QUAD TRIAC SWITCH CARD

Features & Specifications

Applying relays is the most usual way to switch an alternating current (AC) with an electronic control, because of its simplicity and its security, as the switching and switched voltage are completely separated. The low speed (esp. for illuminated advertisements) and the short life of the contacts are however major disadvantages. In order to avoid the disadvantages of the relay without losing the advantages, optocoupler controlled triacs are used. Because of the fact that the outputs are controlled by current instead of voltage, they are less sensitive to input interferences, so that the triac card can easily be mounted near the load and relatively far from the control circuit (e.g. for score boards etc.). This kit can immediately be connected to cards like: K8000, K8050, K8023, K8055, K8046, K8055 or other cards with open collector output. Circuits which can deliver a control current of 10mA or higher can also be used.

Features:

• Four triac outputs
• Inputs galvanically isolated by optocouplers.
• 4 control LED's are provided

Specifications:

• Load: 24 to 240V AC, 0.5A not cooled (max. 4A) per output.
• Control current: 10 to 20mA DC.
• Power Supply: 9V DC/200mA ISOLATED FROM THE MAIN VOLTAGE (isolated winding or another transformer).
• Dimensions: 78 x 90 x 29 mm

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 [ multimeter symbol ]

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.

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 CORRECT MOUNTING SEQUENCE !

Construction

1. Resistors

For use with a regular open collector output and a control voltage of 9 to 15VDC:

For 9-15VDC control:
Rx: 820 (8 - 2 - 1 - B)

If your control voltage is higher, then a higher value resistor must be used.

For 24Vdc:
Rx: 1K8 (1 - 8 - 2 - B)

2. IC's.

IC1: TIL111 or equivalent

IC2: TIL111 or equivalent

IC3: TIL111 or equivalent

IC4: TIL111 or equivalent

Mind the position of the notch: it should point to the Velleman emblem. [ notch symbol ]

3. Transistors

T1: BC547B

T2: BC547B

T3: BC547B

T4: BC547B

4. PCB tabs

VAC: 2X, OUT1: 2X, OUT2: 2X, OUT3: 2X, OUT4: 2X, 9VDC: 2X

IN1: 2X, IN2: 2X, IN3: 2X, IN4: 2X

You can also use terminal connectors. [ connector symbol ]

5. LED. Watch the polarity!

LD1, LD2, LD3, LD4: 5mm Red

LED Polarity: Anode (+), Cathode (-)

6. Triacs

TRI1: TIC206M

TRI2: TIC206M

TRI3: TIC206M

TRI4: TIC206M

Remarks: Make sure the metal backside of the triacs points to the outputs. Apply a layer of tin on the entire PCB track.

If you want to switch more than 1.5A per output, then the triacs need cooling. [ cooling symbol ] You therefore have to mount heatsinks to the triacs. If you mount all the triacs on the same heatsink, then you have to isolate the triacs with mica plates and special plastic washers.

The PCB tacks interconnecting the output connectors and the triacs are not protected by the red solder mask. We advise you to strengthen these in soldering a copper wire of 1.5mm² along the whole print. We must take into account that the entire load current goes through these connections; so up to 4A, if the triacs are cooled !

7. Connection

Connect the minus side of the inputs to the open collector outputs of the interface card(s) (see Fig. 1).

Connect the positive side of all inputs with a control voltage (e.g., +9Vdc to 12Vdc). The negative (GND) of the control voltage must also be connected to the Common (or GND) of the open collector card.

Keep in mind that EACH input of the triac card takes about 12mA from the power supply ! [ power symbol ]

This control voltage has to be COMPLETELY ISOLATED! [ warning symbol ]

To supply the card a separate supply must be used of 9Vdc (see Fig. 1).

Connect the supply for the loads to the points VAC. It may range between 24 and 240 VAC.

Fig. 1: Connection Diagram Description: The diagram shows the K2634 Quad Triac Switch Card connected to a K2609 interface card and a power supply. Inputs IN1-IN4 are connected to the outputs of the K2609. A 9V DC supply is connected to the K2634. The VAC terminals are for the AC load supply (220 VAC shown, ranging 24-240 VAC). A bridge rectifier (4 x 1N4007) and a capacitor (1000 uF, 25V) are shown, likely part of the AC load power supply circuit.

ATTENTION

Everything on the print from the optocouplers to the output side is subjected to this (eventual) hazardous voltage. [ high voltage symbol ]

The loads are connected to OUT1 and OUT4.

Interferences on the mains are possible because of the fact that the load switching does not necessarily takes place on the zero crossing point of the AC. When this should disturb the computer functioning, we advise you to install the triac card near the loads to be switched.

8. Schematic diagram.

Schematic Diagram Description: The schematic shows four channels, each consisting of an optocoupler (connected to input IN1-IN4 via a resistor RX), a transistor (T1-T4), resistors (R5-R12), and a triac (TRI1-TRI4). The triacs are connected in series with the AC load (connected to OUT1-OUT4) and the VAC input. A 9VDC supply is used to power the optocoupler and transistor circuitry.

9. PCB Layout

PCB Layout Description: The diagram illustrates the component placement and connections on the Printed Circuit Board (PCB). It shows the positions for the triacs (TRI1-TRI4), resistors (R1-R12), transistors (T1-T4), ICs (IC1-IC4), LEDs (LD1-LD4), and input/output connectors (IN1-IN4, OUT1-OUT4, VAC, +9VDC). Component designators are clearly marked.

Manufacturer Information

VELLEMAN Components NV

Legen Heirweg 33

9890 Gavere

Belgium Europe

Website: www.velleman.be

Website: www.velleman-kit.com

Modifications and typographical errors reserved.

© Velleman Components nv.

Product Code: H2634IP - 2003 - ED1

Barcode: 5410329310264