Total solder points: 234 Difficulty level: beginner 1o 2o 3o 4o 5þ advanced BASE UNIT for HOME MODULAR LIGHT SYSTEM K8006 Features : þ þ þ þ þ þ þ þ þ þ þ þ Create your own domestic modular light control system For use with optional plug-in dimmer module (K8007) and plug-in timer module (K8008) Bus system holds up to five plug-in units Optically insulated push button inputs Can be controlled with open collector circuits (ex. K8000 computer inter face card or with IR remote control receiver K6711) Local control pushbuttons included LED power and mains indicator LED operation indicator for each channel Low-voltage control circuit for extra safety Each plug-in slot is fused Includes 10 LED’s for pushbutton illumination A custom enclosure for rail mounting is available (B8006) Specifications : þ þ þ þ þ þ þ Five separate channels Maximum output : 2.5A per channel (fuse protected) Push button control current: 150mA Open collector control current: 35mA DC Power supply: 24VAC / 300mA Supply voltage for modules: 110V to 240VAC PCB dimensions: 107 x 160 x 70mm/ 4.2”x6.3”x2.8” modifications reserved ILLUSTRATED ASSEMBLY MANUAL H8006IP-ED2 VELLEMAN COMPONENTS Legen Heirweg 33 9890 Gavere Belgium http://www.velleman.be Assembly hints 1. Assembly (Skipping this can lead to troubles ! ) Ok, so we have your attention. These hints will help you to make this project successful. Read them carefully. 1.1 Make sure you have the right tools: • A good quality soldering iron (25-40W) with a small tip. • Wipe it often on a wet sponge or cloth, to keep it clean; then apply solder to the tip, to give it a wet look. This is called ‘thinning’ and will protect the tip, and enables you to make good connections. When solder rolls off the tip, it needs cleaning. • Thin raisin-core solder. Do not use any flux or grease. • A diagonal cutter to trim excess wires. To avoid injury when cutting excess leads, hold the lead so they cannot fly towards the eyes. • Needle nose pliers, for bending leads, or to hold components in place. • Small blade and phillips screwdrivers. A basic range is fine. For some projects, a basic multi-meter is required, or might be handy 0.0 00 1.2 Assembly Hints : ⇒ Make sure the skill level matches your experience, to avoid disappointments. ⇒ Follow the instructions carefully. Read and understand the entire step before you perform each operation. ⇒ Perform the assembly in the correct order as stated in this manual ⇒ Position all parts on the PCB (Printed Circuit Board) as shown on the drawings. ⇒ Values on the circuit diagram are subject to changes. ⇒ Values in this assembly guide are correct* ⇒ Use the check-boxes to mark your progress. ⇒ Please read the included information on safety and customer service 3 Assembly hints * Typographical inaccuracies excluded. Always look for possible last minute manual updates, indicated as ‘NOTE’ on a separate leaflet. 1.3 Soldering Hints : 1- Mount the component against the PCB surface and carefully solder the leads 2- Make sure the solder joints are cone-shaped and shiny 3- Trim excess leads as close as possible to the solder joint AXIAL COMPONENTS ARE TAPED IN THE CORRECT MOUNTING SEQUENCE ! REMOVE THEM FROM THE TAPE ONE AT A TIME ! 4 P E Verde Blu Viola Grigio Bianco 5 6 7 8 9 S Brun Svart Blå Grön Kulta Dourado Oro Grå Guld Silver Valkoinen Vit B Oro Blanco Harmaa Hopea Branco Sininen Vihreä Morado Purppura Lila Azul Cinzento Gris Violeta Azul Verde Naran- Oranssi Orange jado Amarelo Amarillo Keltainen Gul Verde DK 4K7= ( 4 - 7 - 0 - 1 - 1 ) 1% N Rød Brun Sort Guld Sølv Hvid Grå Violet Blå Grøn Gul Guldl Sølv Hvidt Grå Violet Blå Grønn Gul Orange Orange Rød Brun Sort FÄRG FARVE- FARGESCHEMA KODE KODE Punainen Röd Ruskea Musta VÄRI KOODI SF A Argento Prateado Plata 4 Aranciato Giallo 3 Rojo Rosso 2 Encarnado Laranja Marrone Castanho Marrón Negro 1 Preto Nero 0 C CODICE CODIGO CODIGO O COLORE DE DE COLD CORES ORES E I 4K7= ( 4 - 7 - 2 - B ) 5% GB F NL Gold Silber Weiss Grau Violet Blau Grün Gelb Orange Rot Braun Gold Silver White Grey Purple Blue Green Yellow Orange Red Brown Schwarz Black Or Argent Blanc Gris Violet Bleu Vert Jaune Orange Rouge Brun Noir 2 1 0 4 Goud Zilver Wit Grijs B A 9 8 Paars 7 Blauw 6 Groen 5 Geel Oranje 3 Rood Bruin Zwart FARB COLOUR CODIFI- KLEUR C KODE CODE CATION KODE O D DES E COU- D COLOR= 2… 5 Color code table 5 Construction 1. Diodes (check the polarity) 3. 1/2W Resistors D... R... CATHODE q q q q q q q q q q q q q q q q q D1 : 1N4148 D2 : 1N4148 D3 : 1N4148 D4 : 1N4148 D5 : 1N4148 D6 : 1N4148 D7 : 1N4007 D8 : 1N4007 D9 : 1N4007 D10 : 1N4007 D11 : 1N4007 D12 : 1N4007 D13 : 1N4007 D14 : 1N4007 D15 : 1N4007 D16 : 1N4007 D17 : 1N4007 2. 1/4W Resistor R... q q q q q q q q q q q q q q q q q q q q q q R2: 180 (1-8-1-B-9) R3: 180 (1-8-1-B-9) R4: 2K2 (2-2-2-B-9) R5: 2K2 (2-2-2-B-9) R6: 180 (1-8-1-B-9) R7: 180 (1-8-1-B-9) R8: 2K2 (2-2-2-B-9) R9: 2K2 (2-2-2-B-9) R10: 180 (1-8-1-B-9) R11: 180 (1-8-1-B-9) R12: 2K2 (2-2-2-B-9) R13: 2K2 (2-2-2-B-9) R14: 180 (1-8-1-B-9) R15: 180 (1-8-1-B-9) R16: 2K2 (2-2-2-B-9) R17: 2K2 (2-2-2-B-9) R18: 180 (1-8-1-B-9) R19: 180 (1-8-1-B-9) R20: 2K2 (2-2-2-B-9) R21: 2K2 (2-2-2-B-9) R22: 100K (1-0-4-B-9) R23: 100K (1-0-4-B-9 4. Zener diode (check the polarity) ZD... q R1: 3K3 (3-3-2-B) CATHODE q ZD1 : 47V/1.3W q ZD2 : 47V/1.3W 6 Construction 5. Pushbutton 7. LEDs (Watch the polarity!) COLOR= 2...5 SW... LD... CATHODE q q q q SW1 SW2 SW3 SW4 q SW5 6. IC sockets (check the position) q q q q q q q LD1 : 3mm RED (2) LD2 : 3mm RED (2) LD3 : 3mm RED (2) LD4 : 3mm RED (2) LD5 : 3mm RED (2) LD6 : 3mm RED (2) LD7 : 3mm RED (2) 8. PCB Edge Connectors (Watch the orientation!) q q q q q IC1 : 6P IC2 : 6P IC3 : 6P IC4 : 6P IC5 : 6P SK... HOT GLUE GUN LIJMPISTOOL PISTOLET A COLLE HEISKLEBEPISTOLE q q q q q SK1: 10 POLE SK2: 10 POLE SK3: 10 POLE SK4: 10 POLE SK5: 10 POLE 7 Construction 9. PC Terminal blocks (Slide the terminal blocks, one into each other) q q q q q q q SK14: 2-POLE (wide) SK15: 2-POLE (wide) SK16: 2-POLE (wide) SK17: 2-POLE (wide) SK18: 2-POLE (wide) SK19: 2-POLE (wide) SK20: 2-POLE (wide) 10. Fuse Holder + Fuse F... q SK6 to SK10 : 2P+2P+2P+2P+2P q q q q q q SK11 to SK13 : 2P+2P+2P 8 F1: 2.5A SLOW F2: 2.5A SLOW F3: 2.5A SLOW F4: 2.5A SLOW F5: 2.5A SLOW Construction 11. Electrolytic capacitors. Check the polarity ! 13. Insert the OPTO Coupler into the socket (Watch the position of the notch!) C... IC... 5 1 PIN 1 2 q q q q q 6 4 C1: 22 µF/50V C2: 22 µF/50V C3: 22 µF/50V C4: 22 µF/50V C5: 22 µF/50V 12. Modular Jack SK... q q q q q IC1: 4N27, TIL111 or eq. IC2: 4N27, TIL111 or eq. IC3: 4N27, TIL111 or eq. IC4: 4N27, TIL111 or eq. IC5: 4N27, TIL111 or eq. q SK21: 6-POLE 9 Testing 14. Testing the Unit ! CAUTION: MOST PARTS OF THE CIRCUIT CARRY DANGEROUS VOLTAGES (MAINS) ! OBSERVE ALL SAFETY REQUIREMENTS THAT MIGHT APPLY ! First, make sure to apply an extra layer of solder on all thinned PCB tracks because these have to handle high currents. Connect a light bulb rated for the wall outlet voltage (mains) to LOAD 1. Insert a dimmer module (K8007) or timer module (K8008) into the first slot (mind the direction, the components must point to the left). Connect a 24VAC/300mA source (e.g. transformer) to the 24VAC connector. LD6 will light. Connect the 110-240V mains to the SUPPLY Neutral and Live connector. LD7 will light. WALL OUTLET WALL OUTLET 24VAC/300mA TRANSFORMER DANGER HIGH VOLTAGE 24VAC SK1 SK2 SK3 SK4 1 1 1 10 10 10 10 C 1 C2 C3 C 4 C5 PUSH BUTTON INPUTS SW1 SW2 SW3 SW4 SW5 C1 2 3 4 5 LD7 SK5 1 OPEN COLLECTOR INPUTS DIMMER OR TIMER MODULE LD6 N LOAD1 N LOAD2 N LOAD3 N LOAD4 N LOAD5 N L 24VAC INDICATION SUPPLY VELLEMAN P8006'1 5 4 3 2 1 C Push button SW1. The module will be activated, and the light bulb will light. For dimmer/timer module operation details, please check their manuals. All remaining slots must be tested in the same way. Disconnect the mains when removing modules or wiring. 10 Final Connection 15. Final Connection Choose a suitable location for the unit. Probably, the best location is near the fuse box. An optional enclosure (B8006) is available, for safe installation of the unit on a DIN rail. Whatever enclosure you use, make sure to provide sufficient airflow, as the dimmer modules might run hot during use. If you choose the optional B8006 enclosure, drill a number of ventilation holes in the top and bottom part of the cover lid. The drawing below shows a connection example. Make sure your wiring complies with the local safety requirements. If doubt, consult a licensed technician ! DANGER PRIM N LOAD1 N LOAD2 N LOAD3 N LOAD4 N LOAD5 NSUPPLY L VELLEMAN K8006 C 1 C 2 C 3 C 4 C 5 C 1 2 3 4 5 SW1 SW2 SW3 SW4 SW5 L N CIRCUIT BREAKER 16A 24VAC OPEN COLLECTOR INPUTS TRANSFORMER 24VAC HIGH VOLTAGE L N AC POWER PUSH BUTTONS REMARK: 10 LED’s are provided, together with diodes and resistors, to allow pushbutton illumination. Do not use more than 5 illuminated pushbuttons per channel. See drawing below for hook-up details. PUSH BUTTON C 1N4148 2K2 A C LED C A 11 Interfacing with open collector outpputs 16. Interfacing with open collector outputs The drawing below shows a connection example with open collector outputs (e.g. K8000 computer interface board, or K6711 remote control receiver). The open collector inputs are also available via modular connector SK19, which allows easy and fast connection to a control circuit. DANGER PRIM N LOAD1 N LOAD2 N LOAD3 N LOAD4 N LOAD5 NSUPPLY L VELLEMAN K8006 C 1 C 2 C 3 C 4 C 5 C 1 2 3 4 5 SW1 SW2 SW3 SW4 SW5 L N CIRCUIT BREAKER 16A 24VAC OPEN COLLECTOR INPUTS TRANSFORMER 24VAC HIGH VOLTAGE L N AC POWER OPEN COLLECTOR OUTPUTS C PUSH BUTTONS 12 1 2 3 4 5 IC1 1 C SK6 10 IC2 10 1 LD2 2K2 C2 F2 D1 IC3 10 SW2 SW3 PUSH BUTTON INPUTS SW1 1 LD3 C3 F3 SK3 SW4 SW5 1 1 SK11 C C 10 1 5 SK4 SK19 N LOAD5 LD4 C4 F4 IC4 SK18 N LOAD4 VELLEMAN P8006'1 SK2 2 C 3 C 4 C 5 C SK7 SK8 SK9 SK10 2K2 C1 SK1 D8 R1 ZD1 ZD2 D2 R2 1 LD1 F1 D10 SK17 N LOAD3 D12 LD6 2.5A SLOW SK16 N LOAD2 N IC2 SK12 SK13 LD2 10 1 SK5 E C DATA LOAD LD nc L L nc N LD7 D17 L HIGH VOLTAGE R23 F5 R22 SUPPLY SK20 OPEN COLLECTOR INPUTS 3 4 5 2 D14 24VAC INDICATION 2.5A SLOW 1 D7 R3 R4 R5 D3 R6 1 D9 R7 R8 R9 2.5A SLOW D11 D4 R11 R10 R12 1 R13 2.5A SLOW D13 D5 R15 R14 R16 1 R17 2.5A SLOW D15 D6 R19 R18 R20 1 R21 SK15 N LOAD1 SK21 D16 OPEN COLLECTOR INPUTS SK14 24VAC 5 4 3 2 1 C C5 DANGER PCB Layout 17. PCB Layout 13 14 47V ZD2 ZD1 47V SK14 C1 C SK6 1N4148 2K2 2K2 KRS0611 1 SW2 KRS0611 1N4148 1N4148 D10 1N4007 SK7 2K2 2K2 2 LD2 LED3RL 82/0.6W 6 LD1 2 1 4N27 IC2 2K2/.6W LED3RL 4 R7 82/0.6W R6 D8 1N4148 C 10 10 4 E E R9 9 9 KRS0611 SW3 82/0.6W R11 82/0.6W R10 1N4148 C C 1N4148 8 8 D4 DATA DATA D3 7 7 1N4007 2 1 4N27 6 6 6 SW1 82/0.6W R3 C2 22u/50V LOAD LOAD 5 5 5 2K2/0.6W 5 4 4 R8 IC1 2K2/.6W L L 2K2/0.6W R4 3 3 1N4007 L L D9 2 2 LOAD 1 1 LOAD N N R5 82/0.6W D7 R2 22u/50V LED3RL 24VAC INDICATION LD6 1N4007 D2 1N4148 D1 3K3 R1 SK2 SK1 F2 2.5A SLOW F1 SK16 LOAD2 N 2.5A SLOW SK15 LOAD1 N 1N4148 24VAC SK8 LD3 6 LED3RL 3 2 4 5 1N4148 2K2 2K2 PUSH BUTTON INPUTS C 1N4148 1N4007 D12 C3 22u/50V IC3 2K2/.6W R13 1N4007 D11 1 4N27 2K2/0.6W R12 F3 2.5A SLOW SK17 LOAD3 N KRS0611 SW4 82/0.6W R15 82/0.6W R14 1N4148 D5 10 E 9 C 8 DATA 7 LOAD 6 LOAD 5 4 L 3 L 2 1 N SK3 C 1N4148 1N4148 1N4007 D14 C4 22u/50V SK9 IC4 LD4 LED3RL 2K2 2K2 4 2 6 2K2/.6W R17 1N4007 D13 1 4N27 2K2/0.6W R16 F4 2.5A SLOW 4 5 SK18 LOAD4 N KRS0611 SW5 82/0.6W R19 82/0.6W R18 1N4148 D6 10 E 9 C 8 DATA 7 LOAD 6 LOAD 5 4 L 3 L 2 1 N SK4 C 1N4148 1N4148 1N4007 D16 C5 22u/50V SK10 IC5 2K2 R21 LD5 LED3RL 2K2 2K2 5 2 6 1N4007 D15 1 4N27 2K2/0.6W R20 F5 2.5A SLOW 4 5 SK19 LOAD5 N 1N4007 DANGER HIGH VOLTAGE LED3RL D17 100K/.6W LD7 R22 L 100K/.6W SK20 MAINS R23 5 4 3 2 1 C OPEN COLLECTOR INPUTS SK11...SK13 & SK21 10 E 9 C 8 DATA 7 LOAD 6 LOAD 5 4 L 3 L 2 1 N SK5 N Diagram 18. Diagram 15 VELLEMAN Components Legen Heirweg 33 9890 Gavere Belgium Europe Info ?: http://www.velleman.be Modifications and typographical errors reserved © Velleman H8006IP - 2001 - ED2