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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 24th June 2020, 04:07 PM   #71
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
Congratulations upon your PCB Ordering success! It's fulfilling, it's fun, and it's not terribly difficult! Yay.

Use a Mega328 component tester from eBay to double and triple check every component's value before you stuff it. If you don't own one, buy one. Or use a DMM but it won't give great readings on capacitors.

I recommend stuffing and soldering by component height: shortest and squatty-est first, tallest last. Use common sense, think before acting. So: 115V/230V jumpers first, horizontal mount resistors and inductor and diode second. IC sockets & optocoupler third, ceramic caps fourth. Pin headers fifth, TO-92 transistors sixth. Vertical mount resistors seventh. And so on and so on.

Lay the TO-220 triac upon the PCB to see exactly where its leads need to be bent. Bend them and temporarily stuff the triac (without heatsink). Check whether the mounting hole lines up. If not, adjust the bends or do them over. When all is good, assemble bolt + PCB + heatsink + insulator pad + triac + shoulder washer ("bushing") + locknut/star_washer + nut and tighten. THEN solder and trim the triac leads. I used a Phillips pan head bolt and inserted it up through the PCB from the bottom side. This minimizes the amount of material that pokes down below the board. You can use any length bolt you want: the excess pokes up above the board and doesn't threaten a short to chassis.
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Old 24th June 2020, 04:59 PM   #72
spiggs is online now spiggs  United States
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Quote:
Originally Posted by Mark Johnson View Post
Yes that is the expected result. You are good to go.

I was a bit curious so decided to see what would happen if I tried smaller values of resistors on the output. Worked my way down to ~95 ohm. Same result, 0VAC reading. Apparently doesn't take much to drain away the "phantom voltage" with the switch in the off position. Interesting.
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Old 24th June 2020, 05:03 PM   #73
donhughes111 is offline donhughes111
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Wow. Detailed and very helpful response. Thank you.
Don
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Old 24th June 2020, 05:29 PM   #74
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
Quote:
Originally Posted by spiggs View Post
I was a bit curious so decided to see what would happen if I tried smaller values of resistors on the output. Worked my way down to ~95 ohm. Same result, 0VAC reading. Apparently doesn't take much to drain away the "phantom voltage" with the switch in the off position. Interesting.
Have a look at the schematic attached to post #1. Do you see the snubber composed of C3 and R7? Maybe they conduct a teeny tiny miniscule but nonzero current at 60 Hz.
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Old 26th June 2020, 03:09 AM   #75
Subbu K is offline Subbu K  United States
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PCB: low voltage On-Off switch drives AC mains relay \ includes soft start .. H9KPXG
PCBs ordered on Tuesday and will update once I receive them from the board house. PCBs are 2 oz Copper with ENIG. I will send a pm to the members shown interest with Paypal details.

I have ordered 10 extra, in case some other members need them. Interested members please pm me.

Cost per PCB will be $4.00 + shipping 4 - 5 to US domestic First class package service.

Cheers!
Subbu
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Old 29th June 2020, 04:18 AM   #76
donhughes111 is offline donhughes111
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Default dual mono

How do I connect dual mono or blocks? Dp I just parallel the transformers or do I use 2 boards and how do I connect to the switch. Power limits? one board? two boards?
Thanks,
Don
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Old 29th June 2020, 11:28 PM   #77
donhughes111 is offline donhughes111
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Wow. Terribly written. My excuse is I was really tired at that hour.

Any way, the question should really be "what is the best way to deal with a dual mono configuration and this board".

Thanks,
Don
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Old 30th June 2020, 02:39 AM   #78
PRR is offline PRR  United States
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PCB: low voltage On-Off switch drives AC mains relay \ includes soft start .. H9KPXG
> the question should really be

How do I plug two lamps into one outlet?
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Old 1st July 2020, 01:11 PM   #79
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
Quote:
Originally Posted by donhughes111 View Post
... what is the best way to deal with a dual mono configuration and this board?
I'm sure different builders will have different opinions about what is "best".

Possibilities might include:
  • Two PCBs and two separate on/off switches, would work beautifully
  • Two PCBs and one double pole switch (with separate contacts for Left and for Right), would also work
  • One PCB and one on/off switch would also work, and take up a lot less floor space in your chassis
The illuminated anti-vandal switch that I used (photo and part number in post #16 above) was a double pole switch, and it would be a good choice for the 2nd possibility in this list. Mouser.com offers 334 different double pole illuminated Anti-Vandal switches, so there are plenty to choose from

https://mou.sr/2BhKcpb

ACHTUNG! CAUTION! BEWARE! One arrangement to avoid is "two PCBs and one single pole switch" because this creates a dangerous sneak-path between the +5V terminals of the two AC-to-DC modules. To make this concept work safely and reliably you'll need to hire a seasoned & experienced design consultant (not me!) and figure out all of the worst case situations. IMHO it would be far cheaper and quicker to just buy a double pole switch.


_

Last edited by Mark Johnson; 1st July 2020 at 01:25 PM. Reason: mention floor space
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Old 1st July 2020, 10:11 PM   #80
donhughes111 is offline donhughes111
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Default switches and boards

I win! 3 good choices.
I got the switches from post #16 so the Achtung option won't be looked at.
With my lack of experience, I wasn't sure the board could handle 2 trafo's.
Got the first board stuffed. I think it went well but won't know for sure until I can test it this weekend. Maybe I should post a pic now in case I smoke the board.
It seems I'm always running out of real estate so the 1 and 1 option will probably be 1st choice although I could vertically mount them in same space probably but doesn't seem to be a good reason to do that.
Thank you Mark for all your support and assistance with the project.
Regards,
Don
 

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