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Copyright 2012 Gregory Bartlett
10/5/2012
Helix Light Controller
Helix SSR Daughter
Board v2 Assembly and Setup Manual
Helix SSR Daughter Board v2
Assembly and Setup Manual
1
Comments, Questions or Concerns contact the developer at: [email protected]
Table of Contents Overview .......................................... ................................................... ................................................... .......... 1
Helix SSR Daughter Board Bill Of Materials (BOM) ..................................................... ..................................... 3
Helix SSR Daughter Board BOM Continued ............................................................... .................................. 4
Initial Assembly of the SSR Daughter Board ........................................................... ......................................... 6
Step-by-Step Instructions (Table 1 of 6) ............................................................. ......................................... 6
Step-by-Step Instructions (Table 2 of 6) ............................................................. ......................................... 7
Step-by-Step Instructions (Table 3 of 6) ............................................................. ......................................... 8
Step-by-Step Instructions (Table 4 of 6) ............................................................. ......................................... 9
Step-by-Step Instructions (Table 5 of 6) ............................................................. ....................................... 10
Step-by-Step Instructions (Table 6 of 6) ............................................................. ....................................... 11
Assembly Notes .................................... ................................................... ................................................... 12
Assembly Pictures ................................. ................................................... .................................................. 13
Final Assembly of the SSR Daughter Board ............................................................. ....................................... 14
Final Assembly Steps .............................. ................................................... ................................................. 1 5
Setup of the SSR Daughter Board ................... ................................................... ............................................ 16
Figure 1: Independently Fused Inputs ................................................................ ...................................... 18
Figure 2: Channel Banks 1 and 2 Together w/3 and 4 Independent ...................................... .................. 19
Figure 3: Channel Banks 1 and 2 Together and 3 and 4 Together ....................................... ..................... 20
Figure 4: Channel Bank 1 Independent and 2, 3 and 4 Together ........................................ ..................... 21
Figure 5: All Channel Banks Together ................................................................ ....................................... 22
Overview This is the basic assembly and setup instructions for the Helix SSR Daughter Board v2. It is not the purpose of this
document to teach soldering techniques or basic electronics. If you need assistance in this area there are several
other sources on the internet for this type of information.
The assembly and setup will follow these steps:
1) Initial Assembly of the SSR Daughter board
2) Final Assembly of the SSR Daughter board
3) Setup of the SSR Daughter board
The Helix SSR Daughter Board is fairly complicated to assemble. If you have little experience with PCB assembly
you may want to consider assembling the Helix Daughter Board first.
Helix SSR Daughter Board v2
Assembly and Setup Manual
2
Comments, Questions or Concerns contact the developer at: [email protected]
If you have any suggestions or problems with this manual or assembly of the Helix Main Board please
email the developer at: [email protected]
CAUTION: The Helix SSR Daughter Board requires that you have an understanding of electrical wiring. If you don’t understand how to select the proper gauge of wire or how to make connections to 120 or 240 Volts AC then seek assistance. There are many exposed high voltage connections that are potentially dangerous. This board should be placed in a safe enclosure to protect against electrocution whenever it is powered.
Helix SSR Daughter Board v2
Assembly and Setup Manual
3
Comments, Questions or Concerns contact the developer at: [email protected]
Helix SSR Daughter Board Bill Of Materials (BOM) Part Description Part # Supplier Qty Notes
C1, C2, C3, C4, C5 0.1uF 50V Ceramic Disc Capacitor
594-K104Z15Y5VF53L2 Mouser 5
C6 100 uF Filter Cap 647-UVR1E101MED1TD Mouser 1
C7 4700uF Filter Cap 647-UVR1C472MHD Mouser 1
D1, D2, D3, D4, D5, D6, D7, D8, D9, D10, D11, D12, D13, D14, D15, D16, D17, D18, D19, D20, D21, D22, D23, D24, D25, D26, D27, D28, D29, D30, D31, D32, D33, D35
Red LED 859-LTL1CHKEKNN Mouser 34
D34 1N5817 Diode 821-1N5817 Mouser 1
F1, F2, F3, F4, F5 Fuse Clips 534-3517 Mouser 10
H1 4x0.1" Pin Strip Header 517-929834-01-04-RK Mouser 1
IC1, IC2, IC3, IC4 74HC4094 8bit SIPO Shift Register
511-M74HC4094 Mouser 4
IC5 Quad 5V RS422/RS485 Receiver
595-SN75LBC175N Mouser 1
IC6, IC7, IC8, IC9, IC10, IC11, IC12, IC13, IC14, IC15, IC16, IC17, IC18, IC19, IC20, IC21, IC22, IC23, IC24, IC25, IC26, IC27, IC28, IC29, IC30, IC31, IC32, IC33, IC34, IC35, IC36, IC37
Optocoupler Triac Driver
859-MOC3023 Mouser 32
J2 Vertical RJ-45 Jack 571-5556416-1 Mouser 1
NE1 NE-2 Neon Lamp 606-A9A Mouser 1
R1, R2, R3 100 ohm 1/4W Resistor 291-100-RC Mouser 3
R4, R6, R8, R10, R12, R14, R16, R18, R20, R22, R24, R26, R28, R30, R32, R34, R36, R38, R40, R42, R44, R46, R48, R50, R52, R54, R56, R58, R60, R62, R64, R66
220 ohm 1/4W Resistor 291-220-RC Mouser 32
Helix SSR Daughter Board v2
Assembly and Setup Manual
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Comments, Questions or Concerns contact the developer at: [email protected]
Helix SSR Daughter Board BOM Continued Part Description Part # Supplier Qty Notes
R5, R7, R9, R11, R13, R15, R17, R19, R21, R23, R25, R27, R29, R31, R33, R35, R37, R39, R41, R43, R45, R47, R49, R51, R53, R55, R57, R59, R61, R63, R65, R67
180 ohm 1/4W Resistor 291-180-RC Mouser 32 For 240 VAC operation these resistors should be 330 ohm. Example Part # 291-220-RC
R68, R69 560 ohm 1/4W Resistor 291-560-RC Mouser 2
R70 100Kohm 1/4W Resistor
291-100K-RC Mouser 1
T1 6.3V 0.4A Transformer 838-3FD-312 Mouser 1
TB1, TB2, TB3, TB4, TB5, TB6, TB7, TB8, TB9, TB10, TB11, TB12, TB13, TB14, TB15, TB16, TB17, TB18, TB19, TB20, TB21, TB22, TB23, TB24, TB25, TB26, TB27, TB28, TB29, TB30, TB31, TB32
5.08MM PCB Mount 2P Terminal Block (13A)
571-2828372 Mouser 32
TB33, TB34, TB35, TB36, TB37, TB38, TB39, TB40, TB41, TB42
5.08MM PCB Mount 2 Pos Terminal Block (20A)
571-7969492 Mouser 10
U1, U2, U3, U4, U5, U6, U7, U8, U9, U10, U11, U12, U13, U14, U15, U16, U17, U18, U19, U20, U21, U22, U23, U24, U25, U26, U27, U28, U29, U30, U31, U32
6A, 600V Triac 511-BTA06-600S Mouser 32
U33 DB101 Bridge Rect. 583-DB101C Mouser 1
U34 5V 800ma Voltage Regulator
511-LD1117V50-DG Mouser 1
Helix SSR Daughter Board v2
Assembly and Setup Manual
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Comments, Questions or Concerns contact the developer at: [email protected]
Misc Other Parts
Description Part # Supplier Qty Notes
16p DIP Socket 571-1-390261-4 Mouser 5
6p DIP Socket 571-1-390261-1 Mouser 32
10A 5mmx20mm Fuse 576-0217010.HXP Mouser 4
0.5A 5mmx20mm Fuse 576-0217.500HXP Mouser 1
Fuse Cover 534-3527C Mouser 5
0.1" Shunt 1A 151-8010-E Mouser 2
Recommended Enclosure CG-1500 YBS.COM 1
¼” Luan Board 1 For enclosure back panel
Recommended Spacers 561-KSP117 Mouser 6
#6 x 1” Pan Head Sheet Metal
Screws
6 To mount Daughter Board to
back panel
#8 x ¾” Pan Head Sheet Metal
Screws
4 To mount back panel in
enclosure
Helix SSR Daughter Board v2
Assembly and Setup Manual
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Comments, Questions or Concerns contact the developer at: [email protected]
Initial Assembly of the SSR Daughter Board
The initial assembly of the SSR Daughter board will consist of soldering all of the major components to the PCB,
starting with the components that have the lowest profile and finishing with the ones with the highest profile.
Step-by-Step Instructions (Table 1 of 6)
Step Done Ref Number Value Note
1 R1 100 Ω Brn, Blk, Brn
2 R2 100 Ω Brn, Blk, Brn
3 R3 100 Ω Brn, Blk, Brn
4 R5 180 Ω See Note 1; Brn, Gry, Brn
5 R7 180 Ω See Note 1; Brn, Gry, Brn
6 R9 180 Ω See Note 1; Brn, Gry, Brn
7 R11 180 Ω See Note 1; Brn, Gry, Brn
8 R13 180 Ω See Note 1; Brn, Gry, Brn
9 R15 180 Ω See Note 1; Brn, Gry, Brn
10 R17 180 Ω See Note 1; Brn, Gry, Brn
11 R19 180 Ω See Note 1; Brn, Gry, Brn
12 R21 180 Ω See Note 1; Brn, Gry, Brn
13 R23 180 Ω See Note 1; Brn, Gry, Brn
14 R25 180 Ω See Note 1; Brn, Gry, Brn
15 R27 180 Ω See Note 1; Brn, Gry, Brn
16 R29 180 Ω See Note 1; Brn, Gry, Brn
17 R31 180 Ω See Note 1; Brn, Gry, Brn
18 R33 180 Ω See Note 1; Brn, Gry, Brn
19 R35 180 Ω See Note 1; Brn, Gry, Brn
20 R37 180 Ω See Note 1; Brn, Gry, Brn
21 R39 180 Ω See Note 1; Brn, Gry, Brn
22 R41 180 Ω See Note 1; Brn, Gry, Brn
23 R43 180 Ω See Note 1; Brn, Gry, Brn
24 R45 180 Ω See Note 1; Brn, Gry, Brn
25 R47 180 Ω See Note 1; Brn, Gry, Brn
26 R49 180 Ω See Note 1; Brn, Gry, Brn
27 R51 180 Ω See Note 1; Brn, Gry, Brn
28 R53 180 Ω See Note 1; Brn, Gry, Brn
29 R55 180 Ω See Note 1; Brn, Gry, Brn
30 R57 180 Ω See Note 1; Brn, Gry, Brn
31 R59 180 Ω See Note 1; Brn, Gry, Brn
32 R61 180 Ω See Note 1; Brn, Gry, Brn
33 R63 180 Ω See Note 1; Brn, Gry, Brn
34 R65 180 Ω See Note 1; Brn, Gry, Brn
35 R67 180 Ω See Note 1; Brn, Gry, Brn
36 R68 560 Ω Grn, Blu, Brn
Helix SSR Daughter Board v2
Assembly and Setup Manual
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Comments, Questions or Concerns contact the developer at: [email protected]
Step-by-Step Instructions (Table 2 of 6)
Step Done Ref Number Value Note
37 R69 560 Ω Grn, Blu, Brn
38 R70 100 KΩ Brn, Blk, Ylw
39 D34 1N5817 See Note 2
40 U33 DB101 See Note 3
41 IC1 Socket 16p DIP Socket See Note 4
42 IC3 Socket 16p DIP Socket See Note 4
43 IC5 Socket 16p DIP Socket See Note 4
44 IC2 Socket 16p DIP Socket See Note 4
45 IC4 Socket 16p DIP Socket See Note 4
46 IC6 Socket 6p DIP Socket See Note 4
47 IC7 Socket 6p DIP Socket See Note 4
48 IC8 Socket 6p DIP Socket See Note 4
49 IC9 Socket 6p DIP Socket See Note 4
50 IC10 Socket 6p DIP Socket See Note 4
51 IC11 Socket 6p DIP Socket See Note 4
52 IC12 Socket 6p DIP Socket See Note 4
53 IC13 Socket 6p DIP Socket See Note 4
54 IC14 Socket 6p DIP Socket See Note 4
55 IC15 Socket 6p DIP Socket See Note 4
56 IC16 Socket 6p DIP Socket See Note 4
57 IC17 Socket 6p DIP Socket See Note 4
58 IC18 Socket 6p DIP Socket See Note 4
59 IC19 Socket 6p DIP Socket See Note 4
60 IC20 Socket 6p DIP Socket See Note 4
61 IC21 Socket 6p DIP Socket See Note 4
62 IC22 Socket 6p DIP Socket See Note 4
63 IC23 Socket 6p DIP Socket See Note 4
64 IC24 Socket 6p DIP Socket See Note 4
65 IC25 Socket 6p DIP Socket See Note 4
66 IC26 Socket 6p DIP Socket See Note 4
67 IC27 Socket 6p DIP Socket See Note 4
68 IC28 Socket 6p DIP Socket See Note 4
69 IC29 Socket 6p DIP Socket See Note 4
70 IC30 Socket 6p DIP Socket See Note 4
71 IC31 Socket 6p DIP Socket See Note 4
72 IC32 Socket 6p DIP Socket See Note 4
73 IC33 Socket 6p DIP Socket See Note 4
74 IC34 Socket 6p DIP Socket See Note 4
75 IC35 Socket 6p DIP Socket See Note 4
76 IC36 Socket 6p DIP Socket See Note 4
77 IC37 Socket 6p DIP Socket See Note 4
78 C1 0.1 µF 104M
79 C2 0.1 µF 104M
80 C3 0.1 µF 104M
81 C4 0.1 µF 104M
82 C5 0.1 µF 104M
Helix SSR Daughter Board v2
Assembly and Setup Manual
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Comments, Questions or Concerns contact the developer at: [email protected]
Step-by-Step Instructions (Table 3 of 6)
Step Done Ref Number Value Note
83 D1 Red T-1 (3mm) LED See Note 6
84 D2 Red T-1 (3mm) LED See Note 6
85 D3 Red T-1 (3mm) LED See Note 6
86 D4 Red T-1 (3mm) LED See Note 6
87 D5 Red T-1 (3mm) LED See Note 6
88 D6 Red T-1 (3mm) LED See Note 6
89 D7 Red T-1 (3mm) LED See Note 6
90 D8 Red T-1 (3mm) LED See Note 6
91 D9 Red T-1 (3mm) LED See Note 6
92 D10 Red T-1 (3mm) LED See Note 6
93 D11 Red T-1 (3mm) LED See Note 6
94 D12 Red T-1 (3mm) LED See Note 6
95 D13 Red T-1 (3mm) LED See Note 6
96 D14 Red T-1 (3mm) LED See Note 6
97 D15 Red T-1 (3mm) LED See Note 6
98 D16 Red T-1 (3mm) LED See Note 6
99 D17 Red T-1 (3mm) LED See Note 6
100 D18 Red T-1 (3mm) LED See Note 6
101 D19 Red T-1 (3mm) LED See Note 6
102 D20 Red T-1 (3mm) LED See Note 6
103 D21 Red T-1 (3mm) LED See Note 6
104 D22 Red T-1 (3mm) LED See Note 6
105 D23 Red T-1 (3mm) LED See Note 6
106 D24 Red T-1 (3mm) LED See Note 6
107 D25 Red T-1 (3mm) LED See Note 6
108 D26 Red T-1 (3mm) LED See Note 6
109 D27 Red T-1 (3mm) LED See Note 6
110 D28 Red T-1 (3mm) LED See Note 6
111 D29 Red T-1 (3mm) LED See Note 6
112 D30 Red T-1 (3mm) LED See Note 6
113 D31 Red T-1 (3mm) LED See Note 6
114 D32 Red T-1 (3mm) LED See Note 6
115 D33 Red T-1 (3mm) LED See Note 6
116 D35 Red T-1 (3mm) LED See Note 6
117 H1 4p Header See Note 5
118 F1A Fuse Clip See Note 7
119 F1B Fuse Clip See Note 7
120 F2A Fuse Clip See Note 7
121 F2B Fuse Clip See Note 7
122 F3A Fuse Clip See Note 7
123 F3B Fuse Clip See Note 7
124 F4A Fuse Clip See Note 7
125 F4B Fuse Clip See Note 7
126 F5A Fuse Clip See Note 7
127 F5B Fuse Clip See Note 7
Helix SSR Daughter Board v2
Assembly and Setup Manual
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Comments, Questions or Concerns contact the developer at: [email protected]
Step-by-Step Instructions (Table 4 of 6)
Step Done Ref Number Value Note
128 R4 220 Ω See Note 8; Red, Red, Brn
129 R6 220 Ω See Note 8; Red, Red, Brn
130 R8 220 Ω See Note 8; Red, Red, Brn
131 R10 220 Ω See Note 8; Red, Red, Brn
132 R12 220 Ω See Note 8; Red, Red, Brn
133 R14 220 Ω See Note 8; Red, Red, Brn
134 R16 220 Ω See Note 8; Red, Red, Brn
135 R18 220 Ω See Note 8; Red, Red, Brn
136 R20 220 Ω See Note 8; Red, Red, Brn
137 R22 220 Ω See Note 8; Red, Red, Brn
138 R24 220 Ω See Note 8; Red, Red, Brn
139 R26 220 Ω See Note 8; Red, Red, Brn
140 R28 220 Ω See Note 8; Red, Red, Brn
141 R30 220 Ω See Note 8; Red, Red, Brn
142 R32 220 Ω See Note 8; Red, Red, Brn
143 R34 220 Ω See Note 8; Red, Red, Brn
144 R36 220 Ω See Note 8; Red, Red, Brn
145 R38 220 Ω See Note 8; Red, Red, Brn
146 R40 220 Ω See Note 8; Red, Red, Brn
147 R42 220 Ω See Note 8; Red, Red, Brn
148 R44 220 Ω See Note 8; Red, Red, Brn
149 R46 220 Ω See Note 8; Red, Red, Brn
150 R48 220 Ω See Note 8; Red, Red, Brn
151 R50 220 Ω See Note 8; Red, Red, Brn
152 R52 220 Ω See Note 8; Red, Red, Brn
153 R54 220 Ω See Note 8; Red, Red, Brn
154 R56 220 Ω See Note 8; Red, Red, Brn
155 R58 220 Ω See Note 8; Red, Red, Brn
156 R60 220 Ω See Note 8; Red, Red, Brn
157 R62 220 Ω See Note 8; Red, Red, Brn
158 R64 220 Ω See Note 8; Red, Red, Brn
159 R66 220 Ω See Note 8; Red, Red, Brn
160 TB1 2p Terminal Block See Note 9; Grn Terminal Block, Channel 1 Output
161 TB2 2p Terminal Block See Note 9; Grn Terminal Block, Channel 2 Output
162 TB3 2p Terminal Block See Note 9; Grn Terminal Block, Channel 3 Output
163 TB4 2p Terminal Block See Note 9; Grn Terminal Block, Channel 4 Output
164 TB5 2p Terminal Block See Note 9; Grn Terminal Block, Channel 5 Output
165 TB6 2p Terminal Block See Note 9; Grn Terminal Block, Channel 6 Output
166 TB7 2p Terminal Block See Note 9; Grn Terminal Block, Channel 7 Output
167 TB8 2p Terminal Block See Note 9; Grn Terminal Block, Channel 8 Output
168 TB9 2p Terminal Block See Note 9; Grn Terminal Block, Channel 9 Output
169 TB10 2p Terminal Block See Note 9; Grn Terminal Block, Channel 10 Output
170 TB11 2p Terminal Block See Note 9; Grn Terminal Block, Channel 11 Output
171 TB12 2p Terminal Block See Note 9; Grn Terminal Block, Channel 12 Output
172 TB13 2p Terminal Block See Note 9; Grn Terminal Block, Channel 13 Output
Helix SSR Daughter Board v2
Assembly and Setup Manual
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Comments, Questions or Concerns contact the developer at: [email protected]
Step-by-Step Instructions (Table 5 of 6)
Step Done Ref Number Value Note
173 TB14 2p Terminal Block See Note 9; Grn Terminal Block, Channel 14 Output
174 TB15 2p Terminal Block See Note 9; Grn Terminal Block, Channel 15 Output
175 TB16 2p Terminal Block See Note 9; Grn Terminal Block, Channel 16 Output
176 TB17 2p Terminal Block See Note 9; Grn Terminal Block, Channel 17 Output
177 TB18 2p Terminal Block See Note 9; Grn Terminal Block, Channel 18 Output
178 TB19 2p Terminal Block See Note 9; Grn Terminal Block, Channel 19 Output
179 TB20 2p Terminal Block See Note 9; Grn Terminal Block, Channel 20 Output
180 TB21 2p Terminal Block See Note 9; Grn Terminal Block, Channel 21 Output
181 TB22 2p Terminal Block See Note 9; Grn Terminal Block, Channel 22 Output
182 TB23 2p Terminal Block See Note 9; Grn Terminal Block, Channel 23 Output
183 TB24 2p Terminal Block See Note 9; Grn Terminal Block, Channel 24 Output
184 TB25 2p Terminal Block See Note 9; Grn Terminal Block, Channel 25 Output
185 TB26 2p Terminal Block See Note 9; Grn Terminal Block, Channel 26 Output
186 TB27 2p Terminal Block See Note 9; Grn Terminal Block, Channel 27 Output
187 TB28 2p Terminal Block See Note 9; Grn Terminal Block, Channel 28 Output
188 TB29 2p Terminal Block See Note 9; Grn Terminal Block, Channel 29 Output
189 TB30 2p Terminal Block See Note 9; Grn Terminal Block, Channel 30 Output
190 TB31 2p Terminal Block See Note 9; Grn Terminal Block, Channel 31 Output
191 TB32 2p Terminal Block See Note 9; Grn Terminal Block, Channel 32 Output
192 TB33 2p Terminal Block See Note 10; Blk Terminal Block, AC 1 Input
193 TB34 2p Terminal Block See Note 10; Blk Terminal Block, H1/H2 Jumper
194 TB35 2p Terminal Block See Note 10; Blk Terminal Block, N1/N2 Jumper
195 TB36 2p Terminal Block See Note 10; Blk Terminal Block, AC 3 Input
196 TB37 2p Terminal Block See Note 10; Blk Terminal Block, H3/H4 Jumper
197 TB38 2p Terminal Block See Note 10; Blk Terminal Block, N3/N4 Jumper
198 TB39 2p Terminal Block Blk Terminal Block, AC 2 Input
199 TB40 2p Terminal Block Blk Terminal Block, AC 4 Input
200 TB41 2p Terminal Block Blk Terminal Block, H2/H4 Jumper
201 TB42 2p Terminal Block Blk Terminal Block, N2/N4 Jumper
202 C6 100 µF See Note 11
203 J2 RJ45 Jack Cat 5 Jack
204 U1 6A, 600V Triac See Note 12
205 U2 6A, 600V Triac See Note 12
206 U3 6A, 600V Triac See Note 12
207 U4 6A, 600V Triac See Note 12
208 U5 6A, 600V Triac See Note 12
209 U6 6A, 600V Triac See Note 12
210 U7 6A, 600V Triac See Note 12
211 U8 6A, 600V Triac See Note 12
212 U9 6A, 600V Triac See Note 12
213 U10 6A, 600V Triac See Note 12
214 U12 6A, 600V Triac See Note 12
215 U13 6A, 600V Triac See Note 12
216 U14 6A, 600V Triac See Note 12
217 U15 6A, 600V Triac See Note 12
218 U16 6A, 600V Triac See Note 12
219 U17 6A, 600V Triac See Note 12
220 U18 6A, 600V Triac See Note 12
Helix SSR Daughter Board v2
Assembly and Setup Manual
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Comments, Questions or Concerns contact the developer at: [email protected]
Step-by-Step Instructions (Table 6 of 6)
Step Done Ref Number Value Note
221 U19 6A, 600V Triac See Note 12
222 U20 6A, 600V Triac See Note 12
223 U21 6A, 600V Triac See Note 12
224 U22 6A, 600V Triac See Note 12
225 U23 6A, 600V Triac See Note 12
226 U24 6A, 600V Triac See Note 12
227 U25 6A, 600V Triac See Note 12
228 U26 6A, 600V Triac See Note 12
229 U27 6A, 600V Triac See Note 12
230 U28 6A, 600V Triac See Note 12
231 U29 6A, 600V Triac See Note 12
232 U30 6A, 600V Triac See Note 12
233 U31 6A, 600V Triac See Note 12
234 U32 6A, 600V Triac See Note 12
235 U34 LD1117V50-DG See Note 13, 5V Regulator
236 C7 4700 µF See Note 11
237 T1 3FD-312 See Note 14; 6.3V Center Tap 0.4A Transformer
238 NE1 Neon Bulb
Helix SSR Daughter Board v2
Assembly and Setup Manual
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Comments, Questions or Concerns contact the developer at: [email protected]
Assembly Notes 1. For 240 VAC operation these resistors should be 330 ohm. Example Mouser Part # 291-330-RC
2. Orientation matters with diodes. The diode has a light band marked on one end; this is the cathode. The
diode needs to be inserted in the PCB with this light band oriented with the band mark on the PCB (the
square pad). See Picture 1 for an example of a correctly installed diode.
3. This is a full wave bridge rectifier, orientation matters. Align the markings on top of the chip with the
markings on the PCB. I.e. the pin with "+" inserted in the hole marked "+". Solder on the bottom side of the
PCB.
4. When installing DIP sockets ensure that the notch in the socket is aligned with the notch on the silkscreen.
Also make sure the sockets are flush with the PCB.
5. Solder the header on to the PCB with the longer leads facing up. Make sure the header is perpendicular to
the PCB. See Picture 2 for an example of a correctly installed header.
6. Orientation matters with LEDs. The LED has one pin longer than the other; this is the anode. The LED needs
to be inserted in the PCB with the anode lead in the round pad.
7. Orientation matters with the fuse clips. Make sure to install them in the correct orientation so they will
hold the fuse.
8. These resistors are installed in a vertical configuration. Orientation does not matter. See Picture 3 for an
example of a correctly installed vertical resistor.
9. These terminal blocks can be slid together via a dovetail joint. Connect eight terminal blocks together then
solder them in position. Make sure all of the terminal blocks are flush with the PCB.
10. These terminal blocks can be slid together via a dovetail joint. Connect three terminal blocks together then
solder them in position. Make sure all of the terminal blocks are flush with the PCB.
11. This is an electrolytic capacitor, orientation matters. One side of the capacitor is marked with as negative.
The pin on this side needs to be inserted in the round pad. Make sure the capacitor is flush with the PCB.
12. This is a TO-220 package triac, orientation matters. Install this component so that it matches the silkscreen
layout. Make sure the triac is vertical and seated in the PCB.
13. This is a TO-220 package voltage regulator, orientation matters. Install this component so that it matches
the silkscreen layout, i.e. the tab is aligned with the right side of the silkscreen. The large silkscreen box
around this component is the outline for the heat sink. Do not install the heat sink at this time.
14. Insert the transformer such that the pin numbers on top of the transformer are aligned with the pad
numbers on the PCB. The transformer has small standoff pins. Make sure these standoff pins are flush with
the PCB.
Helix SSR Daughter Board v2
Assembly and Setup Manual
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Comments, Questions or Concerns contact the developer at: [email protected]
Assembly Pictures
Square Pad
Light Band
Picture 1 Picture 2
Diodes 4 Pin Header
Picture 3
Vertical Resistor
Helix SSR Daughter Board v2
Assembly and Setup Manual
14
Comments, Questions or Concerns contact the developer at: [email protected]
Initial Power Up of the SSR Daughter Board Before powering up the SSR Daughter Board for the first time, perform these checks:
• Do NOT install any of the ICs at this time
• Do NOT install the heat sinks on the voltage regulator at this time
• Verify that all diodes, LEDs, electrolytic capacitors, voltage regulator, IC sockets are aligned properly
• Verify that all components are properly soldered and there are no solder bridges or cold joints
Next perform these steps
1. Install a 1A - 15A fuse in fuse holder F1
2. Install a 0.5A fuse in the fuse holder F5
3. Install the shunts (jumpers), Mouser part #151-8010-E, on Header 1 in the correct configuration for your line
voltage. See Picture 4 for 120 VAC and Picture 5 for 240 VAC.
4. Install a power cord on AC1, being careful to properly align the Hot and Neutral leads. The Neutral wire is
the one connected to the wide blade on the plug and is usually white or has ribs or dashes on the wire.
5. Place the SSR Daughter Board on a non-conductive surface
6. Plug in the power cord
7. The Power LED (D33) should be illuminated, if not then unplug the power cord and troubleshoot the power
supply section of the board. The Power LED is powered by the 5VDC regulator which is connected to the
transformer via the full wave rectifier and filter capacitors.
8. With the main board plugged in, carefully touch the heat sink tabs on the voltage regulator. It should be
cool to the touch or slightly warm at most. If it is hot then you have a short circuit somewhere on the
board. Unplug the board, find the short circuit and repair.
9. With the main board plugged in, use a voltage meter to check the voltage between +5V and GND on the test
points. This voltage should be a solid 5VDC. If it seems to be excessively low or high then unplug the main
board and troubleshoot the 5VDC section of the power supply
10. Once the board passes all of these tests then you are finished with the initial testing.
Picture 4 Picture 5
120 VAC 240 VAC
Helix SSR Daughter Board v2
Assembly and Setup Manual
15
Comments, Questions or Concerns contact the developer at: [email protected]
Final Assembly of the SSR Daughter Board Before final assembly, inspect the board to ensure there are no solder bridges, cold joints or unsoldered pads. After
that is completed it is time to install all of the ICs. Make sure they are installed in the correct orientation and that all
of the pins are firmly seated in the sockets. There is a dot next to pin 1 or an indention at the top of the IC chip that
identifies orientation. This dot or indention needs to be aligned with the indention on the socket. It often helps to
lay the chip on its side on a table and carefully bend all of the pins in toward the center of the chip before trying to
insert it into the socket.
Final Assembly Steps Step Done Ref # Value Orientation
1 IC1 74HC4094 8bit SIPO Shift Register Notch Up
2 IC2 74HC4094 8bit SIPO Shift Register Notch Up
3 IC3 74HC4094 8bit SIPO Shift Register Notch Down
4 IC4 74HC4094 8bit SIPO Shift Register Notch Down
5 IC5 SN75LBC175N Notch Up
6 IC6-IC13 MOC3023 Notch Down
7 IC14-IC21 MOC3023 Notch Down
8 IC22-IC29 MOC3023 Notch Up
9 IC30-IC37 MOC3023 Notch Up
10 Heat Sink for 5V Regulator Apply a little heat sink compound to the back side
of the TO-220. The heat sink slips on the TO-220
package very snugly. Should be inside of the
outline on the silkscreen
Helix SSR Daughter Board v2
Assembly and Setup Manual
16
Comments, Questions or Concerns contact the developer at: [email protected]
Setup of the SSR Daughter Board
After the Helix SSR Daughter Board is assembled it needs to be mounted in a weather proof enclosure such as the
CG-1500 from http://wlcventures.com. It is recommended that a wooden back panel, made out of ¼” Luan plywood
or other suitable material, be installed in the enclosure using #6 x ¾” pan head sheet metal screws. The SSR
Daughter Board can then be mounted to the back panel using #6 x 1” pan head sheet metal screws and nylon spacers
such as Mouser Part# 561-KSP117.
Using SPT cable and vampire sockets create 32 pigtails for each of the channel outputs. Install them through the
holes in the bottom of the enclosure and connect them to the channel output terminal blocks. Be sure to observe
proper polarity, the wide opening in the socket is the neutral and it should be connected to the ribbed wire on the
SPT cable. It is suggested that these pigtails be fanned, formed and secured to the back panel using tie wraps and tie
wrap mounts. See Picture 6 for an example of a wired up SSR Daughter Board installed in an enclosure.
The next step is to wire up the AC inputs. There are four channel banks (groups of eight channels) on the SSR
Daughter board. Each channel bank can handle a maximum of 15A; however, the current switched by each channel
should be limited to less than 1A without proper heat sinking. In no case should the current switched by a given
channel exceed 3A without properly upsizing the triacs. The gauge of the AC input wire and the size of the fuse need
to be properly selected to accommodate the planned load. In no case should the fuse be greater than 15A or greater
than the ampacity of the input wire whichever is less. The fuse covers should always be installed even if a fuse isn’t
used. The SSR Daughter Board channel banks can be powered in seven different configurations:
1. Each Channel Bank (CB) independently powered and fused for up to 60A total switching capacity (see Fig 1)
2. CB 1 and CB 2 powered/fused together and CB 3 and CB 4 independently powered/fused for up to 45A total
switching capacity (see Figure 2)
3. CB 1 and CB 2 independently powered/fused and CB 3 and CB 4 powered/fused together for up to 45A total
switching capacity (basically the same as configuration 2)
4. CB 1 and CB 2 powered/fused together and CB 3 and CB 4 powered/fused together for up to 30A total
switching capacity (see Figure 3)
5. CB 1 independently powered/fused and CB 2, CB 3 and CB4 powered/fused together for up to 30A total
switching capacity (see Figure 4)
6. CB 3 independently powered/fused and CB 1, CB 2 and CB 4 powered/fused together for up to 30A total
switching capacity (basically the same as configuration 5)
7. CB 1, CB 2, CB 3 and CB4 all powered/fused together for up to 15A total switching capacity (see Figure 5)
CAUTION: The Helix SSR Daughter Board requires that you have an understanding of electrical wiring. If you don’t understand how to select the proper gauge of wire or how to make connections to 120 or 240 Volts AC then seek assistance. There are many exposed high voltage connections that are potentially dangerous. This board should be placed in a safe enclosure to protect against electrocution whenever it is powered.
Helix SSR Daughter Board v2
Assembly and Setup Manual
17
Comments, Questions or Concerns contact the developer at: [email protected]
The final connections all require standard Cat5 jumper cables. Connect the Channel Bank In, J2, to one of the
Channel Banks on a Helix Main Board. Plug everything in and your Helix SSR Daughter Board is ready to use.
Picture 6
Helix SSR Daughter Board Mounted in an Enclosure
Configured with All Channel Banks Powered/Fused
Off a Single AC Input
Helix SSR Daughter Board v2
Assembly and Setup Manual
18
Comments, Questions or Concerns contact the developer at: [email protected]
Figure 1: Independently Fused Inputs Each Channel Bank independently powered and fused for up to 60A total switching capacity.
No jumper wires are installed and fuses are required in all four fuse holders.
15 A Max
Fuse 15 A Max Fuse
Required Required
AC 1 Input AC 3 Input
15 A Max 15 A Max
AC 2 Input 15 A Max Fuse 15 A Max Fuse AC 4 Input
15 A Max Required Required 15 A Max
Helix SSR Daughter Board v2
Assembly and Setup Manual
19
Comments, Questions or Concerns contact the developer at: [email protected]
Figure 2: Channel Banks 1 and 2 Together w/3 and 4 Independent Channel Bank (CB) 1 and CB 2 powered/fused together and CB 3 and CB 4 independently powered/fused for up to
45A total switching capacity. Jumper wires are installed on H1/H2 Terminal Block (TB) and N1/N2 TB. Fuses are
required in only three fuse holders.
No Fused 15 A Max
Installed Fuse Req'd
Properly sized AC 3 Input
Jumper wires 15 A Max
AC 2 Input 15 A Max Fuse 15 A Max Fuse AC 4 Input
15 A Max Required Required 15 A Max
Helix SSR Daughter Board v2
Assembly and Setup Manual
20
Comments, Questions or Concerns contact the developer at: [email protected]
Figure 3: Channel Banks 1 and 2 Together and 3 and 4 Together Channel Bank (CB) 1 and CB 2 powered/fused together and CB 3 and CB 4 powered/fused together for up to 30A
total switching capacity. Jumper wires are installed on H1/H2 Terminal Block (TB), N1/N2 TB, H3/H4 TB and N3/N4
TB. Fuses are required in only two fuse holders.
No Fused No Fuse
Installed Installed
Properly sized Properly
Jumper wires sized
Jumper
wires
AC 2 Input 15 A Max Fuse 15 A Max Fuse AC 4 Input
15 A Max Required Required 15 A Max
Helix SSR Daughter Board v2
Assembly and Setup Manual
21
Comments, Questions or Concerns contact the developer at: [email protected]
Figure 4: Channel Bank 1 Independent and 2, 3 and 4 Together Channel Bank (CB) 1 independently powered/fused and CB 2, CB 3 and CB4 powered/fused together for up to 30A
total switching capacity. Jumper wires are installed on H2/H4 Terminal Block (TB), N2/N4 TB, H3/H4 TB and N3/N4
TB. Fuses are required in only two fuse holders.
15 A Max Fuse No Fuse
Required Installed
AC 1 Input
15 A Max Properly
sized
Jumper
wires
AC 2 Input 15 A Max Fuse Properly sized No Fuse
15 A Max Required Jumper wires Installed
Helix SSR Daughter Board v2
Assembly and Setup Manual
22
Comments, Questions or Concerns contact the developer at: [email protected]
Figure 5: All Channel Banks Together Channel Bank (CB) 1, CB 2, CB 3 and CB4 all powered/fused together for up to 15A total switching capacity. Jumper
wires are installed on H2/H4 Terminal Block (TB), N2/N4 TB, H1/H2 TB, N1/N2 TB, H3/H4 TB and N3/N4 TB. Only one
fuse is required.
No Fuse No Fuse
Installed Installed
Properly sized Properly
Jumper wires sized
Jumper
wires
AC 2 Input 15 A Max Fuse Properly sized No Fuse
15 A Max Required Jumper wires Installed
Primary Secondary
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