INTRODUCTION:

Armtronix 30AMPS Relay board is a IOT board.The features of the board are:

Wireless control.
On board USB to UART.
On board AC to DC power supp1y 230VAC to 5V DC.
AC virtual switch.

The look and feel and size of the board is 105mm X 70mm is shown in diagram1 has a capacity to drive 30Amps load. The board is separated as base board and daughter card so that there will be isolation from the AC. The daughter card has the Wifi module (ESP 8266) and microcontroller(atmega328) which is used to control the relay through http or mqtt.On board there is USB to UART and micro USB to program the ESP 8266 and atmega328.

The base board has the Power module AC to DC of 100-240VAC to 5V up to 0.6A, fuse holder for glass fuse , relay of 30Amps and Terminal connector. There is isolation to drive relay and spike suppression is also added. Zero cross detection is also available to increase the span of relay.

Step 1: Header Details

The diagram2 gives the details of the headers and terminal blocks

On base board 230VAC is applied to the input terminal block and load is applied to the output block. Switch is connected to the Ac virtual switch.

On the Daughter card the J6 header is used give the 5v or 3.3v to controller, refer the diagram4 this is made be using jumper arrangement. If 1 and 2 pins of J6 is short then the controller runs at 3.3V, if 3 and 2 pins of J6 are short then controller runs at 5V.

J1 header has ESP free gpios , users can use for there purpose.

S1 button is for Key flash for ESP.

S2 button is for reset of ESP.

S3 button is for master reset when you press the button both ESP and Atmega resets.

Step 2: Programming ESP ,Atmega and Connection Between ESP and Atmega

J2 Header is used to upload the firmware to ESP or atmega through the USB to UART by using micro USB.The pin details can be referred from the diagram4.To upload the new firmware to esp via selecting the com port short the pins 3-4,5-6 and 9-10 using jumper settings. To upload the new firmware to atmega via selecting the com port short the pins 1-2, 7-8 and 11-12 using jumper settings .After programming both ESP and Atmega we have to establish connection between ESP and Atmega by shorting pins 1-3 and 5-7 using jumpers.

Step 3: Configuration Details

Power the board with Input with 230V AC the device will host the access point as shown in diagram5, connect the mobile to access point with Armtronix-(mac) EX: Armtronix-1a-65-7 as shown in diagram6. After connecting open browser and type 192.168.4.1 (default IP address) IP address in the browser, it will open the web server as shown in the diagram7, fill the SSID and password and select HTTP, if user wants to connect to MQTT then he has to select MQTT radio button and enter MQTT broker IP address and enter MQTT publish topic and MQTT subscribe topic and submit.

After configuring the submit the ESP 8266 will connect to the router and router assigns IP address to the ESP. Open that IP address in the browser to control the relay.

Without configuring the SSID and Password we can control the relay by connecting to the access point of the device and open the IP address of device i.e 192.168.4.1 the web server page will show the link with the name Control GPIO as shown in the diagram8 by clicking this link also we can control the relay but the response will be slow.

Step 4: Wiring Diagram

The wiring diagram is shown in the diagram3 to input terminal block 230VAC Phase(P) and Neutral(N) is given .The output of relay Normally open (NO) is connected to one end of the load and Neutral(N) to the other end of the load. The AC virtual terminal block is connected to the switch as shown in the diagram3.We can control the relay either by wireless or using AC virtual switch. The load can drive up to 30Amps and the copper pad is exposed to air so that extra lead can be solder to increase the ampere rating.

In the diagram9 can be seen the bottom layer of the PCB where copper track is exposed so that lead can be poured to increase the current rating.