Zero Cross Generator for Ren-C and Ren64 XA-XB

[Wayne J]

After testing of multiple designs to provide a practical / inexpensive power supply/zero cross generator, it has come to light that we cannot do the inexpensive part. There are many power supplies out on the market that are relatively cheap and will do the job, along with all of the PC power supplies that folks have laying around to convert to hobby use. Thus, the need for ZC is still needed. Taking an option that Phil provided and talking to him about it, we have come up with the DIYC ZCG (DoItYourselfChristmas ZeroCrossGenerator) This design uses the H11AA1 with 120VAC. Considering that 120VAC is on the pcb, it will only be provided in a 'kit' form, meaning it will come with the pcb, plastic enclosure, and possibly, the parts. The enclosure will have the necessary holes machined into it. (by yours truely) I would like to supply the parts simply because it is only 7 parts (under $2.50 total) and the shipping would be more than the parts for one unit. If not, then a group buy for the parts only will have to happen at the same time.

I have the pcb drawn up and the enclosure holes laid out. The holes are for the strain relief for the SPT1 or SPT2 cable providing 120VAC. The second hole which I have yet to decide on, will be for the cable that carries the ZC and 5V. I am thinking speaker wire, or similar. If we can come to a group desicion on that I can make the hole accordingly, or not put one in at all, and let the user make their own hole for the cable of their own choice.

Below is the layout I have at this time.


http://i4.photobucket.com/albums/y122/MERC460/xmas/th_ZCG1.jpg (http://i4.photobucket.com/albums/y122/MERC460/xmas/ZCG1.jpg)

and the Mouser BOM
782-H11AA1 1
538-39890-0302 2
571-3902611 1
293-15K-RC 2
836-1127 1

the enclosure is the Polycase LP-11

:cool:

[scorpia]

Seems like a nice design there.

I have been thinking about this issue as well from an aussie point of view. It occured to me that would may be able to use one of the MANY AC adaptors that we have from the light strings.

What im thinking is a version of the above board with resistor values changed to suit 24v AC . all that would be needed then would be to cut a small lenght of cable from the lights and then wire it to the adaptor.

Nice and safe, we get to use an approved adaptor and are only playing with 24v.

I know this doesnt help the guys in the states but maybe it does help us aussies. It would still use the same board etc. just not the 120v cable.

what do you think guys?

Peter

PS: cheap is a matter of opinion. :p

[jrock64]

Here is the zero cross generator that I have used for the last two years.

The zero cross and power are spliced into a 3ft cable and everything is passed down the line.

Only 1/2 inch wide and only 2 1/2 long.
The container is a glitter vial I found at the dollar store.

Joel

[Wayne J]

Here is the zero cross generator that I have used for the last two years.

The zero cross and power are spliced into a 3ft cable and everything is passed down the line.

Only 1/2 inch wide and only 2 1/2 long.
The container is a glitter vial I found at the dollar store.

Joel

Joel... could elaborate on this design? It looks like a very good option to use, easy and simple. ;)

[jrock64]

For details and theory page 30 of xmas's document is the best source.
http://www.ritzfam.com/xmus/16CPicDimmedSSR_Theory_of_Operation_Rev1.9.pdf

Pin 1 & 2 are 15K 1w resistors connected to an ac power cord.
Pin 4 is ground
Pin 5 is the zero cross signal AND a pullup to +5v thru a 27k resistor.

My colors are really creative.
yellow is ground
black is the zero cross signal
white is the +5 pullup

The second is my patch cord that provides the zero cross and 5v from a disk connector.
The only thing I provide in the field is 120v.

Joel

[mp3damo]

Here is a picture of my ZC board which will attach to my Ren-C board. It is using a 24v power supply from an aussie light string. It is only supplying ZC signal and ground. Thanks To Scorpia for his help!!