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PCB: low voltage On-Off switch drives AC mains relay \ includes soft start .. H9KPXG
PCB: low voltage On-Off switch drives AC mains relay \ includes soft start .. H9KPXG
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Old 7th August 2020, 03:21 AM   #101
6L6 is offline 6L6  United States
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PCB: low voltage On-Off switch drives AC mains relay \ includes soft start .. H9KPXG
That relay doesn’t appear to be the proper type... it’s 20V with 8A contacts. The BOM asks for 5V coils and 16A contacts.

RTD14005 TE Connectivity / Schrack | Mouser
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Old 7th August 2020, 03:23 AM   #102
Mark Johnson is offline Mark Johnson  United States
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PCB: low voltage On-Off switch drives AC mains relay \ includes soft start .. H9KPXG
Check the circuit design and schematic and Parts List of H9KPXG once again.

I think you'll find that it contains an AC-to-DC converter whose output is +5V DC. This is applied to the coil of the relay. I think you'll find that the parts list calls for "RTD-14005" which is a relay with a 5VDC coil and 16 ampere contacts. Makes sense: with a 5V supply we need a relay whose coil operates at 5V.

Unfortunately your photographs in post #100 above, appear to show a different relay with a different part number. Your relay appears to have a 20 volt coil and only 8 ampere contacts. That's wrong, twice. I couldn't find a datasheet or a pinout; if the pinout of that substitute relay is different than the RTD-14005, then it is wrong three times -- an award winner. Suggest you unsolder that relay and install the one called for in the Parts List.

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Old 7th August 2020, 03:24 AM   #103
6L6 is offline 6L6  United States
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PCB: low voltage On-Off switch drives AC mains relay \ includes soft start .. H9KPXG
I think we were typing at the same time! LOL
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Old 7th August 2020, 04:41 AM   #104
spiggs is offline spiggs  United States
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Thank you gentlemen. I went back to look at my Mouser order and it clearly says I ordered a RTD-14005 but obviously received something different. Shame on me for not double checking.
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Old 7th August 2020, 05:41 AM   #105
6L6 is offline 6L6  United States
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PCB: low voltage On-Off switch drives AC mains relay \ includes soft start .. H9KPXG
They sent the wrong part? That’s a bummer. I’m sure they will sort it out.
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Old 7th August 2020, 08:45 AM   #106
spiggs is offline spiggs  United States
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Originally Posted by 6L6 View Post
They sent the wrong part? Thatís a bummer. Iím sure they will sort it out.
Yes. I ordered by using a link to a Mouser BOM posted earlier in this thread so I wanted also make sure nothing was off so no one else has this issue. Nope, traced it all the way through from the BOM to web order and invoice. Right part number ordered but wrong part showed up.
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Old 7th August 2020, 12:43 PM   #107
Mark Johnson is offline Mark Johnson  United States
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PCB: low voltage On-Off switch drives AC mains relay \ includes soft start .. H9KPXG
I have an extra RTD-14005 relay, PM me your address and I'll ship it to you right away.
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Old 7th August 2020, 10:26 PM   #108
spiggs is offline spiggs  United States
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Originally Posted by Mark Johnson View Post
...Unfortunately your photographs in post #100 above, appear to show a different relay with a different part number. Your relay appears to have a 20 volt coil and only 8 ampere contacts. That's wrong, twice. I couldn't find a datasheet or a pinout; if the pinout of that substitute relay is different than the RTD-14005, then it is wrong three times -- an award winner...
_
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I have an extra RTD-14005 relay, PM me your address and I'll ship it to you right away.
This is the award I needed, thanks Mark!
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Old 8th August 2020, 12:09 AM   #109
Mark Johnson is offline Mark Johnson  United States
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PCB: low voltage On-Off switch drives AC mains relay \ includes soft start .. H9KPXG
Default Eureka! You can install a 250 Joule(!) ICL into this ACPR+SS board

I just received a couple of 250 Joule rated Inrush Current Limiters from Mouser.com, and I'm delighted to say they can be used with the existing (Rev.C) AC Power Relay & Soft Start PCB. You might remember from post #1 above, that the standard ICLs called for in the Detailed Parts List, are rated for 125 Joules. So these new ones are twice as rugged, twice as beefy, and twice as macho. For those who may be interested, example calculations of Joule requirements are also included in post #1.

These great big ICLs are made by Ametherm. If you think you really want or really need a 250 Joule ICL, the one I recommend for 115VAC mains is Mouser part number 995-MS32-20008 [32 mm diameter / 20 ohms cold / 8A max steady state current], and the one I recommend for 230VAC mains is Mouser part number 995-MS32-50006-L [32 mm diameter / 50 ohms cold / 6 amps max steady state current]. Their .pdf datasheets are attached below.

The footprint on the ACPR+SS PCB Rev.C is deep enough and wide enough to accommodate these 32mm ICLs without touching neighboring components. The drill holes are juuuuust big enough that the "115VAC mains" ICL slides in easily. However the "230VAC mains" ICL has slightly larger diameter leads, so you'll need to reduce them a teeny bit. Sandpaper, needle file, scraping with diagonal cutters, anything you try will probably work. Don't worry, an ICL is not Static Sensitive and it survives an Electro Static Discharge with zero damage. So sand / file / scrape to your heart's content.

Maybe, some day, I might revise the PCB layout and include slightly bigger drill holes, to make the PCB comfortably accept the "230VAC mains" version of the 250 Joule ICL. If there is another compelling reason to make a PCB revision, I'll roll in this change too. Meanwhile, get out your sandpaper and spend a relaxing ten minutes of your time, in exchange for bragging rights about Two Hundred Fifty Joules!! And shake your fist at the lucky DIYers in USA, Japan, Canada, and other places. These fortunate souls can use the 115VAC part number of 250 Joules ICL, which needs no sanding or shaving or scraping.

_
Attached Images
File Type: jpg J250_and_PCB.jpg (386.1 KB, 405 views)
File Type: jpg J250_inserted.jpg (399.7 KB, 407 views)
Attached Files
File Type: pdf ICL_MS32_20008_Ametherm.pdf (23.7 KB, 26 views)
File Type: pdf ICL_MS32_50006_L_Ametherm.pdf (25.7 KB, 15 views)

Last edited by Mark Johnson; 8th August 2020 at 12:18 AM.
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Old 11th August 2020, 02:52 AM   #110
spiggs is offline spiggs  United States
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Originally Posted by Mark Johnson View Post
I have an extra RTD-14005 relay, PM me your address and I'll ship it to you right away.

RTD-14005 received and installed on PCB. The board now passes the 100w bulb test and the meter says I am getting full voltage at the output. Again thank you!
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