KC868-AI ESP32 Smart Controller Instruction Manual

1. Introduction

The KC868-AI is a versatile smart controller module designed for DIY smart home systems and IoT projects. It integrates an ESP32 processor with a rich set of hardware interfaces, including Ethernet, Wi-Fi, RS232, RS485, IR, and RF 433Mhz support. This module features 48 channels of digital dry contact inputs, making it suitable for a wide range of sensor and switch integrations. Its open-source nature and compatibility with platforms like ESPhome, Home Assistant, Tasmota, and Arduino IDE provide extensive flexibility for custom development and automation.

The module's robust design includes digital input optocoupler isolation for enhanced reliability, wide voltage support, and anti-interference capabilities, allowing for long-distance signal transmission up to 1000m. It also features a pluggable terminal design for easy installation and maintenance, and a bottom shell for DIN Rail mounting.

2. Product Overview

The KC868-AI board is a green PCB with blue and green terminal blocks. It features an ESP32-WROOM-32E module, various chips for input/output processing, and connectivity ports.

KC868-AI board overview — Figure 1: KC868-AI Smart Controller Board

Close-up of ESP32 module and components — Figure 2: Close-up view of the ESP32 module and other key components on the KC868-AI board.

Product features: DIN Rail install, stable power supply circuit — Figure 3: Key product features including DIN Rail installation and stable power supply circuit.

Easy installation and maintenance with pluggable terminals — Figure 4: The pluggable terminal design facilitates easy installation and maintenance.

Digital input optocoupler isolation features — Figure 5: Digital input optocoupler isolation provides wide voltage, anti-interference, and supports up to 1000m long-distance connections for various sensors like human infrared, gas, power down, door magnet, light, and wall switch panels.

3. Setup and Wiring

Before connecting, ensure the power supply is disconnected. The KC868-AI module requires a 12V DC power supply. Connect your sensors and devices to the appropriate terminals as shown in the wiring diagram.

KC868-AI detailed wiring diagram — Figure 6: Detailed wiring diagram for the KC868-AI board. This diagram illustrates connections for RS485 (A, B, GND), RS232 (GND, TXD, RXD), Free GPIO (I35, I39, 3.3V, GND, I34, I36), Ethernet, IR Receiver, USB, RF 433MHz Receiver, and 12-24V DC power input. It also shows the 48 digital input channels (1-48) and the S1 Reset and S2 Custom buttons.

3.1 Power Supply

Connect a 12V DC power supply to the designated terminals.

3.2 Digital Inputs

The board features 48 digital dry contact inputs (channels 1-48).
Connect your sensors or switches to these input terminals.
The video below demonstrates the digital input channels.

Video 1: Overview of the KC868-AI board's digital input channels (1-48).

3.3 Communication Interfaces

Ethernet (RJ45): Connect to your local network for wired communication.
Wi-Fi: Configure Wi-Fi settings via the web interface for wireless connectivity.
RS232/RS485: Use these serial ports for communication with compatible devices.
USB (Type-C): For programming and initial setup.
IR Receiver: For receiving infrared signals.
RF 433MHz Receiver: For receiving 433MHz radio frequency signals.

3.4 Buttons

S1: Reset Button: Used to reset the module.
S2: Download Button: Used for firmware download.

4. Operating Instructions

4.1 Software Platforms

The KC868-AI supports various open-source platforms for flexible programming and integration:

Arduino IDE: Write custom code using the Arduino development environment.
ESPhome: Integrate seamlessly with Home Assistant for YAML-based configuration.
Home Assistant: A popular open-source home automation platform.
Tasmota: Open-source firmware for ESP devices, enabling local control and MQTT integration.

Arduino IDE and sample source code files — Figure 7: Arduino IDE environment and available sample source code files for various functions like Alexa Voice, Analog Dimmer, Home Assistant, IR Receive/Send, and Wall Switch.

Arduino IDE for writing code — Figure 8: Example of writing code using the Arduino IDE for the KC868-AI module.

Support for ESPhome and Tasmota firmware — Figure 9: The module supports ESPhome and Tasmota firmware, showing their respective web interfaces for configuration and control.

4.2 Web Interface Configuration

The module provides a web interface for easy configuration and monitoring.

Home Page: Displays essential parameters like board model, software version, build date, serial number, time zone, and WiFi IP address.
Network Settings: Configure Wi-Fi (SSID, password), MQTT broker, HTTP server, TCP server/client, UDP server, and RS232 parameters (baud rate, data bit, stop bit, parity).
Input Configuration: Define how each digital input port works with output ports, including reverse level and bind output options.
Output Configuration: Set actions for each digital output port, such as 'hold on', 'delay', or 'jogging', with adjustable delay times.
Monitoring: View the status of ADC, DAC, Input, and Output channels, and connection status to servers/clients.
IFTTT Automation: Set up 'IF' and 'THEN' conditions for local automation without requiring an internet connection.
Custom Protocol: Define custom protocols for IFTTT functions to integrate with third-party products (HTTP GET/POST, TCP Client, UDP Client, RS232).

Home page of the web interface — Figure 10: The web interface home page displaying system information.

Web interface for network settings — Figure 11: Web interface for configuring network parameters including WiFi, MQTT, HTTP, TCP, UDP, and RS232.

Input configuration in the web interface — Figure 12: Web interface for configuring input behavior, including reverse level and binding to outputs.

Output configuration and monitoring interface — Figure 13: Web interface for setting digital output port actions and monitoring the status of various protocols.

Web interface for monitoring ADC, DAC, Input, Output status — Figure 14: Web interface showing real-time monitoring of ADC, DAC, Input, and Output states.

IFTTT automation setup — Figure 15: Setting up IFTTT (If This Then That) automation rules within the web interface for local control.

Custom protocol definition for IFTTT — Figure 16: Defining custom protocols for IFTTT functions to interact with various third-party devices.

4.3 Mobile App Control

The KC868-AI can be controlled via mobile applications, including Tuya, with the appropriate license code.

Tuya mobile phone application integration — Figure 17: Integration with the Tuya mobile phone application for remote monitoring and control via the internet.

Mobile app screenshots showing input, output, and analog states — Figure 18: Screenshots of a mobile application displaying input states, output states, and analog sensor readings (ADC/DAC).

4.4 GSM Module (Optional)

For remote control without internet, a 4G SIM7600 module can be integrated. This allows control via SMS, voice calls, DTMF commands, or the Tuya application over 4G.

GSM module for remote control — Figure 19: Configuration interface for the 4G SIM7600 GSM module, enabling remote control without internet.

5. Maintenance

Keep the module in a dry, dust-free environment.
Ensure all wiring connections are secure and free from corrosion.
Regularly check for firmware updates from the KinCony official website or forum to ensure optimal performance and security.
Avoid exposing the module to extreme temperatures or direct sunlight.
Clean the board gently with a soft, dry cloth if necessary. Do not use liquids or abrasive cleaners.

6. Troubleshooting

Module not powering on: Verify the 12V DC power supply connection and ensure the power adapter is functional.
No network connectivity: Check Ethernet cable connection or Wi-Fi settings (SSID, password) in the web interface. Ensure your router is functioning correctly.
Inputs not responding: Double-check wiring for dry contact inputs. Ensure sensors/switches are correctly connected and functioning. Verify input configuration in the web interface.
Outputs not activating: Check wiring to output devices. Verify output configuration and IFTTT rules in the web interface.
Firmware update issues: Ensure a stable USB connection and follow the specific update instructions provided by KinCony.
General instability: Try resetting the module using the S1 button. If issues persist, consider restoring factory settings via the web interface (note: this will erase all configurations).

7. Specifications

Feature	Description
Model No.	KC868-AI
Description	KinCony 48 Channel input module - AI
Power Supply	12V DC
Processor	ESP32
Size	220mm*90mm
Interfaces	Ethernet(RJ45)-LAN 100Mbps IPv4/IPv6, Wi-fi, Bluetooth, RS232, RS485, USB(type-c), 433MHz receiver, IIC, IR receiver
Inputs	48 channel dry contact inputs, 2 buttons (S1: Reset, S2: Download)
Communication Method	Bluetooth-Compatible, Wi-fi, IR
State of Assembly	Ready-to-Go
Compatibility	All Compatible
Origin	Mainland China
Certification	CE
Package Weight	0.7 kg
Package Dimensions	23cm x 13cm x 16cm

8. User Tips

Battery Backup: The module does not include a dedicated terminal for battery backup. For uninterruptible operation, consider integrating an external UPS or a 12V DC battery backup system with appropriate charging and protection circuits connected to the main 12V DC input.
Software Flexibility: Leverage the open-source nature of ESP32 and platforms like ESPhome or Tasmota for highly customized automation. Explore the provided sample code for quick starts.
DIN Rail Mounting: Utilize the optional bottom shell for easy and secure installation in industrial control cabinets or smart home distribution boxes.
Online Resources: The KinCony Official Store provides a technical support forum and online video tutorials. These resources are invaluable for learning and troubleshooting.

Technical support forum screenshot — Figure 20: Screenshot of the KinCony Technical Support Forum, a valuable resource for assistance and community interaction.

Figure 21: Online video tutorials and lessons covering various IoT training topics and Arduino home automation projects.

9. Warranty and Support

For technical assistance, troubleshooting, and community discussions, please visit the KinCony Official Store's technical support forum. Online video tutorials and lessons are also available to guide you through various aspects of using the KC868-AI module.

The product is manufactured by KinCony, a brand committed to providing solutions for smart home automation and IoT development.

KinCony KC868-AI

KC868-AI ESP32 Smart Controller Instruction Manual

1. Introduction

2. Product Overview