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!
Testing rev 7.1
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
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.
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.
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.
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 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
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.
Note: there has recently (Sept 16) been some fake/pirated HLK components! Warning!
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.
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.
Total cost for one node is about US$14 where the relay and HLK-pm01 is about US$10(See BOM).
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.
|Fuse||Ceramic Slow Blow Fuse||250V, 0.2A (50W)||Axial||US $0.99||0.09||Ebay: Ceramic Slow Blow Fuse 3.6 x 10mm Axial Leads 125V 250...|
|Thermal Fuse||Thermal Cutoffs FUSE||73degr C||Axial||US $4.99||0.5||Ebay: 10pcs Thermal Cutoffs SEFUSE Microtemp Thermal TF Cuto...|
|F3||Glass Tube Fuse Axial Leads 3.6 x 10mm 2A||2A, 250V||Axial||US $1.99||0.2||Ebay: NEW 10pcs Glass Tube Fuse Axial Leads 3.6 x 10mm 2A 2...|
|g3mc-202pl||Omron SSR Relay (Optional)||g3mc-202pl||Axial||US $5,95||5.95||Ebay: 1PCS G3MC-202PL-VD-2 Encapsulation:ZIP,Solid StateRela...|
|T1||2n2222 npn transistor (not tested!)||NPN||SOT-23||US $0.99||0.0099||Ebay: 100PCS MMBT2222 2N2222 SMD NPN Transistor SOT-23 NEW|
|Varistor||Zinc Oxide Varistor||250VAC 60J 2500A 10mm||Axial||US $1.89||0.19||Ebay: 10 x Zinc Oxide Varistor 250VAC 60J 2500A 10mm|
|AC||2 Pin Screw Terminal Connector||5.08mm||Axial||US $1.23||0.06||Ebay: 20pcs KF301-2P 2 Pin Plug-in Screw Terminal Block Conn...|
|MYSX 1.3||Pinheads 2x7||5.08mm||Axial|
|-||Tactile Push Button Switch||3*6*2.5mm||SMD||US $1.78||0.0178||Ebay: 100pcs 3*6*2.5mm Tactile Push Button Switch Tact Switc...|
|-||Crystal Oscillator||16mHz||SMD||US $1.38||0.069||Ebay: 20Pcs New 16.000MHZ 16MHZ 16M HZ HC-49S Crystal Oscill...|
|-||HLK-PM01||220V to 5V||SMD||US $3.99||3.99||http://www.ebay.com/sch/sis.html?_nkw=HLK-PM01+AC-DC+220V+to...|
|-||NRF24L01+ SMD||SMD||US $7.73||1.546||Ebay: 5PCS New Mini NRF24L01+ SMD 1.27MM RF wireless transce...|
|Volt_Reg||662K 5V-3.3V Step Down Regulator||SOT-23||US $0.99||0.0495||Ebay: 20PCS XC6206P332MR 3.3V 662k SOT-23 TOREX LDO Voltage ...|
|ATMEGA328P-AU||ATMEGA328P||SMD||US $12.16||1.216||Ebay: 10PCS *NEW ATMEGA328P-AU MEGA328P AU ATMEGA328P TQFP-3...|
|C1 (Volt reg)||Capacitor SMD Ceramic||0,1uF||0805||US $4.10||0.041||Ebay: 100PCS 0805 0.1uF 100nF 50V X7R SMD Ceramic Capacitor ...|
|C2 (volt reg)||Capacitor SMD Ceramic||10uF||0805||US $1.47||0.0147||Ebay: 100Pcs chip Value Capacitor 0805 106M 10UF 16V ±20% SM...|
|C3 (Radio)||Capacitor SMD Ceramic||4,7uF||0805||US $2.12||0.0212||Ebay: 100pcs 0805 50V SMD 50v 4.7uF RoHS Capacitors NEW|
|C4 (Oscillator)||Capacitor SMD Ceramic||22pF||0805||US $2.14||0.0214||Ebay: 100PCS 0805 22PF 220J 5% SMD Ceramic Capacitor|
|C5(Oscillator)||Capacitor SMD Ceramic||22pF||0805||US $2.14||0.0214||Ebay: 100PCS 0805 22PF 220J 5% SMD Ceramic Capacitor|
|C6 (Gnd-Vcc)||Capacitor SMD Ceramic||0,1uF||0805||US $4.10||0.041||Ebay: 100PCS 0805 0.1uF 100nF 50V X7R SMD Ceramic Capacitor ...|
|C7 (Aref)||Capacitor SMD Ceramic||0,1uF||0805||US $4.10||0.041||Ebay: 100PCS 0805 0.1uF 100nF 50V X7R SMD Ceramic Capacitor ...|
|C8 (Reset ISCP)||Capacitor SMD Ceramic||0,1uF||0805||US $4.10||0.041||Ebay: 100PCS 0805 0.1uF 100nF 50V X7R SMD Ceramic Capacitor ...|
|C9 (Reset MysX DTR)||Capacitor SMD Ceramic||0,1uF||0805||US $4.10||0.041||Ebay: 100PCS 0805 0.1uF 100nF 50V X7R SMD Ceramic Capacitor ...|
|R1 (Reset button)||Resistor SMD||10k ohm||0805||US $0.99||0.0099||http://www.ebay.com/itm/100pcs-SMD-Chip-Surface-Mount-0805-R...|
|R2 (Led SCK)||Resistor SMD||330 ohm||0805||US $0,99||0.0099||http://www.ebay.com/itm/100pcs-SMD-Chip-Surface-Mount-0805-R...|
|R3 (Led ON)||Resistor SMD||330 ohm||0805||US $0,99||0.0099||http://www.ebay.com/itm/100pcs-SMD-Chip-Surface-Mount-0805-R...|
|R4 (Relay)||Resistor SMD||1k ohm (not sure)||0805||US $0.99||0.0099||http://www.ebay.com/itm/100pcs-SMD-Chip-Surface-Mount-0805-R...|
|LED1||LED SMD||Red||0805||US $0.99||0.0198||Ebay: 50 pcs SMD SMT 0805 Super bright Red LED lamp Bulb GOO...|
|LED2||LED SMD||Red||0805||US $0.99||0.0198||Ebay: 50 pcs SMD SMT 0805 Super bright Red LED lamp Bulb GOO...|
|TestPoints||Total US $||14.1911|