DigiDimmer: Version 3
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).