor
• Wide range of instruction functions display clear, cursor home, display on/off,
cursor on/off, display character blink, cursor shift, display shift.
• Automatic reset circuit, which initializes the controller / driver ICs after power
on.

30
4.3 VOLTAGE MEASURMENT

This circuit is designed to monitor the supply voltage. The supply voltage
that has to monitor is step down by the potential transformer. Usually we are
using the 0-6v potential transformer. The step down voltage is rectified by the
precision rectifier. The precision rectifier is a configuration obtained with an
operational amplifier in order to have a circuit behaving like an ideal diode or
rectifier.
The full wave rectifier is the combination of half wave precision rectifer and
summing amplifier. When the input voltage is negative, there is a negative
voltage on the diode, too, so it works like an open circuit, there is no current in
the load and the output voltage is zero. When the input is positive, it is amplified
by the operational amplifier and it turns the diode on. There is current in the load
and, because of the feedback, the output voltage is equal to the input.

31
4.4 RELAY

A relay is an electrical switch that opens and closes under the control of
another electrical circuit. In the original form, the switch is operated by an
electromagnet to open or close one or many sets of contacts. It was invented by
Joseph Henry in 1835. Because a relay is able to control an output circuit of
higher power than the input circuit, it can be considered to be, in a broad sense,
a form of an electrical amplifier.

Operation

When a current flows through the coil, the resulting magnetic field attracts
an armature that is mechanically linked to a moving contact. The movement
either makes or breaks a connection with a fixed contact. 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. Usually this is a spring, but
gravity is also used commonly in industrial motor starters. Most relays are
manufactured to operate quickly. In a low voltage application, this is to reduce
noise. In a high voltage or high current application, this is to reduce arcing.

If the coil is energized with DC, a diode is frequently installed across the
coil, to dissipate the energy from the collapsing magnetic field at deactivation,
which would otherwise generate a spike of voltage and might cause damage to
circuit components. Some automotive relays already include that diode inside the
relay case. Alternatively a contact protection network, consisting of a capacitor
and resistor in series, may absorb the surge. If the coil is designed to be
energized with AC, a small copper ring can be crimped to the end of the
solenoid. This "shading ring" creates a small out-of-phase current, which
increases the minimum pull on the armature during the AC cycle.

32
4.5 ALARM

An alarm gives an audible or visual warning of a problem or condition.

Alarms include:

Burglar alarms, designed to warn of intrusions; this is often a silent alarm:

the police or guards are warned without indication to the burglar, which increases
the chances of catching him or her. Alarm clocks can produce an alarm at a
given time. Distributed control manufacturing systems or DCSs, found in nuclear
power plants, refineries and chemical facilities also generate alarms to direct the
operator's attention to an important event that he or she needs to address.
Alarms in an Operation and Maintenance (O&M) Monitoring system, which
informs the bad working state of (a particular part of the) system under
monitoring.

Alarms have the capability of causing a fight-or-flight response in humans;

a person under this mindset will panic and either flees the perceived danger or
attempt to eliminate it, often ignoring rational thought in either case. We can
characterize a person in such a state as "alarmed".

With any kind of alarm, the need exists to balance between on the one hand the
danger of false alarms (called "false positives") — the signal going off in the
absence of a problem — and on the other hand failing to signal an actual
problem (called a "false negative"). False alarms can waste resources
expensively and can even be dangerous.

33
5. OVERALL CIRCUIT DIAGRAM

34
6. OVERALL CIRCUIT DIAGRAM DESCRIPTION

6.1 POWER SUPPLY DESCRIPTION

Block diagram

The ac voltage, typically 220V rms, is connected to a transformer, which

steps that ac voltage down to the level of the desired dc output. A diode rectifier
then provides a full-wave rectified voltage that is initially filtered by a simple
capacitor filter to produce a dc voltage. This resulting dc voltage usually has
some ripple or ac voltage variation.
A regulator circuit removes the ripples and also remains the same dc
value even if the input dc voltage varies, or the load connected to the output dc
voltage changes. This voltage regulation is usually obtained using one of the
popular voltage regulator IC units.

TRANSFORMER RECTIFIER FILTER IC REGULATOR LOAD

Block diagram (Power supply)

35
Working principle

Transformer

The transformer will step down the power supply voltage (0-230V) to (0-6V) level.
Then the secondary of the potential transformer will be connected to the
precision rectifier, which is constructed with the help of op–amp. The advantages
of using precision rectifier are it will give peak voltage output as DC; rest of the
circuits will give only RMS output.

Bridge rectifier

When four diodes are connected as shown in figure, the circuit is called as
bridge rectifier. The input to the circuit is applied to the diagonally opposite
corners of the network, and the output is taken from the remaining two corners.

Let us assume that the transformer is working properly and there is a

positive potential, at point A and a negative potential at point B. the positive
potential at point A will forward bias D3 and reverse bias D4.

The negative potential at point B will forward bias D1 and reverse D2. At
this time D3 and D1 are forward biased and will allow current flow to pass
through them; D4 and D2 are reverse biased and will block current flow.

The path for current flow is from point B through D1, up through RL,
through D3, through the secondary of the transformer back to point B. this path is
indicated by the solid arrows. Waveforms (1) and (2) can be observed across D1
and D3.

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 One-half cycle later the polarity across the secondary of the transformer
reverse, forward biasing D2 and D4 and reverse biasing D1 and D3. Current flow
will now be from point A through D4, up through RL, through D2, through the
secondary of T1, and back to point A. This path is indicated by the broken
arrows. Waveforms (3) and (4) can be observed across D2 and D4. The current
flow through RL is always in the same direction. In flowing through RL this
current develops a voltage corresponding to that shown waveform (5). Since
current flows through the load (RL) during both half cycles of the applied voltage,
this bridge rectifier is a full-wave rectifier.

One advantage of a bridge rectifier over a conventional full-wave rectifier

is that with a given transformer the bridge rectifier produces a voltage output that
is nearly twice that of the conventional full-wave circuit.

This may be shown by assigning values to some of the components

shown in views A and B. assume that the same transformer is used in both
circuits. The peak voltage developed between points X and y is 1000 volts in
both circuits. In the conventional full-wave circuit shown—in view A, the peak
voltage from the center tap to either X or Y is 500 volts. Since only one diode can
conduct at any instant, the maximum voltage that can be rectified at any instant
is 500 volts.

The maximum voltage that appears across the load resistor is nearly-but
never exceeds-500 v0lts, as result of the small voltage drop across the diode. In
the bridge rectifier shown in view B, the maximum voltage that can be rectified is
the full secondary voltage, which is 1000 volts. Therefore, the peak output
voltage across the load resistor is nearly 1000 volts. With both circuits using the
same transformer, the bridge rectifier circuit produces a higher output voltage
than the conventional full-wave rectifier circuit.

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IC voltage regulators

Voltage regulators comprise a class of widely used ICs. Regulator

IC units contain the circuitry for reference source, comparator amplifier, control
device, and overload protection all in a single IC. IC units provide regulation of
either a fixed positive voltage, a fixed negative voltage, or an adjustably set
voltage. The regulators can be selected for operation with load currents from
hundreds of milli amperes to tens of amperes, corresponding to power ratings
from milli watts to tens of watts.

Circuit diagram (Power supply)

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 A fixed three-terminal voltage regulator has an unregulated dc input
voltage, Vi, applied to one input terminal, a regulated dc output voltage, Vo, from
a second terminal, with the third terminal connected to ground.
The series 78 regulators provide fixed positive regulated voltages from 5
to 24 volts. Similarly, the series 79 regulators provide fixed negative regulated
voltages from 5 to 24 volts.
• For ICs, microcontroller, LCD --------- 5 volts
• For alarm circuit, op-amp, relay circuits ---------- 12 volts

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6.2 MICROCONTROLLER CIRCUIT

The microcontroller circuit is connected with reset circuit, crystal oscillator

circuit, lcd circuit the reset circuit is the one which is an external interrupt which is
designed to reset the program. And the crystal oscillator circuit is the one used to
generate the pulses to microcontroller and it also called as the heart of the
microcontroller here we have used 12mhz crystal which generates pulses upto
12000000 frequency which is converted it machine cycle frequency when divided
by 12 which is equal to 1000000hz to find the time we have to invert the
frequency so that we get one micro second for each execution of the instruction.

The lcd that is liquid crystal display which is used to display the what we need the
lcd has fourteen pins in which three pins for the command and eight pins for the
data. If the data is given to lcd it is write command which is configured by the
programmer otherwise it is read command in which data read to microcontroller
the data pins are given to the to port0 and command pins are given to the port2.
Other than these pin a one pin configured for the contrast of the lcd. Thus the
microcontroller circuit works

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6.3 VOLTAGE MEASUREMENT CIRCUIT

This circuit is designed to monitor the supply voltage. The supply voltage
that has to monitor is step down by the potential transformer. Usually we are
using the 0-6v potential transformer. The step down voltage is rectified by the
precision rectifier. The precision rectifier is a configuration obtained with an
operational amplifier in order to have a circuit behaving like an ideal diode or
rectifier.
The full wave rectifier is the combination of half wave precision rectifer and
summing amplifier. When the input voltage is negative, there is a negative
voltage on the diode, too, so it works like an open circuit, there is no current in
the load and the output voltage is zero. When the input is positive, it is amplified
by the operational amplifier and it turns the diode on. There is current in the load
and, because of the feedback, the output voltage is equal to the input.
In this case, when the input is greater than zero, D2 is ON and D1 is OFF,
so the output is zero. When the input is less than zero, D2 is OFF and D1 is ON,
and the output is like the input with an amplification of − R2 / R1. The full-wave

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rectifier depends on the fact that both the half-wave rectifier and the summing
amplifier are precision circuits. It operates by producing an inverted half-wave-
rectified signal and then adding that signal at double amplitude to the original
signal in the summing amplifier. The result is a reversal of the selected polarity of
the input signal.
Then the output of the rectified voltage is adjusted to 0-5v with the help of
variable resistor VR1. Then given to ripples are filtered by the C1 capacitor. After
the filtration the corresponding DC voltage is given to ADC or other related
circuit.

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6.4 ALARM

A buzzer or beeper is a signalling device, usually electronic, typically

used in automobiles, household appliances such as a microwave oven, or game
shows. It most commonly consists of a number of switches or sensors connected
to a control unit that determines if and which button was pushed or a preset time
has lapsed, and usually illuminates a light on the appropriate button or control
panel, and sounds a warning in the form of a continuous or intermittent buzzing
or beeping sound. Initially this device was based on an electromechanical system
which was identical to an electric bell without the metal gong (which makes the
ringing noise).

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 Often these units were anchored to a wall or ceiling and used the ceiling
or wall as a sounding board. Another implementation with some AC-connected
devices was to implement a circuit to make the AC current into a noise loud
enough to drive a loudspeaker and hook this circuit up to a cheap 8-ohm
speaker. Nowadays, it is more popular to use a ceramic-based piezoelectric
sounder like a Sonalert which makes a high-pitched tone. Usually these were
hooked up to "driver" circuits which varied the pitch of the sound or pulsed the
sound on and off.

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6.5 RS232 CIRCUIT

RS232 COMMUNICATION

RS232:
In telecommunications, RS-232 is a standard for serial binary data
interconnection between a DTE (Data terminal equipment) and a DCE (Data Circuit-
terminating Equipment). It is commonly used in computer serial ports.
Scope of the Standard:
The Electronic Industries Alliance (EIA) standard RS-232-C [3] as of 1969 defines:
 Electrical signal characteristics such as voltage levels, signaling rate, timing and
slew-rate of signals, voltage withstand level, short-circuit behavior, maximum
stray capacitance and cable length
 Interface mechanical characteristics, pluggable connectors and pin identification
 Functions of each circuit in the interface connector
 Standard subsets of interface circuits for selected telecom applications
The standard does not define such elements as character encoding (for example,
ASCII, Baudot or EBCDIC), or the framing of characters in the data stream (bits per
character, start/stop bits, parity). The standard does not define protocols for error
detection or algorithms for data compression.

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 The standard does not define bit rates for transmission, although the standard says it
is intended for bit rates lower than 20,000 bits per second. Many modern devices can
exceed this speed (38,400 and 57,600 bit/s being common, and 115,200 and 230,400 bit/s
making occasional appearances) while still using RS-232 compatible signal levels.
Details of character format and transmission bit rate are controlled by the serial port
hardware, often a single integrated circuit called a UART that converts data from parallel
to serial form. A typical serial port includes specialized driver and receiver integrated
circuits to convert between internal logic levels and RS-232 compatible signal levels.

Circuit working Description:

In this circuit the MAX 232 IC used as level logic converter. The MAX232 is a
dual driver/receiver that includes a capacive voltage generator to supply EIA 232 voltage
levels from a single 5v supply. Each receiver converts EIA-232 to 5v TTL/CMOS levels.
Each driver converts TLL/CMOS input levels into EIA-232 levels.

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 In this circuit the microcontroller transmitter pin is connected in the MAX232
T2IN pin which converts input 5v TTL/CMOS level to RS232 level. Then T2OUT pin is
connected to reviver pin of 9 pin D type serial connector which is directly connected to
PC.
In PC the transmitting data is given to R2IN of MAX232 through transmitting pin
of 9 pin D type connector which converts the RS232 level to 5v TTL/CMOS level. The
R2OUT pin is connected to receiver pin of the microcontroller. Likewise the data is
transmitted and received between the microcontroller and PC or other device vice versa.

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7. PCB DESIGN

Design and Fabrication of Printed circuit boards

7.1 INTRODUCTION:

Printed circuit boards, or PCBs, form the core of electronic equipment

domestic and industrial. Some of the areas where PCBs are intensively used are
computers, process control, telecommunications and instrumentation.

7.2 MANUFATCURING:

The manufacturing process consists of two methods; print and etch, and
print, plate and etch. The single sided PCBs are usually made using the print and
etch method. The double sided plate through – hole (PTH) boards are made by
the print plate and etch method.

The production of multi layer boards uses both the methods. The inner
layers are printed and etch while the outer layers are produced by print, plate and
etch after pressing the inner layers.

7.3 SOFTWARE:

The software used in our project to obtain the schematic layout is

MICROSIM.

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7.4 PANELISATION:

Here the schematic transformed in to the working positive/negative films. The

circuit is repeated conveniently to accommodate economically as many
circuits as possible in a panel, which can be operated in every sequence of
subsequent steps in the PCB process. This is called penalization. For the
PTH boards, the next operation is drilling.

7.5 DRILLING:

PCB drilling is a state of the art operation. Very small holes are drilled with
high speed CNC drilling machines, giving a wall finish with less or no smear or
epoxy, required for void free through hole plating.

7.6 PLATING:

The heart of the PCB manufacturing process. The holes drilled in the
board are treated both mechanically and chemically before depositing the copper
by the electro less copper platting process.

7.7 ETCHING:
Once a multiplayer board is drilled and electro less copper deposited, the
image available in the form of a film is transferred on to the out side by photo
printing using a dry film printing process. The boards are then electrolytic plated
on to the circuit pattern with copper and tin. The tin-plated deposit serves an etch
resist when copper in the unwanted area is removed by the conveyor’s spray
etching machines with chemical etch ants. The etching machines are attached to
an automatic dosing equipment, which analyses and controls etch ants
concentrations

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7.8 SOLDERMASK:

Since a PCB design may call for very close spacing between conductors,
a solder mask has to be applied on the both sides of the circuitry to avoid the
bridging of conductors. The solder mask ink is applied by screening. The ink is
dried, exposed to UV, developed in a mild alkaline solution and finally cured by
both UV and thermal energy.

HOT AIR LEVELLING:

After applying the solder mask, the circuit pads are soldered using the hot
air leveling process. The bare bodies fluxed and dipped in to a molten solder
bath. While removing the board from the solder bath, hot air is blown on both
sides of the board through air knives in the machines, leaving the board soldered
and leveled. This is one of the common finishes given to the boards. Thus the
double sided plated through whole printed circuit board is manufactured and is
now ready for the components to be soldered.

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8 SOFTWARE TOOLS

8 SOFTWARE TOOLS

8.1 MPLAB

MPLAB IDE is an integrated development environment that provides

development engineers with the flexibility to develop and debug firmware for
various Microchip devices

MPLAB IDE is a Windows-based Integrated Development Environment for the

Microchip Technology Incorporated PICmicrocontroller (MCU) and dsPIC digital
signal controller (DSC) families. In the MPLAB IDE, you can:

• Create source code using the built-in editor.

• Assemble, compile and link source code using various language tools. An
assembler, linker and librarian come with MPLAB IDE. C compilers are
available from Microchip and other third party vendors.
• Debug the executable logic by watching program flow with a simulator,
such as MPLAB SIM, or in real time with an emulator, such as MPLAB
ICE. Third party emulators that work with MPLAB IDE are also available.
• Make timing measurements.
• View variables in Watch windows.
• Program firmware into devices with programmers such as PICSTART Plus
or PRO MATE II.
• Find quick answers to questions from the MPLAB IDE on-line Help.

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8.2 MPLAB SIMULATOR

MPLAB SIM is a discrete-event simulator for the PIC microcontroller (MCU)

families. It is integrated into MPLAB IDE integrated development environment.
The MPLAB SIM debugging tool is designed to model operation of Microchip
Technology's PIC microcontrollers to assist users in debugging software for
these devices

8.3 IC PROG

The PRO MATE II is a Microchip microcontroller device programmer. Through

interchangeable programming socket modules, PRO MATE II enables you to
quickly and easily program the entire line of Microchip PICmicro microcontroller
devices and many of the Microchip memory parts.

PRO MATE II may be used with MPLAB IDE running under supported Windows
OS's (see Read me for PRO MATE II.txt for support list), with the command-line
controller PROCMD or as a stand-alone programmer

8.4 COMPILER-HIGH TECH C

A program written in the high level language called C; which will be converted
into PICmicro MCU machine code by a compiler. Machine code is suitable for
use by a PICmicro MCU or Microchip development system product like MPLAB
IDE.

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8.5 PIC START PLUS PROGRAMMER:

The PIC start plus development system from microchip technology

provides the product development engineer with a highly flexible low cost
microcontroller design tool set for all microchip PIC micro devices. The pic start
plus development system includes PIC start plus development programmer and
MPLAB IDE.

The PIC start plus programmer gives the product developer ability to
program user software in to any of the supported microcontrollers. The PIC start
plus software running under MPLAB provides for full interactive control over the
programmer.

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9. ADVANTAGES

It provides various advantages, those are as following:

1. Less expensive to design the circuit.

2. High reliable, flexible and versatile.

3. Simple & compact circuit.

4. Good performance & less man power.

5. Fully automatic, no manual operation is needed.

6. It is the digital energy meter so we can easily view the consumed

unit digitally

10. APPLICATIONS

All industries, homes and other commercial places

This project is very useful for EB office.

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11. CONCLUSION

The progress in science & technology is a non-stop process. New things and
new technology are being invented. As the technology grows day by day, we can
imagine about the future in which thing we may occupy every place.

The proposed system based on Atmel microcontroller is found to be

more compact, user friendly and less complex, which can readily be used in
order to perform. Several tedious and repetitive tasks. Though it is designed
keeping in mind about the need for industry, it can extended for other
purposes such as commercial & research applications. Due to the probability
of high technology (Microcontroller) used this” PERMANENT SWITCH
BOARD MONITORING USING EMBEDDED WEB SERVER” is fully
software controlled with less hardware circuit. The feature makes this
system is the base for future systems.

The principle of the development of science is that “nothing is impossible”. So

we shall look forward to a bright & sophisticated world.

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12. REFERENCES

MILL MAN J and HAWKIES C.C. “INTEGRATED

ELECTRONICS” MCGRAW HILL, 1972

ROY CHOUDHURY D, SHAIL JAIN, “ LINEAR

INTEGRATED CIRCUIT”, New Age International
Publishers, New Delhi,2000

“THE 8051 MICROCONTROLLER AND EMBEDDED

SYSTEM” by Mohammad Ali Mazidi.

WEBSITES:

http://www.atmel.com/

http://www.microchip.com/

www.8052.com

http://www.beyondlogic.org

http://www.ctv.es/pckits/home.html

http://www.aimglobal.org/

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