Total solder points: 247 Difficulty level: beginner 1 2 3 4 5 advanced 10 Channel, 2-Wire REMOTE CONTROL K8023 Control up to 10 devices from a distance using only 2 wires. ILLUSTRATED ASSEMBLY MANUAL H8023IP-1
Features & Specifications Features: Microprocessor controlled. Inputs can be push-buttons, switches or open collector outputs from another device. The receiver section provide 10 open collector outputs which allow you to control relays directly. Terminal block connectors for all input and output connections are included. All outputs are provided with LED indication. Can be used with our kits: K8000,K8006,K8046,K8050, Can be connected to our standard relay card: K6714, K6714-16 Specifications: 10 open collector outputs 50V/100mA Tested to a distance of up to 50m (55 yards) between control- and receiver section. Operating voltage: Single 12-15V AC or DC, 300mA. Dimensions control pcb (wxdxh): 70x50x16mm (2,7 x2 x0,6 ). Dimensions receiver pcb (wxdxh): 103x50x24mm(4 x2 x1 ). 2
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 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 * Typographical inaccuracies excluded. Always look for possible last minute manual updates, indicated as NOTE on a separate leaflet. 0.000 3
Assembly hints 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 REMOVE THEM FROM THE TAPE ONE AT A TIME! AXIAL COMPONENTS ARE TAPED IN THE COR- RECT MOUNTING SEQUENCE! 4 You will find the colour code for the resistances and the LEDs in the HALG (general manual) and on our website: http://www.velleman.be/common/service.aspx
Construction Assembly of the receiver PCB : P8023R 1. Diodes. Watch the polarity! D1 : 1N4007 D2 : 1N4007 D3 : 1N4007 D4 : 1N4007 D5 : 1N4007 D6 : 1N4007 CATHODE 2. Zenerdiode. Watch the polarity! CATHODE ZD... ZD1 : 5V1 / 500mW D... 3. Resistors R... R1 : 470 (4-7 - 1 - B) R2 : 470 (4-7 - 1 - B) R3 : 470 (4-7 - 1 - B) R4 : 470 (4-7 - 1 - B) R5 : 470 (4-7 - 1 - B) R6 : 470 (4-7 - 1 - B) R7 : 470 (4-7 - 1 - B) R8 : 470 (4-7 - 1 - B) R9 : 470 (4-7 - 1 - B) R10 : 470 (4-7 - 1 - B) R11 : 470 (4-7 - 1 - B) R12 : 56 (5-6 - 0 - B - 9) R13 : 10K (1-0 - 3 - B) R14 : 1K (1-0 - 2 - B) R15 : 22 (2-2 - 0 - B) 4. IC sockets, Watch the position of the notch! IC1 : 18p IC2 : 16p IC3 : 16p 5. Capacitors C1 : 15pF (15) C2 : 15pF (15) C3 : 330pF (331) C4 : 100nF (104) C5 : 100nF (104) C6 : 100nF (104) 5
Construction 6. LEDs. Watch the polarity! LD1 LD2 LD3 LD4 LD5 LD6 LD7 LD8 LD9 LD10 LD11 7. Transistor 3mm RED CATHODE COLOR= 2...5 LD... LD... 8. Electrolytic capacitors. Watch the polarity! C7 : 10µF C8 : 100µF 9. Quartz crystal X1 : 4MHz C... X... 11. Electrolytic capacitor. Watch the polarity! C9 : 1000µF /25V 12. Voltage regulator VR1 : UA7810 VR... C... T1 : BC547B 10. Screw connectors 13. IC s mounting IC1 : VK8023 IC2 : ULN2003 IC3 : ULN2003 1 PIN 1 SK1 SK8 : 2p VK8023=(Programmed PIC16C54C-04) Pay attention to the position of the notch! 6
Construction Assembly of the receiver PCB : P8023S 1. Diode. Watch the polarity! D7 : 1N4007 D... CATHODE R25 : 10K (1-0 - 3 - B) R26 : 10K (1-0 - 3 - B) R27 : 10K (1-0 - 3 - B) R28 : 220 (2-2 - 1 - B - 9) 3. IC socket, Watch the position of the notch! 5. LED. Watch the polarity! LD12 : 3mm RED CATHODE COLOR= 2...5 LD... 2. Resistors IC4 : 18p 6. Transistor LD... R... T2 : BC547B 4. Capacitors R16 : 1K (1-0 - 2 - B) R17 : 4K7 (4-7 - 2 - B) R18 : 10K (1-0 - 3 - B) R19 : 10K (1-0 - 3 - B) R20 : 10K (1-0 - 3 - B) R21 : 10K (1-0 - 3 - B) R22 : 10K (1-0 - 3 - B) R23 : 10K (1-0 - 3 - B) R24 : 10K (1-0 - 3 - B) C10 : 15pF (15) C11 : 15pF (15) C12 : 100nF (104) C13 : 100nF (104) 7. Voltage regulator VR2 : UA78L05 VR... 7
Construction 8. Electrolytic capacitor. Watch the polarity! 11. Electrolytic capacitor. Watch the polarity! C14 : 10µF C... C15 : 470µF /25V C... 9. Quartz crystal X2 : 4MHz X... 12. IC mounting IC4 : VK8023 1 VK8023=(Programmed PIC16C54C-04) PIN 1 10. Screw connectors Pay attention to the position of the notch! SK9 : 3p SK10 SK14 : 2p 8
Hook-up & testing 13. Hook - up & Testing Connect both PCB s P8023S and P8023R according to fig.1. Both push buttons and switches can be used to control the inputs. Keep the distance between the switches or push buttons and the circuit as short as possible. If the circuit is used in a noisy environment (e.g. proximity of electric motors, transformers,.) or if the distance between the switches and the circuit exceeds 1m (3"), a shielded cable must be used to connect the switches. The shield must be connected to the COM terminal. P8023S +VTX- COM 1 2 3 4 5 6 7 8 9 10 If the K8023 circuit is powered from an AC source, then you will need an external DC source to power the relays, and the + Vext terminal must be connected. (fig 1). 12V/300mA S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 RY1...RY10 12..15Vin +VTX- 1 2 3 4 5 6 7 8 9 10 +Vext + Vext - FIG. 1.0 P8023R 9
Operation 14. Operation 1. Control section (P8023S): Both PCBs are connected to each other by means of two wires, VTX+ and VTX-. They supply power to the control board and carry the data signal. This signal contains information regarding the status of the 10 inputs. Filtering and regulating of the power supply is performed by VR2, together with C15, C12, C13 and C14, which also suppress possible oscillation of the voltage regulator. The micro controller continuously monitors the status of the inputs, and switches T2 according to a custom developed serial protocol. This allows a current to flow in the VTX wires. LD12 also lights allowing you to check the operation of the system. 2. Receiver section (P8023R): The receiver end also contains a power supply section. Diodes D1 to D4 rectify the incoming power. Voltage regulator VR1 and the surrounding capacitors make sure the control part receives a regulated 10V. From this 10V, R12, ZD1 and C8 derive 5V DC to supply the microcontroller. The actual receiving part consists of D6, D7, R14, R15 and T1. The current variations in the VTX-lines cause a voltage drop over R15, which is filtered by C3 and amplified by T1, before it is fed to the micro controller. Reception is indicated by LD11. The microcontroller analyses the serial signal, and puts the corresponding outputs high or low. Because the microcontroller cannot sink large currents, we added IC2 and IC3, which provide open collector outputs. 10
Hook-up examples 15. Hook-up Examples 1. Connecting the K8023 to the K6714, relais card. P6714 VB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 From P8023S 12..15Vin +VTX- 1 2 3 4 5 6 7 8 9 10 +Vext P8023R 11
Hook-up examples 2. Connecting the K8023 to the K6711, IR receiver. P8023S +VTX- COM 1 2 3 4 5 6 7 8 9 10 TO P8023R VA VB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 +V P6711 12
Hook-up examples 3. Connecting the K8023 to the K8006, modular light system. Base unit for home modular light system P8006 C 1 2 3 4 5 From P8023S 12V/300mA TO SECOND K8006 12..15Vin +VTX- 1 2 3 4 5 6 7 8 9 10 +Vext P8023R 13
Hook-up examples 4. Connecting the K8023 to the K8000, computer interface card. P8000 Computer Interface Board +IO/1- +IO/2- +IO/3- +IO/4- +IO/5- +IO/6- +IO/7- From P8023S +12VDC 12..15Vin +VTX- 1 2 3 4 5 6 7 8 9 10 +Vext 14 P8023R
Schematic diagram 16. Schematic diagram (Control section) SK9 + VTX - COM 2 D7 1N4007 C15 470µ/25-35V 1 C12 100n VR2 UA78L05 Vin 2 Vout 3 C13 100n C14 10µ 2 2 2 2 2 R18 R19 R20 R21 R22 R23 R24 R25 R26 R27 T2 LD12 LED3RL R28 R16 220/0.6W 1K X2 4MHz C10 15p C11 15p 2 2 R17 4K7 2 16 3 4 17 18 1 2 6 14 VDD IC4 OSC1/CLKIN 15 OSC2/CLKOUT T0CKI RB1 7 MCLR/VPP RB2 8 9 RA0 RB3 RA1 RB4 10 RA2 RB5 11 RA3 RB6 12 13 RB0 RB7 VK8023 (PIC16C54) VSS 5 10K 10K 10K 10K 10K 10K 10K 10K 10K 10K BC547 2 2 1 2 3 4 5 6 7 8 9 10 SK10 SK11 SK12 SK13 SK14 15
Schematic diagram 17. Schematic diagram (Receiver section) 12...15Vin SK1 D1 1N4007 D3 1N4007 D2 D4 1N4007 1N4007 16 X1 4Mhz C1 15p C2 C6 15p 100n 1 C9 C4 100n 1000µ/25V VR1 UA7810 Vin 2 Vout VDD 14 IC1 16 15 OSC1/CLKIN OSC2/CLKOUT 3 7 4 T0CKI RB1 8 MCLR/VPP RB2 17 9 RA0 RB3 18 10 RA1 RB4 1 11 2 RA2 RB5 12 6 RA3 RB6 13 RB0 RB7 VSS 5 VK8023 (PIC16C54) 3 C5 100n R12 56/0.6W C7 10µ ZD1 5V1 C8 100µ R13 10K T1 BC547 R11 470 LED3RL LD11 R14 1K C3 330p IC2 1 IN 1 OUT 1 2 3 IN 2 OUT 2 IN 3 OUT 3 4 IN 4 OUT 4 5 IN 5 OUT 5 6 7 IN 6 OUT 6 8 IN 7 OUT 7 COMMON CLAMP D6 1N4007 D5 1N4007 ULN2003 + SK2 VTX - IC3 1 2 IN 1 OUT 1 IN 2 OUT 2 3 IN 3 OUT 3 4 IN 4 OUT 4 5 R1 R2 R3 R4 R5 R6 R7 R8 R9 IN 5 OUT 5 R10 6 7 IN 6 OUT 6 470 470 470 470 470 470 470 470 470 470 IN 7 OUT 7 8 COMMON CLAMP LD1 LD2 LD3 LD4 LD5 LD6 LD7 LD8 LD9 LD10 ULN2003 LED3RL R15 22 16 15 14 13 12 11 10 9 16 15 14 13 12 11 10 9 1 SK3 2 3 SK4 4 5 SK5 6 7 SK6 8 9 SK7 10 +Vext SK8
17 R19 R21 SK11 COM +VTX- SK9 D7 C15 3 2 1 SK10 R20 R22 SK13 6 5 4 7 SK12 IC4 9 8 10 SK14 R23 R24 R18 C13 T2 R28 VR2 C12 LD12 R26 C14 R27 R16 X2 P8023S'1 VELLEMAN R17 R25 C10 C11 PCB 18. Control PCB
PCB 19. Receiver PCB VR1 C4 D2 D4 12..15Vin SK1 D1 D3 C7 ZD1 R11 R13 LD11 C8 +VTX- SK2 T1 C3 C2 R12 D5 1 2 3 4 SK3 SK4 R15 X1 R14 C6 C1 D6 R1 5 6 7 8 9 SK5 SK6 SK7 VELLEMAN P8023R'1 R2 IC2 R3 R4 R5 R6 R7 10 +Vext R8 SK8 IC3 R9 R10 C5 C9 IC1 LD1 2 3 4 5 6 7 8 9 10 18
VELLEMAN Components NV Legen Heirweg 33 9890 Gavere Belgium Europe www.velleman.be www.velleman-kit.com Modifications and typographical errors reserved Velleman Components nv. H8023IP - 2004 - ED1 5 410329 290818