Serial SSRs

[Matt_Edwards]

I finally made time to come back to a Grinch type replacement. I say "type" because it is not a like for like replacement.

The concept is not new.

The controllers are 16 channel and HC595 based.
Olsen will have ULN2803 and RJ45
Another will be DC SSR as below.
Yet another will be AC SSR

To make a 64 Ch controller you simply plug 4modules in back to back.
The 64 Channel may be comprised of 32 DC channels, 16 AC Channels and say 16 channels of remote SSRs of choice ( DC or AC)

I particularly like RPM's Grinch dimmer as the perfect match to convert these to DMX.
Running off the Parallel port, means the AC will not be dimming capable.

The sample below is my first concept. I need to do the AC and make them all the same size. Connectors are a choice of 5mm screw terminal or Molex pins.

I am contemplating ditching the RJ45s for Parallel port connection and just
right angle pin male and female headers.

[smartalec]

looks good, im guessing your using smd devices?

[n1ist]

That top plane is very swiss-cheesed, with most of the ground currents getting sent between the output terminal blocks. D2's ground back to the X13 power connector is an example of this,
/mike

[ErnieHorning]

I'm assuming that the ground connections at each of the FET's are connected to a simular flood on the other side and there are a couple more near the center. It looks like just moving some of the via's will allow the ground flood to connect together. I think it would pass a semi severe noise test then but doting a few more via's around wouldn't hurt since you have the space.

[fathead45]

oh this is a cool design, im digging it. ill have to watch this thread.

[budude]

Would spinning D2 around 180deg help?

[Matt_Edwards]

I could do away with the top layer ground pour as the bottom layer is pretty good. See attached. And yes D2 pin7 needs a via to the bottom ground plane.

bedude: yes it would but every time I try to do that years of training (may be even bludgeoning come into play). even when Pick & Place machines became the norm, our Product Engineering guys would reject a design if it didn't have all the IC aligned the same way. We were only allowed on variation, that being 90degree, and then they would also have to be aligned the same way.

Here is questions to those in R&D and PE, does this really matter now days. Is any pin1 orientation acceptable? I toiled with spinning D1 & D2 by 90 degree. the main down side to this will be outputs numbering will be CCW, LHS Ch1 to 8 downwards and RHS ch9 to 16 upwards.

As this one is the first of three, the 2804/RJ45 will be next, followed by the AC SSRs and I want the outlines of the DC and AC to be as close a possible I have time to jiggle things around a bit more before locking in the design.

Is there need for a Leaded DC Serial SSR? My BOM cost for the SMD is lower that a leaded one.

[n1ist]

Isn't it D2 pin 8 that needs the via? As for IC directions, we had one board at work with about 300 DIP ICs, all facing one way except one. Real fun to have to probe that one, especially on the ckt side. Nowdays, I try to have all chips face the same way but if it makes the layout harder, I'll give in and rotate the part. I just did a board with the micro set at 45 degrees to make routing easier.

/mike

[smartalec]

Is there need for a Leaded DC Serial SSR? My BOM cost for the SMD is lower that a leaded one.

so i got a soldering station when i should of got a baking oven for the pcb's.
Bugger

[Matt_Edwards]

Got a hot air gun? you'll be right mate.

[smartalec]

Got a hot air gun? you'll be right mate.

got no hot air gun, but im thinking of buying a cheap toaster over with the mods to make it suitable for pcb work..

if your going to be doing something an might end up doing a lot of them i think i have no choice.

i think this is the post http://doityourselfchristmas.com/forums/showthread.php?t=4611&highlight=surface+mount

first i have to get the miss's a new oven so i can hack at the old one;)

Unless you feel sorry for us an sell the boards with all the smd's soldered on.:D

an if you go with something like the printer port 25pin plug or maybe a 37pin,
save's rj45plugs an sockets everyware

[Matt_Edwards]

I would still go buy a hot air gun first. you need one for heat shrink anyway.
Ossito el cheapo's do just fine.

[smartalec]

I would still go buy a hot air gun first. you need one for heat shrink anyway.
Ossito el cheapo's do just fine.
whats wrong with burning your fingers with a lighter shrinking the tube..lol
got me thinking of another tool i need now..
miss's will kill me..lol

[Matt_Edwards]

Well, I spent the best part of a couple of hours the AC SSSR. There is no way to have all the Optos the same orientation! You more experienced guys are probably smirking saying a quiet "thought so".

My intention was to keep as much of the format the same as possible. This is a bit impractical for the Rj45's. there is a lot of blank space.

I need to make two decisions:
keep
Keep all boards the same width ~ 5" or make the RJ45 version significantly smaller and save space (and a bit of cost)
Change the Serial data connectors from RJ45s to Right Angle headers. The Cable connectors would be polarised
connectors. Board to board would simply be std headers

[Matt_Edwards]

ACSSSR is nearing completion.
The board width is now 5.4"

[budude]

Nice clean layout there Matt. Minor point - why not move the AC connector closer to the outputs with the fuse on the inside. This would keep the Neutral run from crossing near the Hot.

[ErnieHorning]

Matt there's something hanging above D2 that looks like a ratsnest line. Is it just a leftover from editing. Freaked me out; I thought my LCD was cracked.:rolleyes:

[Matt_Edwards]

Bedude,
Making the board slightly bigger will enable the AC IN to behind the mounting Screw. However I have always had an issue with having a steel screw the could short out any whiskers of wires the may not be installed correctly in the TB. As it is now AC IN can rest on the lo voltage side of the Opto. This is not optimal but less of and issue for me.

Ernie, sorry for the stress out. I haven't seen these errors since moving away from EDA Client 98.

[Matt_Edwards]

Either way I tried to position the AC in connectors they fowled with a component. So added an extra 1/2" ad everything is sweet.

Now I am off to a week's R&R in the Great Aussie Bush. I wanted to get these designs to the point I could stop and mull over them for a while.
the Final result:

16 Ch AC SSSR 4.5x5.5"
32 Ch 'Grinch' 4x5.5"
16 Ch DC SSSR 4x5.5"

These controllers can be plugged into each other to make up the number and type of channels you want. Using RPM Grinch Dimmer any combination AC or DC can be used up to 64channels.
Beginners can use them as a Grinch replacement with an addition feature omitting the remote SSRs and still plug them in the parallel port..

Have a great week.

[n1ist]

Matt-
The AC input looks much better on this one. One note - vias that connect to planes don't need thermals, since you aren't soldering leads in them. Not a problem, but the smaller size can sometimes help routing.
/mike

[Matt_Edwards]

We're back from holidays. It was brilliant to go where there is no mobile phone coverage and no internet. No contact unless we want it! the down side was the rain. It was a great time to think.

I have been able to add the final touches to my Serial SSRs. In fact serial is a bit miss leading they really are SPI SSRs. All going well all three go out to the fab shop this or next week.

There are a number of USB to SPI interfaces out there. And it strikes me that this may be helpful for the next beginners controller.

[Matt_Edwards]

Got the boards in and Assembled a couple.
They look good but are yet to be tested.


32ch SMT Grinch
http://doityourselfchristmas.com/forums/picture.php?pictureid=765&albumid=86&dl=1272511452&thumb=1

16ch DC Serial SSR
http://doityourselfchristmas.com/forums/picture.php?pictureid=764&albumid=86&dl=1272511452&thumb=1

16ch AC Serial SSR
http://doityourselfchristmas.com/forums/picture.php?pictureid=767&albumid=86&dl=1272511718&thumb=1

[aussiephil]

so i got a soldering station when i should of got a baking oven for the pcb's.
Bugger

All those look easy to hand solder any way :)

[Matt_Edwards]

Aussiephil you're spot on.:D All bar the DC can be soldered with a fine tip soldering iron and patience. the DC is best done in an oven or maybe with a Hot Air gun.

BTW I did the DC is my little toaster Oven. It doesn't have a controller yet, so I was the controller.;)

[Matt_Edwards]

I just love it when things come together.

This is progress on my Serial SSRs. Latest photos opf my 48ch DC Mega Tree controller.
the last one shows prototype of the DMX to SPI developing.