Programmable Power Relay

Senior Design IIFinal Presentation

April, 23 2009

Team Members

Jameson Mitchell Electrical Engineering PC to PIC communication GUI Design

David Null Electrical Engineering TRIAC control Firmware Design Schematic Design PCB Layout

Rick Wolbrecht Electrical Engineering Packet Encoding GUI Design

Lane Simmons Electrical Engineering Team Leader Firmware Design Website Design

Overview• Introduction• Problem• Solution• Final Product• Practical Constraints• Bill of Materials• Technical Constraints• Software Testing• Hardware Testing• Questions

Introduction

What is the PPR supposed to do?• Control device power using schedule• Allow automated control• Minimize need for user input after schedule is

set

+

Problem 

 • Current power strips have limited features

No programmable timing schedule No interactive user interface No dimming capability No battery backup

 

Solution

 • "Smart" power strip with enhanced features

o Programmable Timing Schedule for AC-switchingo PC software applicationo Dimmingo Battery Backup

• Possible Target Markets• Task Automation• Security

Final Product

Pre-Build Concept

Finished Design

Practical Constraints

Health and Safety

• Must conform to Underwriters Laboratories (UL) standards for safetyoNon-conducive Casingo Fused Overcurrent Protection

Economic• Must be manufactured for less than $50

Bill of MaterialsDescription Part

NumberPrototype Cost

Production Cost

1000 units

Advanced Electronics PCB 2247819 33.00 5.21

PIC24HJ64GP502 PIC24HJ64GP502-I/SO-ND 5.82 3.81

MODULE USB - SERIAL MODULE MINI

768-1022-ND 17.5 13.12

IC RTC SERIAL 512K 8-DIP DS1307+-ND 3.74 1.69

IC AC/DC CONV 5V 200MA SIP10 BP5063-5-ND 6.72 4.2

FUSEHOLDER ATO 20A IN-LINE F1086-ND 3.9 1.74

BATTERY LITHIUM COIN 3V 16MM  P034-ND 1.00 0.53

HOLDER COIN CELL FOR 16MM CELL

BH600-ND 0.83 0.45

TRIAC ISOL 600V 25A TO-3 Q6025P5-ND 11.92 5.4

CAP .1UF 200V 10% CER RADIAL 399-4387-ND 0.96 0.28

Description Part Number Prototype Cost

Production Cost

1000 units

Optocouplers 6Pin 250V 512-MOC3011SR2M 1.52 0.668

CAP 22UF 200V ELECT VR RADIAL

493-1178-ND 0.47 0.16

ZERO CROSSING512-FOD8143S 0.38 0.134

USB MINI B CONNECTOR798-UX40-MB-5P 1.18 0

USB MINI B PANEL MOUNT523-MUSB-B151-34 11.66 0

RECTIFIER 400V 1A DO-41 1N4004DICT-ND 0.3 0.02

INDUCTOR HIGH CURRENT 820.0UH DN7786-ND 2.63 1.05

SUR ABSORBER 5MM 360V 600A ZNR P7243-ND 0.25 0.1

CRYSTAL 32.768KHZ CYLX801-ND 0.3 0.16

4.7 x 3.5 x 3.2 Polycarbonate Enclosure 546-1554G2GYCL 18.29 5.5

MOD PWR NEMA OUTLETS SNAP-IN PNL 486-1082-ND 1.9 1.06

  Total: $122.37 $45.28

Technical Constraints

Technical Constraints   

• Real time clock must operate at all times, under all power conditions

• Timing schedule accuracy must include Years, Months, Days, Hours, Minutes, Seconds

• PC is required to operate user interface

• Must supply power to internals from 120VAC

• Switching power must operate up to 120VAC at 15A (NEMA 5-15 Standard) [1]

• Must support output dimming

Technical Constraints ResultsFrom Design I

RTCC Operation PassTiming Schedule Accuracy Pass

PC Operation Pass

AC/DC Power Supply Pass

Power Output Pass

Output Dimming Fail

Technical Constraints Resultsin Design II

RTCC Operation PassTiming Schedule Accuracy Pass

PC Operation Pass

AC/DC Power Supply Pass

Power Output Pass

Output Dimming Pass

Software Tests• Text File I/O• Serial Port I/O • Conversion Method• Exception Handling• Event Deletion Method

Text File Test• Enter Event into GUI• Event is saved to text file

Text File Test• Text file data is loaded

into memory upon opening of application

Serial Port Test

• Serial Port was scoped to see if packet is being sent

Error Checking Test

Conversion Test• Convert Event class

data into packet format

Conversion Test

Conversion Test

Event Deletion Test

Event Deletion Test

Hardware Tests

PCB Testing

• Populate in sections• Test each section directly after population• Exception with surface mount(PIC)• Tests:

– Power (AC/DC 120VAC to 5VDC, 5VDC to 3.3VDC, Zero Crossing)

– PIC communication(programming)– RTCC– TRIAC control

PCB Power

ZERO CROSSING

AC/DC 5VDC

3.3VDC

PCB Communication

ICSP USB

RTCC and TRIAC Control

TRIAC Header on Bottom of Board

TRIAC Output / Dimming Tests

Finished PCBBefore Population

Populated and Tested Fully Functional Board

Single Event (Constant Power)

Repeating Event (Constant Power)

Single Event (Interrupted Power)

Repeating Event (Interrupted Power)

Single Event (Constant Power)*Dimmed*

Repeating Event (Constant Power)*Dimmed*

Single Event (Interrupted Power)*Dimmed*

Repeating Event (Interrupted Power)*Dimmed*

Outlet 1

Outlet 2

Simultaneous Startup/Shutdown Outlets 1&2

Offset Startup/Shutdown Outlets 1&2

Test Cases

Questions ?

References•[1] Powercords Online, "IDC Plugs - Standards," [Online]. Availible http://www.powercords.co.uk/standard.htm 

•[2] "Appliance Wiring Material, UL 758." Underwriters Laboratories. http://ulstandardsinfonet.ul.com/scopes/0758.html. Accessed September 16, 2008.

•[3] “Isolé® IDP-3050 Plug Load Control.” WattStopper.  http://www.wattstopper.com/products/details.html?id=74&category=122&type=Commercial. Accessed August 27, 2008.

•[4] “Bits Energy Saving Smart Strips.” Bits Limited. http://catalog.bitsltd.us/power_strips/. Accessed August 27, 2008.

•[5] “6-PIN Dip Random Phase Optoisolators Triac Driver Output.” Programmable Power Relay Datasheets. http://www.ece.msstate.edu/courses/design/2008/smartcord/downloads/MOC3011-M.pdf. Accessed December 1, 2008.