Galak Electronics Electronic kits and components

VG-305A AC Traffic Light Controller Kit

Thank you for your purchase of the AC Traffic Light Controller kit. Our kits are engineered to

provide key elements for understanding electronics design and theory. In fact, we make it our

goal to produce kits that will apply important electronic principles using analog and digital

technology, and easy to find off-the-shelf components.

Our Programmable series of kits incorporate microcontroller technology due to the simplicity of

the electronics and ease of assembly. It allows for a greater range of functionality, while

maintaining a cost effective solution for some of today’s more challenging electronics needs

and requirements.

The AC Traffic Light Controller uses a simple algorithm to access the selected pattern in its

internal ROM and sequences this pattern into the LEDs. Each pattern uses 8 bytes for each

step of the unique pattern. If you are interested in learning more about the program feel free to

email us at the address listed below.

To build this kit you will need a soldering iron, solder and a sharp pair of cutters. A multimeter

is also recommended to measure values and voltages.

Before getting starting, make sure you have all of the items listed on the next page to ensure

you have a complete kit. If any of the listed items are missing, please contact us toll free at

(302) 832-1978 or online at sales@galakelectronics.com.

We appreciate your business, so feel free to provide us with any suggestions or comments you

may have regarding this kit or any other Galak Electronics kit.

Website: GalakElectronics.com

Email: sales@galakelectronics.com

Phone: (302) 832-1978

Kit Contents

PART DESIGNATOR DESCRIPTION QUANTITY

R1 R4 R7 Resistor, 330Ω 1/2 Watt 5% (orange orange brown gold) 3

R2 R5 R8 Resistor, 470Ω 1/2 Watt 5% (yellow violet brown gold) 3

R3 R6 R9 Resistor, 39Ω 1/2 Watt 5% (orange white black gold) 3

R10 R11 R12 R13 Resistor, 10KΩ 3 Watt 5% (brown black orange gold) 4

R14 Resistor, 47KΩ 1/4 Watt 5% (yellow violet orange gold) 1

R15 R16 R17 R18 Resistor, 10KΩ 1/4 Watt 5% (brown black orange gold) 4

R19 R20 R21 Resistor, 330Ω 1/4 Watt 5% (orange orange brown gold) 3

VR1 Potentiometer, 25KΩ 0.15 Watt Trimmer (black) 1

C1 C3 C5 Capacitor, 0.047µF 630V Monolithic Ceramic (473 blue) 3

C2 C4 C6 Capacitor, 0.01µF 1KV Ceramic Disc (103 light blue) 3

C7 Capacitor, 220uF 16V Aluminum Electrolytic (black) 1

C8 Capacitor, 0.33uF 50V Monolithic Ceramic (334 blue) 1

C9 C10 Capacitor, 0.1uF 50V Monolithic Ceramic (104 yellow) 2

D1 Diode, 1N4007 1000V 1A Rectifier 1

D2 Diode, 1N4745A 16V 1W Zener 1

LED1 LED, Green T1 Diffused (3mm) 1

LED2 LED, Yellow T1 Diffused (3mm) 1

LED3 LED, Red T1 Diffused (3mm) 1

Q1 Q2 Q3 Triac, MAC12 400V 12A (TO-220, hardware included) 3

IC1 IC2 IC3 IC, MOC3063 Optoisolator Triac Output (DIP-6) 3

IC4 IC, ATtiny84 8kB Programmed Microcontroller (DIP-14) 1

IC5 IC, LP2950 LDO Voltage Regulator 5V 100mA (TO-92) 1

S1 Switch Pushbutton, Momentary Normally Open 1

JP1 JP2 JP3 Header, 2 pin 0.100” spacing (includes shunt jumper) 3

CN1 Connector, 2 position terminal block 5.0 mm (green) 1

CN2 CN3 CN4 Connector, 2 position terminal block 3.5 mm (black) 3

F1a F1b Fuse Clip, 2AG/5mm PCB mount 2

F1 Fuse, 5A 250VAC 5x20 Fast Acting 1

PCB1 PCB, Double-sided 3.00" x 1.95" (7.6 cm x 5.0 cm) 1

INSTR1 Instructions, AC Traffic Light Controller kit 1

PC Board Top and Bottom artwork

IMPORTANT NOTICE: Please observe all applicable electrical wiring codes when

utilizing this product. This device is fused with a 10/250VAC fast acting fuse.

Replace only with an equally rated UL approved fuse. The user understands that

Galak Electronics is not liable for any damages (including shock, fire, property damage or

death) due to the improper use or installation of this product. Please contact us if you have

concerns about safe and proper installation of this product.

SHOCK HAZARD: When making adjustments to your unit, use extreme caution not

to touch any of the components while power is applied. We highly recommend

disconnecting power while making adjustments to the time delay and jumpers.

Failure to follow these precautions may lead shock, fire, property damage or even death.

FEATURES:

• New easy to program mode selection with pushbutton control.

• 8 specific traffic light sequence modes including 4 standard modes.

• Separate digital control for "YELLOW" allowing for more realistic operation.

• User selectable time delay from 5 seconds to 2 minutes.

• Wide input voltage range from 90-130VAC with input fuse protection.

• Independent outputs channels for operating LEDs or Incadescent lamps.

• Solid state switching for silent operation (no clicking mechanical relays).

• Snubbing circuitry to protect from inductive kickback and reverse voltage spikes.

• Onboard LEDs to show current output states.

• Compatible with virtually all types of 120VAC traffic lights.

• Four mounting holes to allow for easy mounting or fixturing.

AC Traffic Light Controller Schematic

Populating the PC board

Make sure to properly identify each of the components, locating them on the layout below and

on the parts list included in these instructions.

To simplify the process of populating the PCB with components, start with the lower profile

components first before moving on to the higher profile components. In this case, mount the

resistors first, slightly bending the leads outward to hold them in place for soldering. Do the

same for D1 and D2, making sure that their bands match those on the PCB silkscreen.

Additionally, mount R13-R16 approximately 1/8” off the PC board. This will keep the dissipated

heat away from the board.

Next, mount the ICs using caution not to bend the leads under the chip (the exception being

IC5, which can be mounted along with the transistors). Make sure the ICs are oriented as

shown on the silkscreen. Additionally, ensure all pins are in the holes before pushing the IC

firmly into the board. Use caution when handling the ICs as they are static sensitive. Try to

hold the IC by the ends, avoiding the leads if possible. When soldering the ICs, do not solder all

the pins consecutively. Start at the corners and solder each IC before moving on to the more

central pins. This will help prevent applying too much heat to the IC at one time.

At this point, the transistors can be mounted. Make sure to observe proper orientation for the

transistors and that they are properly identified (Don’t forget IC5). For Q1-Q3, bend the leads

at a 90 degree angle about 1/4” of an inch from the base of the package. Use the provided

hardware to mount them before soldering them (This will prevent stress on the pins). Now

mount capacitor C7. This capacitor is polarized and must be oriented with the white negative

band opposite the “+” on the silkscreen (indicated by the red arrow). The rest of the capacitors

are non-polarized and can be mounted either way. C2, C4 and C6 can be mounted last, as

they are taller than the other capacitors.

Next, the LEDs can be fitted. Again, observe polarity as indicated on the PCB silkscreen. The

LEDs have a flat edge on their base that will match the silkscreen on the PCB (The flat edge

should be next to the LED label). Mount VR1 trim pot, the connectors CN1, CN2, CN3 and

CN4 as well as the two pin headers, JP1 and JP2.

Last but not least, mount the two fuse clips. We suggest mounting the fuse between them as

this will make it easier to insert and hold them in place while soldering. Observe that there are

indents on each clip that cradle the fuse. Make sure these indents are facing outward, away

from the fuse.

Powering up the AC Traffic Light Controller

IMPORTANT NOTICE: Please observe all applicable electrical wiring codes when

utilizing this product. This device is fused with a 5A/250VAC fast acting fuse. Replace only with

an equally rated UL approved fuse. The user understands that Galak Electronics is not liable

for any damages (including shock, fire, property damage or death) due to the improper use or

installation of this product. Please contact us if you have concerns about safe and proper

installation of this product. This unit is not intended for outdoor use.

Once the board assembly is complete, verify that all the components are oriented properly and in

the correct locations. After double-checking your work, attach your AC power leads to CN1. The

neutral wire (white) connects to the terminal marked NEUT and the hot wire (black) connects to

the terminal marked LINE. Make sure that both terminals are sufficiently tight to ensure that the

wires don’t come loose. Do not power the unit on at this point. Make sure the unit is on a non-

conductive surface or securely mounted. It is not necessary to connect the outputs at this point.

SHOCK HAZARD: When making adjustments to your unit, use extreme caution not

to touch any of the components while power is applied. We highly recommend

disconnecting power while making adjustments to the time delay and jumpers.

Failure to follow these precautions may lead shock, fire, property damage or even death.

Using a screwdriver, turn VR1 all the way counter-clockwise to set the sequencing speed to the

minimum. Apply AC power to the unit. The RED LED should illuminate immediately. After about

20 seconds the GREEN LED will illuminate and eventually the YELLOW LED will illuminate

briefly before returning to RED. To increase the duration of the YELLOW light the jumpers can

be fitted (Make sure to disconnect power when making changes). Leaving both JP1 and JP2

open will set the YELLOW light to a minimum ON time of 3 seconds. Fitting JP1 will increase the

delay to 4 seconds. Fitting JP2 only will set the delay to 5 seconds. Finally, fitting both JP1 and

JP2 will increase the yellow delay time to the maximum of 6 seconds. Experiment with the delay

and jumpers to get the right combination of cycle time and YELLOW light delay.

If you don’t get any response from the LEDs after applying power, disconnect your AC power

source and check all your connections. If you still don’t get any response or if the fuse has blown

please contact Galak industries. In the event that the problem can’t be resolved, we will be

happy to repair your unit free of charge in most cases. You just pay the shipping costs.

Modes of Operation

Mode 1: Standard Traffic Light Sequence

Mode 2: British Traffic Light

Sequence

Mode 3: Red-Yellow-Green All flash Sequence

Mode 4: Red-Yellow-Green

Up-down Sequence

Mode 5: Red Light Flashing

Only Sequence

Mode 6: Yellow Light

Flashing Only Sequence

Mode 7: Green Light

Flashing Only Sequence

Mode 9: Sweeping Lights

Sequence

To select one of the nine modes, first remove the JP3

jumper (pictured on the right). Push the button to cycle

through each pattern shown above. When the button is

pressed, all three outputs will flash rapidly indicating the

number of the selected sequence. Thus, if mode 5 is

selected, the outputs will flash rapidly 5 times. Once the

desire mode has been selected, make sure to replace jumper JP3 to lock in the chosen pattern.

The yellow delay (shown in the chart below) will adjust the yellow time duration for the first two

modes, but also affects the number of flashes for Mode 3. Not shown above, mode 8 is random.

Yellow Delay JP1 JP2 Yellow Delay JP1 JP2

3 Seconds Removed Removed 5 Seconds Removed Present

4 Seconds Present Removed 6 Seconds Present Present

Connecting to the Outputs

Now that you have verified that the unit is functioning properly, you can

connect up your AC loads. First, make sure the AC power is disconnected

before making any connections. Insert the neutral wire (white) from your RED

light into terminal “1” of CN4 and insert the hot wire (black) from your RED

light into terminal “2” of CN4.

Next, Insert the neutral wire (white) from your YELLOW light in to terminal “1”

of CN3 and insert the hot wire (black) from your YELLOW into terminal “2” of

CN3 (denoted with “YELLOW”).

Finally, Insert the neutral wire (white) from your GREEN light into terminal “1”

of CN2 and insert the hot wire (black) from your GREEN light into terminal “2”

of CN2 (denoted with GREEN). Please note that if only one neutral wire is

available it can be connected to any of the three terminal “1” connections.

Make sure that all six terminals are sufficiently tight to ensure that the wires

don’t come loose. At this point you are ready to power up your AC Traffic

Light Controller. If everything is functioning properly, your traffic light should follow the LEDs on

the controller. Please note that the power resistors R13-R16 will get warm (up to 50°C or 122°F).

This is completely normal.

IMPORTANT NOTICE: If you are installing this unit in a metal enclosure, the enclosure must

be properly grounded. If you are connecting directly to a junction box, make sure to use a 3-

conductor UL approved cable. The green wire should be connected to the junction box ground

and the other end should be connected to the traffic light enclosure via a ground stud or self-

tapping screw. Conversely, if using a power cable, ensure that the power cable has a ground

prong, and again connect the green wire to the traffic light enclosure via a ground stud or self-

tapping screw. Failure to follow these precautions may lead shock, fire, property damage or

even death. Please contact use at (302) 832-1978 if you have any questions or concerns.

SPECIFICATIONS:

Supply Voltage 90VAC to 125VAC

Output Rating 120VAC @ 3.5A per channel (fused at 5A)

Input and Output Connector 14-26AWG, Screw Terminals

Cycle Delay Range VR1: 20-120 seconds (Yellow 3-6 seconds)

Board Dimensions 3.94 x 1.97" (10 cm x 5.0 cm)

Board Material 0.062" (1.6 mm) FR-4, with green solder mask & silk screen

Finished Weight 1.6 ounces (46 grams)

Good luck and enjoy you new AC Traffic Light Controller. We appreciate your business.

Galak Electronics

Electronic kits and components

Email: sales@galakelectronics.com

Phone: (302) 832-1978