This is a new version of DigiDimmer. It addresses the problems pointed out in may last post. As in previous designs, the high voltage circuit (Triac, Power Supply, Monitors) is on the bottom board and the low voltage ciruit (CPU, LEDs, Switches) is on the top board. The board will be cut in half and the top board is lifted out of the page and goes directly over the bottom board. That is, the top side of the top board is the top of the dimmer. The bottom side of the bottom board is the bottom of the dimmer.

The notch on the left is for an 'air gap' switch. You will notice two headers (two pins each) on either side of the notch on the bottom board. The idea is the have a couple pieces of metal fashioned to bridge the gap (notch). A plastic plunger will separate them if it is pulled up.

This design still uses the Power Integrations controller for the power supply. Mar suspects I am going to have trouble with this controller but I neither of us has the proper equipment to measure if I have a problem. This is an unresolved issue...

This design is can be configured for six different products. They are, 600W and 1000W versions of 2-key, 6-key and 8-key devices. The exact configurations are explained in the schematic (see below) and also in the description below of the part view of the layout.

This design uses a CEL ZFSM-201 MC13224 module (it is the large yellow square in the parts view below). These modules are pretty expensive and I fully intend to replace it with either something Mar makes or something I make myself. However, I was curious if I could do a six product/2-board layout with a huge module. The answer is that it can be done.

The CEL ZFSM-201 module has two antenna options. You can use the on-board inv-F antenna or you can mount your own MXCC connector and connect a whip antenna. I wanted to experiment with both these options so I decided to make two versions of this board. One with all the board poured with copper ground plane and another with only half the board covered in ground plane. The 'half-poured' version will be used for testing the inv-F antenna. The 'all-poured' version will be used for testing the whip.

To support the whip antenna, a large mounting hole was designed into the bottom board so a whip antenna could be soldered directly to the CEL module and then fed down through the hole (into the box).

Here is the schematic.
Here is the BOM.

No Ground View. This is a view of the layout without any ground planes.
Parts View. This is a view of just the parts layout. Components placed on the top of a board are in white. Components placed ont the bottom side of a board are in yellow. Notice that there are 10 switches in the design. However, not all of them are populated at the same time. See the 'Interface' page of the schematic for exact part combinations. Also notice that the top of the top board (the surface facing into the room) has two white horizontal lines about 125 mils from the horizontal edges. These lines mark the elevated section of the face of the switch so all the buttons and lights reside inside these lines. The plane for the 6 and 8 key devices is to place square-ish buttons over the switches but also between these lines. My guess is these lines and switch locations will move around a bit once the mechanical design is farther along.
All Pour View. This is what the board looks like with both sides of both boards completely flooded with ground plane. This is the version that would be used to test the whip antenna. Notice that mounting hole 144 is positioned under the CEL MXCC connector location (I hope!) so an whip antenna (a piece of wire) can be fed through the hole and soldered tot he module.
Half Pour View. This is what the board looks like with only the left half (about) of each sided poured with ground plane. This version will be used to test the inv-F antenna on the CEL. So... it is a little 'busy' above and below the antenna (parts, traces, ...etc). However, since both the inv-F antenna and the whip antenna are in the box, this might not matter. The inv-F antenna might do just as good as the whip. The whip would be perpendicular to the boards and thus radiate into the walls of the switch box. The inv-F will be parallel to the boards and would radiate into the back of the box. However, in either case, the radio waves have to escape the box (probably through the two forward vents) so the difference between the two might not matter.