Programmable Power Relay Senior Design II Final Presentation April,

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-switching o PC software application o Dimming o 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 safety o Non-conducive Casing o Fused Overcurrent Protection

Economic Must be manufactured for less than $50

Bill of Materials DescriptionPart Number Prototype Cost Product ion Cost 1000 units Advanced Electronics PCB PIC24HJ64GP502 PIC24HJ6 4GP502- I/SO-ND MODULE USB - SERIAL MODULE MINI ND IC RTC SERIAL 512K 8-DIP DS ND IC AC/DC CONV 5V 200MA SIP10 BP ND FUSEHOLDER ATO 20A IN-LINE F1086- ND BATTERY LITHIUM COIN 3V 16MM P034-ND HOLDER COIN CELL FOR 16MM CELL BH600- ND TRIAC ISOL 600V 25A TO-3 Q6025P 5-ND CAP.1UF 200V 10% CER RADIAL ND DescriptionPart NumberPrototype Cost Product ion Cost 1000 units Optocouplers 6Pin 250V 512- MOC3011SR2M CAP 22UF 200V ELECT VR RADIAL ND ZERO CROSSING 512-FOD8143S USB MINI B CONNECTOR 798-UX40-MB-5P1.180 USB MINI B PANEL MOUNT 523-MUSB-B RECTIFIER 400V 1A DO-41 1N4004DICT-ND INDUCTOR HIGH CURRENT 820.0UH DN7786-ND SUR ABSORBER 5MM 360V 600A ZNR P7243-ND CRYSTAL KHZ CYL X801-ND x 3.5 x 3.2 Polycarbonate Enclosure G2GYCL MOD PWR NEMA OUTLETS SNAP-IN PNL ND Total: $122.37$45.28

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 Results From Design I RTCC OperationPass Timing Schedule AccuracyPass PC OperationPass AC/DC Power SupplyPass Power OutputPass Output DimmingFail

Technical Constraints Results in Design II RTCC OperationPass Timing Schedule AccuracyPass PC OperationPass AC/DC Power SupplyPass Power OutputPass Output DimmingPass

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

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 ICSPUSB

RTCC and TRIAC Control TRIAC Header on Bottom of Board

TRIAC Output / Dimming Tests

Finished PCB Before Population Populated and Tested Fully Functional Board

Single Event (Constan t 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 Simultaneou s Startup/Shut down Outlets 1&2 Offset Startup/Shut down Outlets 1&2 Test Cases

Questions ?

References [1] Powercords Online, "IDC Plugs - Standards," [Online]. Availible [2] "Appliance Wiring Material, UL 758." Underwriters Laboratories. Accessed September 16, [3] “Isolé® IDP-3050 Plug Load Control.” WattStopper. &type=Commercial. Accessed August 27, &type=Commercial [4] “Bits Energy Saving Smart Strips.” Bits Limited. Accessed August 27, [5] “6-PIN Dip Random Phase Optoisolators Triac Driver Output.” Programmable Power Relay Datasheets. M.pdf. Accessed December 1, M.pdf