ATSAMW25 AT16225: Atmel Smart Plug Hardware User Guide Application Note Introduction The Atmel® Smart Plug Reference Design provides a system solution for a Wi-Fi® enabled power plug that can turn on/off power from the main plug in three ways: using the QTouch® button, using the Android™ app with a Wi-Fi connection, or using a scheduled on/off from the Android app. It is an IoT application using the ATSAMW25 module (a highly integrated module with ATSAMD21, WINC1500, ECC508A), and an ATM90E26 device to realize ARM® Cortex®-M0+ MCU control, Wi-Fi connection, CryptoAuthentication with secure hardware key storage, QTouch sensing, and energy metering functions with an optimized BOM. This document describes the hardware design of the smart plug reference design. Features Turnkey solution with small form factor Three models following either US, EU, or Chinese standards AC input 90-265V and 50/60Hz Max output power: 2200W(10A) Based on ATSAMW25 module – ATSAMD21 Cortex-M0+ MCUWINC1500 IEEE 802.11 b/g/n 2.4G Wi-Fi Controller – ECC508A hardware Authentication and Encryption ATM90E26 power and energy metering function QTouch button CE/FCC/UL&CUL Certification Figure 1. Atmel Smart Plug Kits Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 Table of Contents 1 Overview ..................................................................................................................... 3 1.1 2 MCU Board ................................................................................................................... 4 2.1 2.2 2.3 2.4 2.5 2.6 3 4.6 4.7 6.3 6.4 2 PCB Stack Structure ........................................................................................................................... 17 Reprogram the Kit ..................................................................................................... 18 6.1 6.2 7 Power Board Overview........................................................................................................................ 10 AC-DC .............................................................................................................................................. 11 DC-DC .............................................................................................................................................. 12 Power Measurement ........................................................................................................................... 12 Power Measurement Calibration ......................................................................................................... 14 4.5.1 Calculation of the GL .............................................................................................................. 14 4.5.2 Calculation of the Ugain.......................................................................................................... 14 4.5.3 Calculation of the Igain ........................................................................................................... 14 4.5.4 Calculation of the PL_Constant .............................................................................................. 14 The Relay ............................................................................................................................................ 14 Plug and Socket .................................................................................................................................. 15 PCB Assembly ........................................................................................................... 17 5.1 6 Touch Board Overview .......................................................................................................................... 9 Touch Sensors ...................................................................................................................................... 9 LEDs for Wi-Fi and Power ................................................................................................................... 10 3.3.1 Wi-Fi LED ............................................................................................................................... 10 3.3.2 Power LED ............................................................................................................................. 10 3.3.3 LED Pin Definition on SAM W25 ............................................................................................ 10 Power Board .............................................................................................................. 10 4.1 4.2 4.3 4.4 4.5 5 MCU Board Overview............................................................................................................................ 4 ATSAMW25 .......................................................................................................................................... 5 Programming Interface .......................................................................................................................... 7 Header to Touch Board ......................................................................................................................... 7 Header to Power Board ......................................................................................................................... 8 DataFlash (Not Mounted) ...................................................................................................................... 8 Touch Board ................................................................................................................ 9 3.1 3.2 3.3 4 System Overview .................................................................................................................................. 3 Open the Kit ........................................................................................................................................ 18 Power Supply ...................................................................................................................................... 18 6.2.1 Onboard AC Power ................................................................................................................ 18 6.2.2 External DC power ................................................................................................................. 19 Programming Tools ............................................................................................................................. 20 Programming ....................................................................................................................................... 21 Revision History ........................................................................................................ 22 AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] 2 Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 1 Overview The smart plug consists of three PCBs: Power board, MCU board, and Touch board. The MCU board is vertically mounted to the Power board and the Touch board is connected to the MCU board by a pin connector. 1.1 Touch Board: Touch pad and LEDs. MCU Board: ATSAMW25, 32KHz crystal, DataFlash footprint (not mounted). Power Board: Socket and Plug, AC-DC, DC-DC, Power Measurement, Relay. System Overview Figure 1-1. System Block Diagram Output Socket E N Input Plug L Relay Fuse ATM90E26 DC/DC 12V 3.3V ATSAMW25 LEDs AC/DC DataFlash Button AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 3 3 Figure 1-2. Overview of the Smart Plug Kit PCBs 2 MCU Board 2.1 MCU Board Overview Figure 2-1. 4 MCU Board Overview AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] 4 Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 2.2 ATSAMW25 The Atmel SmartConnect SAM W25 is a low-power Wi-Fi certified module. This highly integrated module offers the ideal solution for designers seeking Wi-Fi connectivity. The SAM W25 integrates an 802.11 IP stack on top of the Wi-Fi core and fully covers RF certifications. The SAM W25 module is based on Atmel’s industry-leading WINC1500 Wi-Fi core combined with Atmel’s latest ARM Cortex-M0+ based microcontroller (SAM D21) technology. This turnkey system provides an integrated software solution with application and security protocols such as TLS and integrated network services (TCP/IP stack). ATSAMW25 is the control center of the smart plug kit. It covers all the intelligent functions including the Wi-Fi connection, touch button, relay control, temperature sensing and protection, LED indicators, and timing. Figure 2-2. Schematic for ATSAMW25 Table 2-1. ATSAMW25 Pinout Pin # SAM W25 function System function Description 0 GND GND Heat sink pads in the bottom 1 GND GND 2 UART TXD Wi-Fi TXD For ATWINC1500 firmware upgrade 3 UART RXD Wi-Fi RXD For ATWINC1500 firmware upgrade 4 Wi-Fi Chip En NC 5 Wi-Fi GPIO_1 RTC 6 NC NC Not Used AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 5 5 Pin # 6 SAM W25 function System function Description 7 VBAT VCC Power supply 8 PA16 Flash SPI MOSI DataFlash Interface 9 PA17 Flash SPI CLK DataFlash Interface 10 GND GND 11 PA18 Flash SPI SS DataFlash Interface 12 PA19 Flash SPI MISO DataFlash Interface 13 PA20 RTC Not Used 14 PA21 LED WR Red LED for Wi-Fi 15 PA22 LED WG Green LED for Wi-Fi 16 PA23 LED WY Yellow LED for Wi-Fi 17 GND GND 18 PA24 Test TXD Fixture test interface 19 PA25 Test RXD Fixture test interface 20 GND GND 21 VCC VCC Power supply 22 PB22 Relay Relay ON/OFF 23 PB23 NC 24 RESET_N MCU Reset SAM D21 reset pin 25 PA30 MCU SWDCLK SWD SWDCLK pin 26 PA31 MCU SWDIO SWD SWDCLK pin 27 PB02 LED PR Red LED for Power 28 PB03 LED PG Green LED for Power 29 PA00 XIN32 32kHz External Crystal 30 PA01 XOUT32 32kHz External Crystal 31 PA02 NC 32 GND GND 33 PA03 NC 34 PA04 NC 35 PA05 Touch Guard 2 Touch Guard sensor 36 PA06 Touch Key Touch key sensor 37 PA07 Touch Guard 1 Touch Guard sensor 38 PA08 Crypto SDA Reserved interface for internal crypto 39 PA09 Crypto SCL Reserved interface for internal crypto 40 PA10 PM TXD Interface for Power Measurement device 41 PA11 PM RXD Interface for Power Measurement device 42 GND GND AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] 6 Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 Pin # 2.3 SAM W25 function System function Description 43 PB10 NC 44 PB11 NC 45 Wi-Fi GPIO_15 NC 46 Wi-Fi GPIO_16 NC 47 Wi-Fi GPIO_18 NC 48 Wi-Fi I2C SCL I2C SCL Reserved interface for internal WINC1500 49 Wi-Fi I2C SDA I2C SDA Reserved interface for internal WINC1500 50 Wi-Fi Reset_n NC 51 GND GND Programming Interface Since SAM W25 uses the SAM D21 as the controller, the user can use the SWD interface to Program and debug the device. Table 2-2. Pin Definition of SWD Interface SWD header pin 2.4 Pin definition ATSAMW25 pin 1 SWDCLK 25 2 GND 3 NC 4 VCC 5 SWDIO 26 6 RESET 24 7 NC 8 NC 9 NC 10 NC Header to Touch Board The Touch Board is connected to MCU Board through a 10-pin header, it contains the tracks for the touch sensors and LEDs. The header also makes it possible to power the MCU externally. Table 2-3. Header to Touch Board Touch header pin Pin definition ATSAMW25 pin 1 GND (External power input if onboard power is not available) 2 VCC (External power input if onboard power is not available) 3 Touch Guard Sensor 1 37 4 Power LED Green 28 5 Touch Key Sensor 36 AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 7 7 2.5 6 Power LED Red 27 7 Touch Guard Sensor 2 35 8 Wi-Fi LED Red 14 9 Wi-Fi LED Yellow 16 10 Wi-Fi LED Green 15 Header to Power Board The MCU Board is mounted directly on the Power Board by a 12-pin header. Table 2-4. 2.6 Header to Power Board Power header pin Pin definition ATSAMW25 pin 1 VCC 2 GND 3 Wi-Fi TXD (Reserved for Wi-Fi firmware upgrade on fixture) 2 4 Wi-Fi RXD (Reserved for Wi-Fi firmware upgrade on fixture) 3 5 Test RXD (Reserved for fixture) 19 6 Test TXD (Reserved for fixture) 18 Power Measurement RXD (Interface for MCU and power measurement device) 41 7 Power Measurement TXD (Interface for MCU and power measurement device) 40 8 9 MCU Reset (Reserved for fixture) 24 10 Relay Control 22 11 MCU SWDIO (Reserved for fixture) 26 12 MCU SWDCLK (Reserved for fixture) 25 DataFlash (Not Mounted) Space for a DataFlash device is reserved (but not mounted) on the board. This can be used to store more data locally if needed. Figure 2-3. 8 Schematic of DataFlash Part AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] 8 Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 Table 2-5. BoM for the DataFlash Part if Mounted Designator Value Vendor Part Number Description C107 100nF Murata GRM155R71H104KE14 Ceramic capacitor, SMD 0402, X7R, 50V, 10% R111 10k Yageo RC0402FR-0710KL Thick film resistor, SMD 0402, 1/16W, 1% U102 1M Byte Winbond W25Q80DVUXIE Serial Flash, 8-lead USON 2*3mm Table below shows the pin definition of SAM W25 for DataFlash. Table 2-6. Pin Definition of DataFlash and SAM W25 Pin name on DataFlash Pin name on ATSAMW25 ATSAMW25 pin FLASH_SPI_SS PA18 11 FLASH_SPI_MISO PA19 12 FLASH_SPI_MOSI PA16 8 FLASH_SPI_CLK PA17 9 3 Touch Board 3.1 Touch Board Overview The Touch board contains the Touch sensors and the LEDs for Wi-Fi and Power. Figure 3-1. 3.2 Touch Board Overview Touch Sensors Touch sensors are designed based on the self-capacitor using the QTouch technology. Except the Touch Key which handles the ON/OFF/Reset function, another two touch sensors act as the touch guard. The touch guard sensors will prevent some scenarios from spurious triggering. AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 9 9 Table 3-1. 3.3 Pin definition of Touch Sensor and SAM W25 Pad name on touch board Pin name on ATSAMW25 ATSAMW25 pin Touch Key PA06 36 Touch Guard 1 PA07 37 Touch Guard 2 PA05 35 LEDs for Wi-Fi and Power All LEDs including the Wi-Fi and Power LEDs are driven by the ATSAMW25 GPIOs directly, Logic 1 enables the LEDs. Note: For better output current performance, the I/O pins needs be set to high drive strength: DRVSTR = 1. Different color LEDs are used to indicate different status of the plug. 3.3.1 3.3.2 3.3.3 Wi-Fi LED Yellow blink: Plug in SoftAP mode, not connected (waiting for Phone to connect) Yellow: Plug in SoftAP mode, connected to a phone (during this period, Phone App sends SSID/password to plug) Green blink: Plug in STA mode, connecting to home Access Point (AP) Green: Plug in STA mode, connected to home AP, connection is good Red: In error state Power LED Green when ON Red when OFF LED Pin Definition on SAM W25 Table 3-2. Pin Definition of LEDs and SAM W25 LED name on touch board Active logic Pin name on ATSAMW25 ATSAMW25 pin Wi-Fi Yellow 1 PA23 16 Wi-Fi Green 1 PA22 15 Wi-Fi Red 1 PA21 14 Power Green 1 PB03 28 Power Red 1 PB02 27 4 Power Board 4.1 Power Board Overview The Power Board contains an AC-DC converter, a DC-DC converter, the power measurement circuit, relay, and the plug and socket. 10 AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] 1 Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 0 Figure 4-1. 4.2 Power Board Overview AC-DC The AC-DC part transforms the 100V~240V AC input voltage into a 12V/120mA (typical) DC output. The 12V DC supplies the relay and the DC-DC converter. Figure 4-2. Schematic of AC-DC Part AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 11 1 1 The transformer T301 is a custom component with the parameters below. 4.3 Figure 4-3. Transformer Design Table 4-1. Wire Definition of Transformer Wire Type Start to end Turns Tape N1 2UEW Φ 0.15x1P 3-1 70Ts 1Ts N2 2UEW Φ 0.15x1P 4-5 23Ts 2Ts N4 TRWB Φ 0.35x1P 7-6 24Ts 3Ts DC-DC The DC-DC converter converts the DC voltage level from 12V to 3.3V for the SAM W25 module. The MP1470 is a typical buck DC-DC converter, with the output range set to 3.16V to 3.36V. Figure 4-4. 4.4 Schematic of DC-DC Part Power Measurement The ATM90E26 works as the power measurement device to get the actual output power. There are two signals sampled by ATM90E26, one is the voltage which comes from the L line, another is the differential voltage based on the current in sense resistor R311. 12 AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] 1 Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 2 Figure 4-5. Sampled Signal of Power Measurement The power measurement device will calculate and output the sampled voltage, current, and power to SAM W25 through the UART port. Considering the different power supply system, 2 optocouplers are used to isolate the SAM W25 and M90E26. Figure 4-6. Schematic of Power Measurement AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 13 1 3 Table 4-2. 4.5 Pin Definition of Power Measurement and SAM W25 Pin Name for Uart Pin name on ATSAMW25 ATSAMW25 pin PWR_PM_TXD PA10 40 PWR_PM_RXD PA11 41 Power Measurement Calibration Before using the ATM90E26 in user application, some parameters need be calculated, such as GL, Ugain, Igain, and PL_Contant. 4.5.1 MC: Pulse constant of the energy meter, unit is imp/kWh or imp/kvarh; Assume MC = 10000 Un: Reference voltage, unit is V; Assume Un = 220V Ib: Basic current, unit is A; Assume Ib = 1A GL: L line current circuit gain VL: Sampling voltage of the L line circuit at Ib, unit is mV VU: Sampling voltage of the voltage circuit at Un, unit is mV Calculation of the GL With the shunt resistor = 1mΩ, Max. current I = 10A. When, GL = 24 VLsample = 1mΩ * 10A * 24 = 240mV 4.5.2 Calculation of the Ugain The default Ugain is based on the condition below: Ugain = 26400 (6720H), Voltage divider coefficient = 880, Assume Un = 220V, VL = 220 / (880 + 1) Considering the voltage divider resistors used in smart plug, Voltage divider coefficient = (430 + 430) = 860 So, Ugain = 26400 * (220 / (860 + 1)) / (220 / (880 + 1)) = 27013 (6985H) 4.5.3 Calculation of the Igain From AN 46102, R = 200µΩ, I = 5A, Lgain = 24 <=> Igain = 31251 (7A13H) by default In SmartPlug solution, R = 1mΩ, I = 2A, Lgain = 24 <=> Igain = 31251 * (1000 * 2A * 24) / (200 * 10A * 24) = 62502 (F426H) 4.5.4 Calculation of the PL_Constant PL_Constant = int (838860800 * GL * VL * Vu / MC * Un * Ib) = 838860800 * 24 * 1 * (220 / (860 + 1)) / 10000 * 220 * 1 = 2338287(23ADEFH) 4.6 The Relay The relay is cascaded in the AC input and output. So, the Relay can direct control the ON/OFF of the AC output. The rated current of the relay is 10A, this means the output power is limited to Max 2200W (@ 220V AC). 14 AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] 1 Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 4 Note: 4.7 Some electronic devices may generate a surge current far larger than the rated current; damaging the relay by welding the contact shut. When this happens the output will be always ON and the kit will be out of control. If this happens you must cut the input voltage manually immediately. From testing it has been observed that a surge current of less than 50A can make the contactor adhere. Figure 4-7. Schematic of Relay Control Table 4-3. Pin Definition of Relay Relay Contorl Name Active Logic Pin name on ATSAMW25 ATSAMW25 pin PWR_RELAY 1 PB22 22 Plug and Socket There are three types of the Plug and Socket: US, EU, and CN. They share the same PCB. AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 15 1 5 Figure 4-8. 16 US, EU, and CN standard of Plug and Socket AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] 1 Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 6 5 PCB Assembly 5.1 PCB Stack Structure The touch board is assembled in the front case of the kit, and the power board together with the MCU board is fixed in the rear case. When the front and rear case are closed, make sure the touch board connector is aligned with the MCU board pin header. Figure 5-1. PCB Stack Structure Overview AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 17 1 7 6 Reprogram the Kit 6.1 Open the Kit If the user needs to reprogram the kit with custom code, the kit needs be opened first. 6.2 Figure 6-1. Remove the Silica Gel and Screws Figure 6-2. Open the Kit Power Supply There are two methods to power the Kit while reprogramming: Onboard AC power and external DC power. 6.2.1 Onboard AC Power At first, connect the programming tools and Kit with the 10-pin SWD connector. Then, plug the Kit into the AC socket and the kit will be powered by the onboard power supply. 18 AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] 1 Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 8 After programming, the user needs to remove the kit from the AC socket first and then disconnect the programmer/debugger from the SWD header. Note: The user needs be very carefully during operation and avoid touching any of the components since they are not isolated and can easily lead to an electrical shock. Figure 6-3. 6.2.2 Kit Powered by the Onboard AC Input External DC power As described in the MCU board chapter, the kit can also be powered by an external 3.3VDC supply. Before connecting the 3.3VC, the user needs to make sure the kit is not connected to the AC input. Connect the 3.3V power supply on pin1 and pin2 of Touch header and make sure the polarity is correct. Note: It is recommended to use the external DC to power the board while reprogramming since it is far safer than the AC power. Figure 6-4. Kit Powered by the External DC Input AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 19 1 9 Figure 6-5. Note: 6.3 External Power Input The Power Pins in on the touch header is connected in parallel with the power supply (3.3V) on the power board. Never connect an external power supply while the onboard power is available. Programming Tools The smart plug uses the SWD as the programming and debug\interface, it supports all tools which supports the SWD interface. Some tools support a direct connection with the 1.27mm pitch, 10-pin socket. Figures below show the connection example of programming tools. 20 Figure 6-6. Atmel-ICE Connection Figure 6-7. JTAGICE3 Connection AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] 2 Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 0 For other programming tools which do not have the 1.27mm pitch, 10-pin socket, the user needs to connect the SWD lines manually. 6.4 Programming Connect the kit to a PC with Atmel Studio installed. Click Tools → Device Programming to open the programming dialog. Then, program the kit as show below. Note: The Device selector must be set to ATSAMD21G18A. Figure 6-8. Reprogramming Flow by Atmel Studio Programming steps: 1. Select the programming tool. 2. Choose device (must be ATSAMD21G18A) and select the interface (must be SWD). 3. Apply the setting. 4. To ensure the correct connection, press ‘Read’ to get the device signature and target voltage. 5. Browse to the folder where the code located, and select it. 6. Program the device. The status can be displayed in the information frame below. AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 21 2 1 7 22 Revision History Doc Rev. Date 42689A 03/2016 Comments Initial document release. AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE] 2 Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016 2 Atmel Corporation 1600 Technology Drive, San Jose, CA 95110 USA T: (+1)(408) 441.0311 F: (+1)(408) 436.4200 │ www.atmel.com © 2016 Atmel Corporation. / Rev.: Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016. 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