In Wall AC/DC Pcb (with Relay) for MySensors (SMD)

This is a PCB that uses AC power to run a MySensors node and a relay (SSR) inside a wall socket. The main goal is to have a MySensors node with I/O to be able to build your own node with your own sensors inside a normal (European) wall socket. It comes with PCB and a 3d box for protection and safety.

This is a development of my first In-Wall-ACDC-Pcb-for-MySensors (Not SMD components, only axial)

Note: This PCB are using SMD components!

Current Status and revision

Testing rev 7.1

Rev 7.1 (Under testing - latest rev).

  • ISCP header now connects from botton (mirrored).
  • MYSX 2.4
  • Relay circuit improved.
  • Added silkmask with AC-DC seperation (Rev 7.1 > 5mm)
  • AC clearance 2.5mm minimum
  • Safety recommendations: This PCB meets the criteria of pollution level II (2,5mm (Basic) AC seperation and 5mm (Reinforced) AC-DC sepertion) and can be used "where only non-conductive contamination occurs. However, occasional temporary conductivity must be expected as a result of moisture condensation." Always use a sealed case to avoid contamination. Always read disclaimer.txt before using this PCB.

Rev 7.0 (TESTED)

  • Changes in resistors and NPN transistor for relay to work better.
  • Designed 3dboxes for safety.
  • Increased AC-DC separation (Rev 7 = 5mm)
  • AC clearance 2.5mm minimum, added millings.
  • Redesigned outer dimension/border.
  • Safety recommendations: This PCB meets the criteria of pollution level II (2,5mm (Basic) AC seperation and 5mm (Reinforced) AC-DC separation ) and can be used "where only non-conductive contamination occurs. However, occasional temporary conductivity must be expected as a result of moisture condensation." To be on the safe side - use a sealed case!

For rev history, see Changes.txt

Note when buying through openhardware.io may say another rev. This is only revision for manufacturer, not current PCB revision. I always update PCB gerber files for sale first on openhardware.io

Why??

I designed this project for the main purpose of safely powering a node from a AC source. Battery operations and 5v phone chargers in all its glory but I needed a node small enough to put inside a wall-socket, adaptable/dynamic and AC powered.

We have AC mains running everywhere in our houses today and this project aims for converting AC to 5vDC with safety as priority #1.

Aim of this project

  • Convert 240v/120v AC to 5v DC (using HLK-PM01)

  • Make it safe!

  • Fit inside standard appliance box / in wall

  • Run MySensors node (Arduino Pro Mini, NRF24L01+, MysX Gpio for sensors)

  • Have a on board relay (SSR).

  • Make it as small as possible using SMD components.

How??

By using this you have everything you need for a AC powered MySensors node. With MysX connector you have plenty of options both digital and analog input/outputs for you sensors. For the AC power there are both a temperature fuse, a normal fuse, and a varistor to protect your node.

I wanted the node to be dynamic (no sensor specific) - and therefore the MysX connector. Now you can add any sensor you like to the connector. Also, while at it - why not add a relay. Since Im going to use this around AC i might also be able to switch it in the same time.

Follow this thread for latest info: https://forum.mysensors.org/topic/4187/in-wall-pcb-with-relay-for-mysensors-smd

Build instructions coming soon, see BOM for more info.

What??

Power - Using the HLK-PM01 converting AC 240/120v to 5v dc and running the MySensors node. The input is protected with a fuse, temp fuse and varistor (read this discussion).

MySensors - A Atmega328p-au (normal schematics) and a Nrf24l01+ SMD Radio with all the normal components.

I/O - MysX (Raw input not possible) + some extra (A4+A5), ICSP**

Relay(SSR) - A Omron G3MC-202PL protected with a fuse of your choise (axial)

3d-box - A part of safety, attached is a .stl file with a case for 3d printing. This can be printed in your 3d printer or sent to a 3d-hub.

Safety

Safety is one of the most important aspects of this project! Se more here: https://forum.mysensors.org/topic/4175/clearance-creepage-and-other-safety-aspects-in-mysensors-pcbs. It is highly recommended to use the latest revision for best safety.

Text below is written for the latest posted revision. For older revisions, please see changes.txt

AC-DC Separation

My thoughts has been to separate AC (primary) and DC (secondary) sides completely. At this point (Rev 7.0) this separation is 6.5mm so below minimum for use outdoor (in pollution level 3 = 8.0mm) but it should be OK if you dont use in in worst case pollution. In upcoming revisions I may add millings to increase creepage. This revision i recommend using it indoors and with the 3d case (or any case!) If you put it in a completely sealed case it should be ok to use outdoor.

The HLK-PM01 has been discussed in many threads here and are transformer based so it should be safe. More about it here and here.

Note: there has recently (Sept 16) been some fake/pirated HLK components! Warning!

AC high voltage trace creepage

As for the separation within the AC traces I have tried to use 3mm creepage and clearance but this turned out to be to hard. This PCB (Rev 7.0) has a creepage distance on the AC side of 2.5mm. This means if you are using 240v you can put it in pollution level II Sames as above, dont use it outdoors and put it in a case.

Disclaimer

If you order or use this you agree to and understand that the author is not liable for any injury or damage howsoever caused and that you use this PCB at your own risk. This is DIY and the author has not made any professional test. This product has not been marked with any certification marks and cant be guaranteed to compliance with any standards.

Cost?

Total cost for one node is about US$14 where the relay and HLK-pm01 is about US$10(See BOM).

Bonus

You can actually cut/split the PCB between AC and DC side and get a normal 5v MySensors node where you can attach sensors to MysX connector.

I want it!

  • Order 10pcs: openhardware.io (Recommended!) and support me and MySensors!
  • Download from this page to get Eagles and Gerber files.
  • If you want a faster shipping time or less pieces you can buy them from me via Ebay.

Questions needing answers

  • Reliability, when will it fail? (compared to a commercial product?)
  • How will it fail? What is it weakest point?
  • Will my safety components be enough and prevail damage... ?
  • What will happen when it fails?

Images

Design Files

Bill of Material

PCBPartValueSizeCost (Feb-16)Cost/PcsLink
FuseCeramic Slow Blow Fuse250V, 0.2A (50W)AxialUS $0.99 0.09Ebay: Ceramic Slow Blow Fuse 3.6 x 10mm Axial Leads 125V 250...
Thermal FuseThermal Cutoffs FUSE73degr CAxialUS $4.990.5Ebay: 10pcs Thermal Cutoffs SEFUSE Microtemp Thermal TF Cuto...
F3Glass Tube Fuse Axial Leads 3.6 x 10mm 2A2A, 250VAxialUS $1.990.2Ebay: NEW 10pcs Glass Tube Fuse Axial Leads 3.6 x 10mm 2A 2...
g3mc-202plOmron SSR Relay (Optional)g3mc-202plAxialUS $5,955.95Ebay: 1PCS G3MC-202PL-VD-2 Encapsulation:ZIP,Solid StateRela...
T12n2222 npn transistor (not tested!)NPNSOT-23 US $0.990.0099Ebay: 100PCS MMBT2222 2N2222 SMD NPN Transistor SOT-23 NEW
VaristorZinc Oxide Varistor 250VAC 60J 2500A 10mmAxialUS $1.89 0.19Ebay: 10 x Zinc Oxide Varistor 250VAC 60J 2500A 10mm
AC2 Pin Screw Terminal Connector 5.08mmAxialUS $1.230.06Ebay: 20pcs KF301-2P 2 Pin Plug-in Screw Terminal Block Conn...
ISCPPinheads 2x35.08mmAxial
MYSX 1.3Pinheads 2x75.08mmAxial
-Tactile Push Button Switch3*6*2.5mmSMDUS $1.780.0178Ebay: 100pcs 3*6*2.5mm Tactile Push Button Switch Tact Switc...
-Crystal Oscillator16mHzSMDUS $1.380.069Ebay: 20Pcs New 16.000MHZ 16MHZ 16M HZ HC-49S Crystal Oscill...
-HLK-PM01220V to 5VSMDUS $3.993.99http://www.ebay.com/sch/sis.html?_nkw=HLK-PM01+AC-DC+220V+to...
-NRF24L01+ SMDSMDUS $7.731.546Ebay: 5PCS New Mini NRF24L01+ SMD 1.27MM RF wireless transce...
Volt_Reg662K 5V-3.3V Step Down RegulatorSOT-23 US $0.990.0495Ebay: 20PCS XC6206P332MR 3.3V 662k SOT-23 TOREX LDO Voltage ...
ATMEGA328P-AUATMEGA328PSMDUS $12.161.216Ebay: 10PCS * 2016++ NEW ATMEGA328P-AU MEGA328P AU ATMEGA328...
C1 (Volt reg)Capacitor SMD Ceramic0,1uF0805US $4.100.041Ebay: 100PCS 0805 0.1uF 100nF 50V X7R SMD Ceramic Capacitor ...
C2 (volt reg)Capacitor SMD Ceramic10uF0805US $1.470.0147Ebay: 100Pcs chip Value Capacitor 0805 106M 10UF 16V ±20% SM...
C3 (Radio)Capacitor SMD Ceramic4,7uF0805US $2.120.0212Ebay: 100pcs 0805 50V SMD 50v 4.7uF RoHS Capacitors NEW
C4 (Oscillator)Capacitor SMD Ceramic22pF0805US $2.140.0214Ebay: 100PCS 0805 22PF 220J 5% SMD Ceramic Capacitor
C5(Oscillator)Capacitor SMD Ceramic22pF0805US $2.140.0214Ebay: 100PCS 0805 22PF 220J 5% SMD Ceramic Capacitor
C6 (Gnd-Vcc)Capacitor SMD Ceramic0,1uF0805US $4.100.041Ebay: 100PCS 0805 0.1uF 100nF 50V X7R SMD Ceramic Capacitor ...
C7  (Aref)Capacitor SMD Ceramic0,1uF0805US $4.100.041Ebay: 100PCS 0805 0.1uF 100nF 50V X7R SMD Ceramic Capacitor ...
C8 (Reset ISCP)Capacitor SMD Ceramic0,1uF0805US $4.100.041Ebay: 100PCS 0805 0.1uF 100nF 50V X7R SMD Ceramic Capacitor ...
C9 (Reset MysX DTR)Capacitor SMD Ceramic0,1uF0805US $4.100.041Ebay: 100PCS 0805 0.1uF 100nF 50V X7R SMD Ceramic Capacitor ...
R1 (Reset button)Resistor SMD10k ohm0805US $0.990.0099http://www.ebay.com/itm/100pcs-SMD-Chip-Surface-Mount-0805-R...
R2 (Led SCK)Resistor SMD330 ohm0805US $0,990.0099http://www.ebay.com/itm/100pcs-SMD-Chip-Surface-Mount-0805-R...
R3 (Led ON)Resistor SMD330 ohm0805US $0,990.0099http://www.ebay.com/itm/100pcs-SMD-Chip-Surface-Mount-0805-R...
R4 (Relay)Resistor SMD1k ohm (not sure)0805US $0.990.0099http://www.ebay.com/itm/100pcs-SMD-Chip-Surface-Mount-0805-R...
LED1LED SMDRed0805US $0.990.0198Ebay: 50 pcs SMD SMT 0805 Super bright Red LED lamp Bulb GOO...
LED2LED SMDRed0805US $0.990.0198Ebay: 50 pcs SMD SMT 0805 Super bright Red LED lamp Bulb GOO...
TestPointsTotal US $14.1911
TPGndGnd
Tp15v
Tp23.3v

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