Another SSR option

[jmelvin]

Back on the old forum I posted about another SSR option. After testing for a couple months its been working very well.
I've been using a Sharp (http://document.sharpsma.com/files/s102s01_e.pdf//url)
SSR I found thumbing through Mousers huge catalog. The part number is an 825-S102S01F. I know its over kill being an 8amp chip, but they have 2 and 4 amp sips also. I would love feed back on the PCB from wjohn on getting some boards made. Overall these are cheaper and smaller.

UPDATE: John and I have been working up a prototype. It's 2x1.5 inches.

[Wayne J]

Looks good.
The option of a practical heat sink is out, with the arragment. Though some don't use one anyways. You may want to add a 'connectivity' LED, not a necessity though.

You can have your own boards made. The company wjohn uses is http://www.pcbnet.com/
You will need 'gerber' files though. Express pcb does a great job also. Just group a bunch of them on one board and cut them apart yourself for a cheaper price.

How many of those are you wanting? That is a very simple board to etch yourself too.

[jmelvin]

Well I have never etched a board before. And as far as a heatsink, being an 8amp sip they didn't get hot at all when I tested them with 6 strings on 1 ssr. They got slightly hot when i used them with 75w floodlights.

[Wayne J]

I do like it. Very small and versitile.

8)

[grages]

That is very sweet and compact. So it combines the Opto Isolator and the Triac in one package. What is the Value of R1?

[wjohn]

what is the SSR module worth?

The current SSR boards parts list are around $10.00, and the pcb is 1 - 1.5 $ all up.

If you can get the SSR modules for under 8$, thus would be worth looking into.

John

[Zane]

I did a little modification to the boards original file. I made it slightly smaller (the smaller the better) and added a power indicating LED.

[grages]

So, would we need to put an external fuse on this, and a connector block?

[Wayne J]

One resistor is all that is needed for all 4 triac's? Will the voltage drop be within range to operate all four and not down the switching? Maybe a SIP instead?

[jmelvin]

"One resistor is all that is needed for all 4 triac's? Will the voltage drop be within range to operate all four and not down the switching? Maybe a SIP instead?"
-I'm not sure, I used the same 750 ohm resistor from Sean's SSR. I haven't had any problems so far.

"what is the SSR module worth?"
-The SSR's themselves range from $2.00 to $5.00 depending on amp rating and if u want zero crossing (not dim able). I'm not sure what it would cost to manufacture the boards.

[Zane]

So, would we need to put an external fuse on this, and a connector block?

I would think a little inline fuse that you can pick up at a hardware store for like a buck each.

[grages]

Here is my variation based on Zanes layout of jmelvins SSR board.

[ErnieHorning]

That’s interesting… The connector is now almost half the size of the board. :D

[grages]

I have never done anything with PCB's before but just playing around with jmelvins design I have arranged it so it is 1x1.5 with Zanes LED. This is fun :!: :)

I think I did it all correctly, the one trace between the resistors is funny looking.

[jmelvin]

You can have your own boards made. The company wjohn uses is http://www.pcbnet.com/
I spoke to Sonny at PCBNET, he said the boards could be made for about 1.00 a piece. Less if we ordered more than 100 pieces.

[grages]

The only problem with the Molex connectors is that there does not seem to be enough clearance between the holes in the pcb and the ssr's for the body of the connector.

Link to the drawing for the Block
http://www.molex.com/cmc_upload/0/000/902/115/39890-03XX.pdf

I tried to upload the pdf and I get the following message


Upload Error: Could not upload Attachment to ./files/molex_5mm_840.pdf.

I have been looking for some connector that would work while keeping the board tiny. It looks to me like we would need at least 4.5 mm between the center of the connector pin to the edge of the ssr for this connector to work.

[grages]

This is my 8a design with the 3.5 mm (smaller than the 5mm sean used) terminal blocks I created in ExpressPCB. As you can see the problem with the clearance between the blocks and the SSR's.

Shawn

[ErnieHorning]

Just another way. The area is about the same.

[grages]

Just another way. The area is about the same.

To me the problem still lies in the connectors. You have to at least extend the board so the solder pins are within the board and connect the traces. Still very small.

Here it is...

[Wayne J]

The rj45 can hang off the board some, if needs be.
:)

[grages]

The rj45 can hang off the board some, if needs be.
:)

Yea your right. Here is a design with the 3.5 mm connectors. If it will let me I will attach the connector component p files

[grages]

I think this is it. The RJ45 and the connectors are on opposite sides of the board. There is a little over hang and thats OK. Are there any thoughts on trace width and seperation for etch at home boards?

[BillAd]

Granges,

I flipped the RJ45 jack, see if this suites you. Also I try to avoid very small traces when home etching so you may wish to increase the .010 to .015. I find this results in a better transfer when ironing the circuit down from the photo paper and leaves a bit more copper if the etched board is rough.

Bill

[grages]

Grages,

I flipped the RJ45 jack, see if this suites you. Also I try to avoid very small traces when home etching so you may wish to increase the .010 to .015. I find this results in a better transfer when ironing the circuit down from the photo paper and leaves a bit more copper if the etched board is rough.

Bill

Thanks Bill. I had configured one like that also. Not sure which one I like the best. The one like yours has the simplest traces which for home etching is probably a better choice than the last one I posted. I'm not sure why Express PCB puts sets trace size the way it does but I glad to have an idea of the right size. Maybe on the 4th I will have time to try etching the boards.

Shawn Grage

[grages]

Jack250 asked for a Bill of Materials(BOM) for this board so I have taken a wack at it. It is located at http://spreadsheets.google.com/pub?key=pFOlOhXTSMDK58lcOgq3LQA

Hopefully someone will review it and let me know if it is not correct.



Mouser # Part # Manufacturer Description Quantity
852-S102S01F S102S01F Sharp Opto-Triac 4 Corrected Thanks RL
571-5202514 520251-4 Tyco Electronics RJ45 1
538-39357-0002 39357-0002 Molex 2 Terminal Block 3.5 mm 1
538-39357-0003 39357-0003 Molex 3 Terminal Block 3.5 mm 1
604-WP7104EC WP7104EC Kingbright LED T-1 Red WaterClear 1
660-CF1/4C751J CF1/4C751J KOA Spear R1 750ohms 1
660-CF1/4C751J CF1/4C751J KOA Spear R2 750ohms ** 1

[Doug-in-the-woods]

I copied/pasted your part number over at Mouser - no match-no part, etc.?

[RavingLunatic]

The only part number that doesn't work is:

825-S102S01F it should be 852-S102S01F

after that little correction all part numbers are loaded at mouser.

[jmelvin]

Can someone point me in the right direction to get my schematic into a Gerber file?

[jmelvin]

updated first post

[MakeitBright]

Has anyone etched any of these boards yet? I would love to get a bunch for my Olsen 595 and get all the channels going. I'm currently using large SSRs and am limited by how much they cost. So I end up going with a few to start. Would love to get all 64 of these channels up and running. Someone holler if they can make and sell some of these. If not, Merry Christmas lights anyway! LOL.

[Ronp]

PM SENT

[flintman]

what program are the pcb files using I use PCB artist and can't view that files.

[Wayne J]

what program are the pcb files using I use PCB artist and can't view that files.

http://www.expresspcb.com/ExpressPCBHtm/Download.htm

[flintman]

thanks

[wjohn]

Has anyone etched any of these boards yet? I would love to get a bunch for my Olsen 595 and get all the channels going. I'm currently using large SSRs and am limited by how much they cost. So I end up going with a few to start. Would love to get all 64 of these channels up and running. Someone holler if they can make and sell some of these. If not, Merry Christmas lights anyway! LOL.

I have made this board for James, the first run was 40 PCBs, and James has them set up and running.

The PCBs are 1.500 x 1.700 inches square.

[Richh]

Would Sharp S202S02 SSRs work with this set up? There are some of these on ebay (3 each on a pcb, lot of 8 pcbs)

Thanks,

RIch

[jmelvin]

Would Sharp S202S02 SSRs work with this set up? There are some of these on ebay (3 each on a pcb, lot of 8 pcbs)

Thanks,

RIch

Those will work just fine but they are not dimmable.
Only difference between S102S01 (http://http://document.sharpsma.com/files/s102s01_e.pdf) and S202S02 (http://http://document.sharpsma.com/files/s202s02_e.pdf) is zero crossing and higher load voltage rating.