REMOTE OPERATED GARAGE OPENER

INTRODUCTION:
The most important problems faced parking in garage is need of another person for
opening/ closing of garage or need of getting out of your car just to open or shut the
garage door. Here is an easy and cheap solution to this problem: Remote operated
garage opener.
The garage door will be operated by a remote. So now there is no need of getting out of
your car again n again just to open or close the garages door.
This circuit uses an IR remote to activate the receiver circuit mounted at the garage door.
The user needs to carry the remote with him in his car or pocket or anywhere else. And
yes multiple remotes can be built to operate the circuit. Also any conventional TV or
music systems remote can be used to operate the circuit.

BLOCK DIAGRAM

LCD

IR receiver
Microcontroller

Timer circuit

Motor Driver

Circuit Description
The system consists of five sections namely IR remote, power supply section, IR receiver
and timer circuit, microcontroller circuit, motor driver circuit and alarm circuitry.

1. Power Supply Section

The power supply circuit is made to provide 6V regulated power supply. First the 230V
ac is stepped down to 12V ac by using a 230V primary to 12-0-12V secondary
transformer. This 12V ac is rectified using a bridge rectifier. This dc is then fed to the
positive voltage regulator ICs 7806 which will provide 6V regulated power supply.
2. IR Remote and Receiver Section
The circuit comprises transmitter and receiver sections. The transmitter section is built
around IC 555 (IC), which is wired as an astable multivibrator and produces about 38kHz
frequency. IR LED1 emits 38kHz modulated signals up to a distance of 4.6 metres (15
feet). The modulated IR beam from the transmitter continuously falls on the receiver
section built around IR sensor TS0P1738, IC 555 and some discrete cornponents. The
receiver sensor TS0P1738 responds to 38kHz frequency. The modulated IR beam falling
on receiver sensor TS0P1738 makes its output low which triggers the 555IC and it
produces a high pulse and when TSOP1738 doesnt receives the IR rays, its output goes
high which doesnt trigger the 555 IC.

3. Microcontroller circuit
Here we have used microcontroller AT89S52. Pin P1.0 of the microcontroller is
configured as an input pin to take the input from the timer circuit. Rest ports of controller
are configured as an output ports. The microcontroller controls motor driver and LCD.
The LCD is used to display the status of the garages door.

4. Motor Driver Section

The motor driver circuit consists of an L293D IC which is a dual motor driver IC and
consists of two H- Bridges to control the motion of two motors. Here we are using only
single section of the two.

Source Code
The source code for the microcontroller is written in C language and is compiled using
the popular C compiler keil uvision3.

CIRCUIT DIAGRAMS

2. LCD Module circuit

3.

Motor driver circuit

VCC
5V

IO1

U3
IO2

L293D

S1
MOTOR

IR transmitter/ remote circuit

5. Power supply

PCB AND COMPONENT LAYOUTS

Main board

Motor driver

Power supply

IR remote

APPLICATIONS
1.
2.
3.
4.

Offices
Homes
Flats
Hotels

COMONENT LIST
S. No.

Component

Pieces

1N4007 DIODES

LCD

LM7812

LM7805

MOC 7811

BUZZER

11.0592 MHZ XTAL

L293D

AT89S52

10

12-0-12 TRANSFORMER

11

TACTILE SWITCHES

10

12

10uf capacitor

13

1000uF capacitor

14

12V DC MOTOR

SOURCE CODE
#include<reg52.h>
void delay(unsigned int);
void lcdcmd(unsigned char);
void lcddata(unsigned char);
void lcdready();
void msg();
void lighton();
void lightoff();
void pumpon();
void pumpoff();
void gateopen();
void gateclose();
void opengate();
void closegate();
void am5();
void am6();
void am7();
void am8();
void am9();
void pm5();
void pm6();
void pm7();
void pm8();
void pm9();
sfr ldata = 0xA0;
sbit rs = P3^7;
sbit rw = P3^6;
sbit en = P3^5;
sbit busy = P2^7;
sbit light1 = P0^5;
sbit pump = P0^6;
sbit light2 = P0^7;
sbit m1 = P0^0;
sbit m2 = P0^1;
sbit buzz = P1^0;
void main()
{

P0 = 0x00;
P1 = 0x00;
msg();
delay(200);
while(1)
{
light2 = 1;
am5();
gateopen();
opengate();
lighton();
light1 = 1;
pumpon();
pump = 1;
delay(200);
am6();
delay(500);
am7();
delay(500);
am8();
lightoff();
light2 = 0;
light1 = 0;
delay(500);
am9();
buzz = 1;
delay(300);
buzz = 0;
delay(200);
pumpoff();
pump = 0;
gateclose();
closegate();
delay(1000);
////////////////////////////////////////////////////evening////////////////////////////
light2 = 1;
pm5();
gateopen();
opengate();
lighton();
light1 = 1;
pumpon();
pump = 1;

delay(200);
pm6();
delay(500);
pm7();
delay(500);
pm8();
//
//

light2 = 0;
light1 = 0;
delay(500);
pm9();
lightoff();
light1 = 0;
buzz = 1;
delay(300);
buzz = 0;
delay(200);
pumpoff();
pump = 0;
gateclose();
closegate();
delay(1000);

}
void msg()
{
unsigned char proj[] = "Public Garden Automation";
unsigned char z;
lcdcmd(0x01);
lcdcmd(0x81);
for(z = 0; z <= 12; z++)
{
lcddata(proj[z]);
}

lcdcmd(0xc3);
for(z = 14; z <= 23; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void gateopen()
{
unsigned char proj[] = "Opening Gates";
unsigned char z;
lcdcmd(0x01);
lcdcmd(0x81);
for(z = 0; z <= 12; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void gateclose()
{
unsigned char proj[] = "Closing Gates";
unsigned char z;
lcdcmd(0x01);
lcdcmd(0x81);
for(z = 0; z <= 12; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void lighton()
{
unsigned char proj[] = "Lights ON";
unsigned char z;

lcdcmd(0x01);
lcdcmd(0x83);
for(z = 0; z <= 8; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void lightoff()
{
unsigned char proj[] = "Lights OFF";
unsigned char z;
lcdcmd(0x01);
lcdcmd(0x83);
for(z = 0; z <= 9; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void pumpon()
{
unsigned char proj[] = "Pumps ON";
unsigned char z;
lcdcmd(0x01);
lcdcmd(0x84);
for(z = 0; z <= 7; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void pumpoff()
{
unsigned char proj[] = "Pumps OFF";
unsigned char z;

lcdcmd(0x01);
lcdcmd(0x84);
for(z = 0; z <= 8; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void am5()
{
unsigned char proj[] = "5:00 AM";
unsigned char z;
lcdcmd(0x01);
lcdcmd(0x84);
for(z = 0; z <= 6; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void am6()
{
unsigned char proj[] = "6:00 AM";
unsigned char z;
lcdcmd(0x01);
lcdcmd(0x84);
for(z = 0; z <= 6; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void am7()
{
unsigned char proj[] = "7:00 AM";

unsigned char z;
lcdcmd(0x01);
lcdcmd(0x84);
for(z = 0; z <= 6; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void am8()
{
unsigned char proj[] = "8:00 AM";
unsigned char z;
lcdcmd(0x01);
lcdcmd(0x84);
for(z = 0; z <= 6; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void am9()
{
unsigned char proj[] = "9:00 AM";
unsigned char z;
lcdcmd(0x01);
lcdcmd(0x84);
for(z = 0; z <= 6; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void pm5()
{
unsigned char proj[] = "5:00 PM";

unsigned char z;
lcdcmd(0x01);
lcdcmd(0x84);
for(z = 0; z <= 6; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void pm6()
{
unsigned char proj[] = "6:00 PM";
unsigned char z;
lcdcmd(0x01);
lcdcmd(0x84);
for(z = 0; z <= 6; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void pm7()
{
unsigned char proj[] = "7:00 PM";
unsigned char z;
lcdcmd(0x01);
lcdcmd(0x84);
for(z = 0; z <= 6; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void pm8()
{

unsigned char proj[] = "8:00 PM";

unsigned char z;
lcdcmd(0x01);
lcdcmd(0x84);
for(z = 0; z <= 6; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void pm9()
{
unsigned char proj[] = "9:00 PM";
unsigned char z;
lcdcmd(0x01);
lcdcmd(0x84);
for(z = 0; z <= 6; z++)
{
lcddata(proj[z]);
}
delay(200);
}
void opengate()
{
m1 = 1;
m2 = 0;
delay(300);
m1 = m2 = 0;
}
void closegate()
{
m1 = 0;
m2 = 1;
delay(300);
m1 = m2 = 0;
}
void delay(unsigned int itime)

{
unsigned int i,j;
for(i=0;i<itime;i++)
for(j=0;j<1275;j++);
}
void lcdcmd(unsigned char value)
{
lcdready();
ldata = value;
rs = 0;
rw = 0;
en = 1;
delay(1);
en = 0;
return;
}
void lcddata(unsigned char value)
{
lcdready();
ldata = value;
rs = 1;
rw = 0;
en = 1;
delay(1);
en = 0;
return;
}
void lcdready()
{
busy = 1;
rs = 0;
rw = 1;
while(busy == 1)
{
en = 0;
delay(1);
en = 1;
}
return;
}

COMPONENT DESCRIPTION

AT89S52 MICROCONTROLLER
FEATURES
Compatible with MCS-51 Products
8K Bytes of In-System Programmable (ISP) Flash Memory
Endurance: 1000 Write/Erase Cycles
4.0V to 5.5V Operating Range
Fully Static Operation: 0 Hz to 33 MHz
Three-level Program Memory Lock
256 x 8-bit Internal RAM
32 Programmable I/O Lines
Three 16-bit Timer/Counters
Eight Interrupt Sources
Full Duplex UART Serial Channel
Low-power Idle and Power-down Modes
Interrupt Recovery from Power-down Mode
Watchdog Timer
Dual Data Pointer
Power-off Flag

DESCRIPTION
The AT89S52 is a low-power, high-performance CMOS 8-bit microcontroller with 8Kbytes
of in-system programmable Flash memory. The device is manufactured using Atmels highdensity nonvolatile memory technology and is compatible with the industry-standard 80C51
instruction set and pin out. The on-chip Flash allows the program memory to be
reprogrammed in-system or by a conventional nonvolatile memory programmer. By
combining a versatile 8-bit CPU with in-system programmable Flash on a monolithic chip,
the Atmel AT89S52 is a powerful microcontroller which provides a highly-flexible and costeffective solution to many embedded control applications. The AT89S52 provides the
following standard features: 8K bytes of Flash, 256 bytes of RAM, 32 I/O lines, Watchdog
timer, two data pointers, three 16-bit timer/counters, a six-vector two-level interrupt
architecture, a full duplex serial port, on-chip oscillator, and clock circuitry. In addition, the

AT89S52 is designed with static logic for operation down to zero frequency and supports two
software selectable power saving modes. The Idle Mode stops the CPU while allowing the
RAM, timer/counters, serial port, and interrupt system to continue functioning. The Powerdown mode saves the RAM contents but freezes the oscillator, disabling all other chip
functions until the next interrupt or hardware reset.

FIG-3.1 PIN CONFIGURATION OF 8-BIT MICROCONTROLLER

PIN DESCRIPTION
VCC
Supply voltage.
GND
Ground.

Port 0
Port 0 is an 8-bit open drain bidirectional I/O port. As an output port, each pin can sink eight
TTL inputs. When 1s are written to port 0 pins, the pins can be used as high- impedance
inputs.
Port 0 can also be configured to be the multiplexed low- order address/data bus during
accesses to external program and data memory. In this mode, P0 has internal pullups.
Port 0 also receives the code bytes during Flash programming and outputs the code bytes
during program verification. External pullups are required during program verification.

Port 1
Port 1 is an 8-bit bidirectional I/O port with internal pullups. The Port 1 output buffers can
sink/source four TTL inputs. When 1s are written to Port 1 pins, they are pulled high by
the internal pullups and can be used as inputs. As inputs, Port 1 pins that are externally being
pulled low will source current (I ) because of the internal pullups.
In addition, P1.0 and P1.1 can be configured to be the timer/counter 2 external count input
(P1.0/T2) and the timer/counter 2 trigger input (P1.1/T2EX), respectively, as shown in the
following table.

Port 1 also receives the low-order address bytes during Flash programming and verification.

Port Pin
P1.0

Alternate Functions
T2(external count input to Timer/counter 2),

P1.1

clock-out
T2EX (Timer/counter 2 capture/related trigger

P1.5
P1.6
P1.7

and direction control)

MOSI (used for In-System Programming)
MISO (used for In-System Programming)
SCK(used for In-System Programming)

TABLE-3.1 PROGRAMMING & VERIFICATION OF PORT 1

Port 2
Port 2 is an 8-bit bidirectional I/O port with internal pullups. The Port 2 output buffers can
sink/source four TTL inputs. When 1s are written to Port 2 pins, they are pulled high by the
internal pullups and can be used as inputs. As inputs, Port 2 pins that are externally being
pulled low will source current (I ) because of the internal pullups.
Port 2 emits the high-order address byte during fetches from external program memory &
during accesses to external data memory that use 16-bit addresses (MOVX @ DPTR). In this
application, Port 2 uses strong internal pullups when emitting 1s. During accesses to external
data memory that use 8-bit addresses (MOVX @ RI), Port 2 emits the contents of the P2
Special Function Register.
Port 2 also receives the high-order address bits and some control signals during Flash
programming and verification.

Port 3
Port 3 is an 8-bit bidirectional I/O port with internal pullups. The Port 3 output buffers can
sink/source four TTL inputs. When 1s are written to Port 3 pins, they are pulled high by the
internal pullups and can be used as inputs. As inputs, Port 3 pins that are externally being
pulled low will source current (IIL) because of the pullups.
Port 3 also serves the functions of various special features of the AT89S52, as shown in the
following table.
Port 3 also receives some control signals for Flash programming and verification.

TABLE-3.2 PROGRAMMING & VERIFICATION OF PORT 3

RST
Reset input. A high on this pin for two machine cycles while the oscillator is running resets
the device. This pin drives High for 96 oscillator periods after the Watchdog times out. The
DISRTO bit in SFR AUXR (address 8EH) can be used to disable this feature. In the default
state of bit DISRTO, the RESET HIGH out feature is enabled.

ALE/PROG
Address Latch Enable (ALE) is an output pulse for latching the low byte of the address
during accesses to external memory. This pin is also the program pulse input (PROG)
during Flash programming.
In normal operation, ALE is emitted at a constant rate of 1/6 the oscillator frequency and may
be used for external timing or clocking purposes. Note, however, that one
ALE pulse is skipped during each access to external data memory.
If desired, ALE operation can be disabled by setting bit 0 of SFR location 8EH. With the bit
set, ALE is active only during a MOVX or MOVC instruction. Otherwise, the pin is weakly
pulled high. Setting the ALE-disable bit has no effect if the microcontroller is in external
execution mode.

PSEN
Program Store Enable (PSEN) is the read strobe to external program memory.
When the AT89S52 is executing code from external program memory, PSEN is activated
twice each machine cycle, except that two PSEN activations are skipped during each access
to external data memory.

EA/VPP
External Access Enable. EA must be strapped to GND in order to enable the device to fetch
code from external program memory locations starting at 0000H up to FFFFH.
Note, however, that if lock bit 1 is programmed, EA will be internally latched on reset.
EA should be strapped to VCC for internal program executions.
This pin also receives the 12-volt programming enable voltage (V ) during Flash
programming.

XTAL1
Input to the inverting oscillator amplifier and input to the internal clock operating circuit.

XTAL2
Output from the inverting oscillator amplifier.

MEMORY ORGANIZATION
MCS-51 devices have a separate address space for Program and Data Memory. Up to 64K
bytes each of external Program and Data Memory can be addressed.

PROGRAM MEMORY
If the EA pin is connected to GND, all program fetches are directed to external memory.
On the AT89S52, if EA is connected to Vcc , program fetches to addresses 0000H through
1FFFH are directed to internal memory and fetches to addresses 2000H through
FFFFH are to external memory.

DATA MEMORY
The AT89S52 implements 256 bytes of on-chip RAM. The upper 128 bytes occupy a parallel
address space to the Special Function Registers. This means that the upper 128
bytes have the same addresses as the SFR space but are physically separate from SFR space.
When an instruction accesses an internal location above address 7FH, the address mode used
in the instruction specifies whether the CPU accesses the upper 128 bytes
of RAM or the SFR space. Instructions which use direct addressing access of the SFR space.
For example, the following direct addressing instruction accesses the SFR at location 0A0H
(which is P2).
MOV 0A0H, #data

Instructions that use indirect addressing access the upper 128 bytes of RAM. For example,
the following indirect addressing instruction, where R0 contains 0A0H, accesses the data byte
at address 0A0H, rather than P2 (whose address is 0A0H).
MOV @R0, #data

Note that stack operations are examples of indirect addressing, so the upper 128 bytes of data
RAM are available as stack space.

The 8051 developed and launched in the early 80`s, is one of the most popular micro
controller in use today. It has a reasonably large amount of built in ROM and RAM. In
addition it has the ability to access external memory.
The generic term `8x51` is used to define the device. The value of x defining the kind of
ROM, i.e. x=0, indicates none, x=3, indicates mask ROM, x=7, indicates EPROM and x=9
indicates EEPROM or Flash.
The early 8051, namely the 8031 was designed without any ROM. This device could run only
with external memory connected to it. Subsequent developments lead to the development of
the PROM or the programmable ROM. This type had the disadvantage of being highly

unreliable.
Finally there is the FLASH, which is an improvement over the EEPROM. While the terms
EEPROM and flash are sometimes used interchangeably, the difference lies in the fact that
flash erases the complete memory at one stroke, and not act on the individual cells. This
results in reducing the time for erasure.

ADVANTAGE
The memory of the microcontroller can be extended up to 64k.
This microcontroller is one of the easiest microcontrollers to learn.
The 8051 microcontroller is in the field for more than 20 years. There are lots of books and
study materials are readily available for 8051.

ARCHITECTURE
Architecture is must to learn because before learning new machine it is necessary to learn the
capabilities of the machine. This is some thing like before learning about the car you cannot
become a good driver. The architecture of the 8051 is given below.

ARCHITECTURE OF 8-BIT MICROCONTROLLER

The 8051 doesnt have any special feature than other microcontroller. The only feature is that
it is easy to learn. Architecture makes us to know about the hardware features of the
microcontroller. The features of the 8051 are

4K Bytes of Flash Memory

128 x 8-Bit Internal RAM

Fully Static Operation: 1 MHz to 24 MHz

32 Programmable I/O Lines

Two 16-Bit Timer/Counters

Six Interrupt Sources (5 Vectored)

Programmable Serial Channel

Low Power Idle and Power Down Modes

VOLTAGE REGULATOR

The Digital board can use any power supply that creates a DC voltage between 6 and 12
volts. A 5V voltage regulator (7805) is used to ensure that no more than 5V is delivered to the
Digital board regardless of the voltage present at the J12 connector (provided that voltage is
less than 12VDC). The regulator functions by using a diode to clamp the output voltage at
5VDC regardless of the input voltage - excess voltage is converted to heat and dissipated
through the body of the regulator. If a DC supply of greater than 12V is used, excessive heat
will be generated, and the board may be damaged. If a DC supply of less than 5V is used,
insufficient voltage will be present at the regulators output.

FIGURE OF VOLTAGE REGULATOR

RELAY

Automotive-style miniature relay, dust cover is taken off

A relay is an electrically operated switch. Many relays use an electromagnet to operate a
switching mechanism mechanically, but other operating principles are also used. Relays are
used where it is necessary to control a circuit by a low-power signal (with complete electrical
isolation between control and controlled circuits), or where several circuits must be
controlled by one signal. The first relays were used in long distance telegraph circuits,
repeating the signal coming in from one circuit and re-transmitting it to another. Relays were
used extensively in telephone exchanges and early computers to perform logical operations.
A type of relay that can handle the high power required to directly drive an electric motor is
called a contactor. Solid-state relays control power circuits with no moving parts, instead
using a semiconductor device to perform switching. Relays with calibrated operating
characteristics and sometimes multiple operating coils are used to protect electrical circuits
from overload or faults; in modern electric power systems these functions are performed by
digital instruments still called "protective relays".

Basic design and operation

Simple electromechanical relay

Small relay as used in electronics

A simple electromagnetic relay 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
one or more sets of contacts (there are two in the relay pictured). The armature is hinged to
the yoke and mechanically linked to one or more sets of moving 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. Other relays may have more or fewer sets of contacts depending on their function.
The relay in the picture also has a wire connecting the armature to the yoke. This ensures
continuity of the circuit between the moving contacts on the armature, and the circuit track on
the printed circuit board (PCB) via the yoke, which is soldered to the PCB.
When an electric current is passed through the coil it generates a magnetic field that attracts
the armature, and the consequent movement of the movable contact(s) either makes or breaks
(depending upon construction) 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. Usually this force is provided by 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 reduces noise; in a high voltage or current application it
reduces arcing.

When the coil is energized with direct current, a diode is often placed across the coil to
dissipate the energy from the collapsing magnetic field at deactivation, which would
otherwise generate a voltage spike dangerous to semiconductor circuit components. Some
automotive relays include a diode inside the relay case. Alternatively, a contact protection
network consisting of a capacitor and resistor in series (snubber circuit) may absorb the
surge. If the coil is designed to be energized with alternating current (AC), a small copper
"shading ring" can be crimped to the end of the solenoid, creating a small out-of-phase
current which increases the minimum pull on the armature during the AC cycle.[1]
A solid-state relay uses a thyristor or other solid-state switching device, activated by the
control signal, to switch the controlled load, instead of a solenoid. An optocoupler (a lightemitting diode (LED) coupled with a photo transistor) can be used to isolate control and
controlled circuits.
Types

Latching relay

Latching relay, dust cover removed, showing pawl and ratchet mechanism. The ratchet
operates a cam, which raises and lowers the moving contact arm, seen edge-on just below it.
The moving and fixed contacts are visible at the left side of the image.
A latching relay has two relaxed states (bistable). These are also called "impulse", "keep", or
"stay" relays. When the current is switched off, the relay remains in its last state. This is
achieved with a solenoid operating a ratchet and cam mechanism, or by having two opposing
coils with an over-center spring or permanent magnet to hold the armature and contacts in
position while the coil is relaxed, or with a remanent core. In the ratchet and cam example,
the first pulse to the coil turns the relay on and the second pulse turns it off. In the two coil
example, a pulse to one coil turns the relay on and a pulse to the opposite coil turns the relay
off. This type of relay has the advantage that it consumes power only for an instant, while it is
being switched, and it retains its last setting across a power outage. A remanent core latching
relay requires a current pulse of opposite polarity to make it change state.

Reed relay
A reed relay is a reed switch enclosed in a solenoid. The switch has a set of contacts inside
an evacuated or inert gas-filled glass tube which protects the contacts against atmospheric
corrosion; the contacts are made of magnetic material that makes them move under the
influence of the field of the enclosing solenoid. Reed relays can switch faster than larger
relays, require only little power from the control circuit, but have low switching current and
voltage ratings.

Top, middle: reed switches, bottom: reed relay

Mercury-wetted relay
A mercury-wetted reed relay is a form of reed relay in which the contacts are wetted with
mercury. Such relays are used to switch low-voltage signals (one volt or less) where the
mercury reduces the contact resistance and associated voltage drop, for low-current signals
where surface contamination may make for a poor contact, or for high-speed applications
where the mercury eliminates contact bounce. Mercury wetted relays are position-sensitive
and must be mounted vertically to work properly. Because of the toxicity and expense of
liquid mercury, these relays are now rarely used. See also mercury switch.
Polarized relay
A polarized relay placed the armature between the poles of a permanent magnet to increase
sensitivity. Polarized relays were used in middle 20th Century telephone exchanges to detect
faint pulses and correct telegraphic distortion. The poles were on screws, so a technician
could first adjust them for maximum sensitivity and then apply a bias spring to set the critical
current that would operate the relay.
Machine tool relay
A machine tool relay is a type standardized for industrial control of machine tools, transfer
machines, and other sequential control. They are characterized by a large number of contacts
(sometimes extendable in the field) which are easily converted from normally-open to
normally-closed status, easily replaceable coils, and a form factor that allows compactly
installing many relays in a control panel. Although such relays once were the backbone of
automation in such industries as automobile assembly, the programmable logic controller
(PLC) mostly displaced the machine tool relay from sequential control applications.

Contactor relay
A contactor is a very heavy-duty relay used for switching electric motors and lighting loads,
although contactors are not generally called relays. Continuous current ratings for common
contactors range from 10 amps to several hundred amps. High-current contacts are made with
alloys containing silver. The unavoidable arcing causes the contacts to oxidize; however,
silver oxide is still a good conductor.[2] Such devices are often used for motor starters. A
motor starter is a contactor with overload protection devices attached. The overload sensing
devices are a form of heat operated relay where a coil heats a bi-metal strip, or where a solder
pot melts, releasing a spring to operate auxiliary contacts. These auxiliary contacts are in
series with the coil. If the overload senses excess current in the load, the coil is de-energized.
Contactor relays can be extremely loud to operate, making them unfit for use where noise is a
chief concern.
Solid-state relay

Solid state relay, which has no moving parts

25 A or 40 A solid state contactors

A solid state relay (SSR) is a solid state electronic component that provides a similar
function to an electromechanical relay but does not have any moving components, increasing
long-term reliability. With early SSR's, the tradeoff came from the fact that every transistor
has a small voltage drop across it. This voltage drop limited the amount of current a given
SSR could handle. As transistors improved, higher current SSR's, able to handle 100 to 1,200
Amperes, have become commercially available. Compared to electromagnetic relays, they
may be falsely triggered by transients.

Solid state contactor relay

A solid state contactor is a heavy-duty solid state relay, including the necessary heat sink,
used for switching electric heaters, small electric motors and lighting loads; where frequent
on/off cycles are required. There are no moving parts to wear out and there is no contact
bounce due to vibration. They are activated by AC control signals or DC control signals from
Programmable logic controller (PLCs), PCs, Transistor-transistor logic (TTL) sources, or
other microprocessor and microcontroller controls.
Buchholz relay
A Buchholz relay is a safety device sensing the accumulation of gas in large oil-filled
transformers, which will alarm on slow accumulation of gas or shut down the transformer if
gas is produced rapidly in the transformer oil.
Forced-guided contacts relay
A forced-guided contacts relay has relay contacts that are mechanically linked together, so
that when the relay coil is energized or de-energized, all of the linked contacts move together.
If one set of contacts in the relay becomes immobilized, no other contact of the same relay
will be able to move. The function of forced-guided contacts is to enable the safety circuit to
check the status of the relay. Forced-guided contacts are also known as "positive-guided
contacts", "captive contacts", "locked contacts", or "safety relays".
Overload protection relay
Electric motors need overcurrent protection to prevent damage from over-loading the motor,
or to protect against short circuits in connecting cables or internal faults in the motor
windings.[3] One type of electric motor overload protection relay is operated by a heating
element in series with the electric motor. The heat generated by the motor current heats a
bimetallic strip or melts solder, releasing a spring to operate contacts. Where the overload
relay is exposed to the same environment as the motor, a useful though crude compensation
for motor ambient temperature is provided.

Pole and throw

Circuit symbols of relays. (C denotes the common terminal in SPDT and DPDT types.)
File:Relaycov.jpg
The diagram on the package of a DPDT AC coil relay
Since relays are switches, the terminology applied to switches is also applied to relays. A
relay will switch one or more poles, each of whose contacts can be thrown by energizing the
coil in one of three ways:
Normally-open (NO) contacts connect the circuit when the relay is activated; the
circuit is disconnected when the relay is inactive. It is also called a Form A contact or
"make" contact.

Normally-closed (NC) contacts disconnect the circuit when the relay is activated; the
circuit is connected when the relay is inactive. It is also called a Form B contact or
"break" contact.

Change-over (CO), or double-throw (DT), contacts control two circuits: one

normally-open contact and one normally-closed contact with a common terminal. It is
also called a Form C contact or "transfer" contact ("break before make"). If this type
of contact utilizes a "make before break" functionality, then it is called a Form D
contact.

The following designations are commonly encountered:

SPST Single Pole Single Throw. These have two terminals which can be connected
or disconnected. Including two for the coil, such a relay has four terminals in total. It
is ambiguous whether the pole is normally open or normally closed. The terminology
"SPNO" and "SPNC" is sometimes used to resolve the ambiguity.

SPDT Single Pole Double Throw. A common terminal connects to either of two
others. Including two for the coil, such a relay has five terminals in total.

DPST Double Pole Single Throw. These have two pairs of terminals. Equivalent to
two SPST switches or relays actuated by a single coil. Including two for the coil, such
a relay has six terminals in total. The poles may be Form A or Form B (or one of
each).

DPDT Double Pole Double Throw. These have two rows of change-over terminals.
Equivalent to two SPDT switches or relays actuated by a single coil. Such a relay has
eight terminals, including the coil.

The "S" or "D" may be replaced with a number, indicating multiple switches connected to a
single actuator. For example 4PDT indicates a four pole double throw relay (with 14
terminals).
EN 50005 are among applicable standards for relay terminal numbering; a typical EN 50005compliant SPDT relay's terminals would be numbered 11, 12, 14, A1 and A2 for the C, NC,
NO, and coil connections, respectively.
Applications
Relays are used to and for:
Control a high-voltage circuit with a low-voltage signal, as in some types of modems
or audio amplifiers,

Control a high-current circuit with a low-current signal, as in the starter solenoid of an

automobile,

Detect and isolate faults on transmission and distribution lines by opening and closing
circuit breakers (protection relays),

A DPDT AC coil relay with "ice cube" packaging

Isolate the controlling circuit from the controlled circuit when the two are at different
potentials, for example when controlling a mains-powered device from a low-voltage
switch. The latter is often applied to control office lighting as the low voltage wires
are easily installed in partitions, which may be often moved as needs change. They
may also be controlled by room occupancy detectors in an effort to conserve energy,

Logic functions. For example, the boolean AND function is realised by connecting
normally open relay contacts in series, the OR function by connecting normally open
contacts in parallel. The change-over or Form C contacts perform the XOR (exclusive
or) function. Similar functions for NAND and NOR are accomplished using normally
closed contacts. The Ladder programming language is often used for designing relay
logic networks.

Early computing. Before vacuum tubes and transistors, relays were used as
logical elements in digital computers. See ARRA (computer), Harvard Mark
II, Zuse Z2, and Zuse Z3.

Safety-critical logic. Because relays are much more resistant than

semiconductors to nuclear radiation, they are widely used in safety-critical
logic, such as the control panels of radioactive waste-handling machinery.

Time delay functions. Relays can be modified to delay opening or delay closing a set
of contacts. A very short (a fraction of a second) delay would use a copper disk
between the armature and moving blade assembly. Current flowing in the disk
maintains magnetic field for a short time, lengthening release time. For a slightly
longer (up to a minute) delay, a dashpot is used. A dashpot is a piston filled with fluid
that is allowed to escape slowly. The time period can be varied by increasing or
decreasing the flow rate. For longer time periods, a mechanical clockwork timer is
installed.

Relay application considerations

A large relay with two coils and many sets of contacts, used in an old telephone switching
system.

Several 30-contact relays in "Connector" circuits in mid 20th century 1XB switch and 5XB
switch telephone exchanges; cover removed
Selection of an appropriate relay for a particular application requires evaluation of many
different factors:
Number and type of contacts normally open, normally closed, (double-throw)

Contact sequence "Make before Break" or "Break before Make". For example, the
old style telephone exchanges required Make-before-break so that the connection
didn't get dropped while dialling the number.

Rating of contacts small relays switch a few amperes, large contactors are rated for
up to 3000 amperes, alternating or direct current

Voltage rating of contacts typical control relays rated 300 VAC or 600 VAC,
automotive types to 50 VDC, special high-voltage relays to about 15 000 V

Coil voltage machine-tool relays usually 24 VAC, 120 or 250 VAC, relays for
switchgear may have 125 V or 250 VDC coils, "sensitive" relays operate on a few
milliamperes

Coil current

Package/enclosure open, touch-safe, double-voltage for isolation between circuits,

explosion proof, outdoor, oil and splash resistant, washable for printed circuit board
assembly

Assembly Some relays feature a sticker that keeps the enclosure sealed to allow
PCB post soldering cleaning, which is removed once assembly is complete.

Mounting sockets, plug board, rail mount, panel mount, through-panel mount,
enclosure for mounting on walls or equipment

Switching time where high speed is required

"Dry" contacts when switching very low level signals, special contact materials may
be needed such as gold-plated contacts

Contact protection suppress arcing in very inductive circuits

Coil protection suppress the surge voltage produced when switching the coil current

Isolation between coil circuit and contacts

Aerospace or radiation-resistant testing, special quality assurance

Expected mechanical loads due to acceleration some relays used in aerospace

applications are designed to function in shock loads of 50 g or more

Accessories such as timers, auxiliary contacts, pilot lamps, test buttons

Regulatory approvals

Stray magnetic linkage between coils of adjacent relays on a printed circuit board.

Protective relays
Main article: protective relay
For protection of electrical apparatus and transmission lines, electromechanical relays with
accurate operating characteristics were used to detect overload, short-circuits, and other
faults. While many such relays remain in use, digital devices now provide equivalent
protective functions.
Railway signalling

Part of a relay interlocking using miniature plug-in relays

UK Q-style signalling relay and base

Railway signalling relays are very big and cumbersome compared to the mostly small
voltages (less than 120 V) and currents (perhaps 100 mA) that they switch. Contacts are
widely spaced to prevent dangerous flashovers and short circuits over a lifetime that may
exceed fifty years. BR930 series plug-in relays are widely used on railways following British

practice. These are 120 mm high, 180 mm deep and 56 mm wide and weigh about 1400 g,
and can have up to 16 separate contacts, say 12 make and 4 break contacts.
Since rail signal circuits must be highly reliable, special techniques are used to detect and
prevent failures in the relay system. To protect against false feeds, double switching relay
contacts are often used on both the positive and negative side of a circuit, so that two false
feeds are needed to cause a false signal. Not all relay circuits can be proved so there is
reliance on construction features such as carbon to silver contacts to resist lightning induced
contact welding and to provide AC immunity.
Opto-isolators are also used in some instances with railway signalling, especially where only
a single contact is to be switched.

RESISTORS
As Resistors are so small it is not possible to print their resistance value on the side so a
Colour code system is used.

FIG-10.1 COLOUR CODE OF RESISTORS

FIG-10.2 COMBINATION OF RESISTORS

RESISTOR COMBINATION
RESISTORS IN SERIES
When two or more resistors are placed end to end they are said to be connected in series. The
positions of resistors in circuits are shown by a sequence of numbers from R1, R2, R3,
upwards. Not to be confused with their values 2R2 4K7 etc.Total resistance for resistors in
series is R = R1 + R2

RESISTOR IN PARALLEL
When two or more resistors are placed side by side they are said to be connected in parallel.
Total resistance for two resistors in parallel is R = (R1 x R2)/ R1 + R2).

RESISTORS IN SERIES & PARALLEL

The total resistance for resistors placed in a combination of series and parallel is found in
stages. First add the two resistors in series. Then find the total resistance.
R4 = R1 +R2 Then R = R4 x R3 / R4 + R3
This can be combined into (R1 + R2) x R3 / (R1 + R2) + R3

CAPACITOR
The capacitor's function is to store electricity, or electrical energy. The capacitor also
functions as a filter, passing alternating current (AC), and blocking direct current (DC).
This symbol is used to indicate a capacitor in a circuit diagram. The capacitor is constructed
with two electrode plates facing each other, but separated by an insulator. When DC voltage
is applied
to the capacitor, an electric charge is stored on each electrode. While the capacitor is charging
up, current flows.

ELECTROLYTIC CAPACITOR(ELECTROCHEMICAL TYPE CAPACITOR)

Aluminum is used for the electrodes by using a thin oxidization membrane.
Large values of capacitance can be obtained in comparison with the size of the capacitor,
because the dielectric used is very thin.

FIG-11.1 ELECTROLYTIC CAPACITOR

CERAMIC CAPACITORS
Ceramic capacitors are constructed with materials such as titanium acid barium used as the
dielectric. Internally, these capacitors are not constructed as a coil, so they can be used in
high frequency applications. Typically, they are used in circuits which bypass high frequency
signals to ground. These capacitors have the shape of a disk. Their capacitance is
comparatively small.

CERAMIC

CAPACITOR

MICA CAPACITOR
These capacitors use Mica for the dielectric. Mica capacitors have good stability because
their temperature coefficient is small. Because their frequency characteristic is excellent, they
are used for resonance circuits, and high frequency filters. Also, they have good insulation,
and so can be utilized in high voltage circuits. It was often used for vacuum tube style radio
transmitters, etc.
Mica capacitors do not have high values of capacitance, and they can be relatively
Expensive.

MICA CAPACITOR

L293D IC

600mA OUTPUT CURRENT CAPABILITY PER CHANNEL

1.2A PEAK OUTPUT CURRENT (non repetitive) PER CHANNEL
ENABLE FACILITY
OVERTEMPERATUREPROTECTION
LOGICAL 0 INPUT VOLTAGE UP TO 1.5 V (HIGH NOISE IMMUNITY)
INTERNAL CLAMP DIODES

DESCRIPTION
The Device is a monolithic integrated high voltage, high current four channel driver designed
to
accept standard DTL or TTL logic levels and drive inductive loads (such as relays solenoides,
DC and stepping motors) and switching power transistors. To simplify use as two bridges
each pair of channels is equipped with an enable input. A separate supply input is provided
for the logic, allowing operation at a lower voltage and internal clamp diodes are included.
This device is suitable for use in switching applications at frequencies up to 5 kHz. The
L293D is assembled in a 16 lead plastic packaage which has 4 center pins connected together
and used for heatsinking The L293DD is assembled in a 20 lead surface mount which has 8
center pins connected together and used for heatsinking.

DC MOTOR
Here slow speed dc motor with gear box to reduce the speed of the platform. This type of
gear motor is getting from the second hand machine. Supply voltage of this dc motor is 6 to 9
volt dc. As we vary the voltage speed is also vary. Current consumption of dc motor is 200
ma. It is also possible to use a stepper motor. If we use stepper motor then we require a high
current supply. Normal stepper motors require a minimum 1 A power supply.
Brushless DC motors use a rotating permanent magnet in the rotor, and stationary electrical
magnets on the motor housing. A motor controller converts DC to AC. This design is simpler
than that of brushed motors because it eliminates the complication of transferring power from
outside the motor to the spinning rotor. Advantages of brushless motors include long life
span, little or no maintenance, and high efficiency. Disadvantages include high initial cost,
and more complicated motor speed controllers.

FIGURE OF DC MOTOR

16 x 2 CHARACTER LCD
FEATURES
5 x 8 dots with cursor
Built-in controller (KS 0066 or Equivalent)
+ 5V power supply (Also available for + 3V)
1/16 duty cycle
B/L to be driven by pin 1, pin 2 or pin 15, pin 16 or A.K (LED)
N.V. optional for + 3V power supply 1293

MECHANICAL DIMENSION OF LCD

PRINTED CIRCUIT BOARD (PCB)

Printed circuit boards have copper tracks connecting the holes where the components are
placed. They are designed specially for each circuit and make construction very easy.
Electronics Club members will receive an etched PCB that will need cleaning and drilling
before soldering.

CLEANING & DRILLING

Clean off the protective coating from the PCB using a PCB rubber or steel wool so

that all the copper tracks are bright and shiny..

Drill the holes with a 1mm diameter bit. This is easiest with a proper electric PCB

drill in a stand, but a hand-held miniature electric drill can be used if you take care to avoid
twisting

and

snapping

the

small

drill

bit.

A few may holes may need to be larger, for example preset resistors usually need a 1.5mm
diameter hole. It is simplest to re-drill these special holes afterwards.
Check

carefully

to

make

sure

you

find

all

the

holes.

Even with experience it is easy to miss one or two.

PCB CONSTRUCTION
Layout of desired circuit diagram and preparation is first and most important operation in any
printed circuit board manufacturing process. First of all layout of component side is to be
made in accordance with available component dimensions. The following points are to be
observed while forming the layout of PCB:
1.

Between two components, sufficient space should be maintained.

2.

High wattage/max. Dissipated components should be mounted at a sufficient

distance from semiconductor and electrolytic capacitors.

The single sided PCB is used for general purpose application where the cost is to be low and
the layout is simple.

PREPARING CIRCUIT LAYOUT

First of all the actual size circuit layout is to be drawn on the copper clad board. Then enamel
paint is applied on the tracks of connection with the help of sharp brush. We have to apply the
paint surrounding the pain at which the connection is to be made. It avoids the disconnection
between the leg of the component and circuit track. After completion of painting work, it is
allowed to dry.

ETCHING
The removal of excess of copper on the plate apart from the printed circuit is known as
etching. For this process the copper clad board with printed circuit is placed in the solution of
FeC13 (ferric chloride with 3-4 drops of HC1 in it and is kept so for about 2 hrs.) and taken
out when all excess copper is removed from the PCB.
After etching the PCB is kept in clean water for about half an hour in order to get PCB away
from dry acidic profile, which may cause poor performance of the circuit.
After the PCB has been thoroughly washed paint is removed by soft piece of cloth dipped in
thinner or turpentine. Then PCB is checked as per the layout. Now the PCB is ready for use.

DRILLING
After completion of painting work, holes of 1/32 inch (1mm) diameter are drilled ay desired
points where we have to fix the components.

SOLDERING
Soldering is the process of joining two metallic conductors, the joint where the two metallic
conductors are to be joined or fused is heated with a device called soldering iron and then an
alloy of tin and lead called solder is applied which melts and cover the joint. The solder cools
and solidifies quickly to ensure a good and durable connection between the joined metals.
Covering the joint with solder prevents oxidation.
Good soldering practices are very important for assembling any electronic circuit. A poor
solder joint or connection in electronic circuits is the cause of most services problems. Given
below are some important steps to be followed in good and correct soldering practice:
1.

Use correct type of soldering iron and solder. Avoid the use of excessive flux.

2.

Keep the solder iron hot during the working period and let it rest on its stand when
not in use.

3.

All components leads and wires should be thoroughly cleaned to remove dust and
rust before soldering.

4.

Enough heat is applied to the joint so that the solder metal flow over the joint.

5.

Over heating of the components in PCB is avoided. Over heating may result in
damage of components of PCBs.

6.

Too much solder is not used to avoid short circuits between conduction paths on a
PCB.

EQUIPMENTS REQUIRED
The various tools and equipments required for construction of an intercom are given below:
1.

Solder kit consist of:

a.

Soldering iron.

b.

Soldering wire.

c.

Flux.

2.

Combination pliers.

3.

Tweezers

4.

Long nose pliers

5.

Pen knife

6.

Brushes.

7.

Screw drivers.

8.

Small files.

9.

Cutter

10.

Clipper

11.

Breadboard.

PRECAUTIONS
1.

The quantity of soldering of component on PCB should be good quantity.

2.

The component fitted on the PCB should loosely fit.

3.

Do not touch the PCB layer with hands and for fitting component use long nose
liers only.

4.

Use 25 w pencil bit soldering iron only.

REFERENCES

1.
2.
3.
4.
5.

www.discovercircuits.com
www.rickeysworld.com
www.alldatasheets.com
www.datasheetscatalogue.com
EFY magazine May 2008