Project files: Mains controller & standby PSU

What is it?
These are the project files for my mains controller and standby-PSU shown here. Also included are the files for a simple standby-PSU without any control logic for a MeanWell IRM-series power module from 5-20W if you just need an AUX-voltage (or a very simple single-rail PSU).

As mentioned in the original post I am not completely happy with these inasmuch as I haven’t really been able to get to a “one-size fits all” version. However, as both versions work (and should work well in the right application) then I am posting the files anyway. You should probably use the transformer version if you need 5V power for logic circuitry because they output is well-regulated. Max. DC output capability is probably around 250-300 mA for supporting circuitry if you subtract the power drawn by LEDs and the SSR etc. (assuming a 6VAC EI-30 transformer is used). For 12V out with a 12VAC transformer, you are probably closer to 150-200 mA as the limit. You should use the IRM-based version if you need more power, such as 12V/24V for fans etc. With an IRM10-12 power module you have around 12V/800mA to play with – plenty for even large fans and other supporting circuitry.

Note: If you are interested in the transformer-based version you may want to hold on for another couple of weeks as I have a “version 1.5” of this on order. Same transformer and same board size, but a few layout tweaks that should make the board more usable.

How big are the boards?

  • Transformer version: 3.7″ x 1.875″ (app. 94 x 48 mm)
  • IRM-version: 3.625″ x 1.75″ (app. 92 x 45 mm)
  • Separate IRM PSU: 2.95″ x 1.25″ (app. 75x32mm)

What is the status of the boards?
The transformer-based version is in version 1.1. The only change from v1.0 is that I changed the lead spacing for the snubber capacitor from 5mm to 7.5mm so that a proper X2-rated part can be used.
For the IRM-version, the files are the same v2.0 version that I built and showed in the original post.

Does it use any special/expensive/hard-to-find parts?
Not too many 🙂

  • The snubber cap across the SSR must be 7.5mm lead spacing and X2-rated. Mouser has them and you may be able to get them from elsewhere as well.
  • The SSR can be had from many sources, including Reichelt, Mouser, ebay etc.
  • The transformer is a fairly common EI30 type which can also be bought from many sources such as Reichelt, TME etc. Note that EI-30 is, strictly speaking, only the core type of the transformer. Always confirm dimensions and pin connections etc. against the manufacturer’s datasheet before you buy.
  • If you want to build the IRM-version then the IRM module itself is a bit expensive. Mouser has them, but if you are in Europe then TME is actually cheaper although at the time of writing this their stocks are a bit erratic.

Anything else I need to know?

  • The connections are quite simple:
    – Mains: For AC input.
    – Load: For the device to be turned on by the SSR. On the IRM-version there are two outputs, but they are in parallel so it does not matter which one is used.
    – Switch: This is the “main” trigger. Short the “trigger” pin to the positive rail via a latching switch to turn on the SSR.
    – Test: This is a shorting jumper for testing purposes. Shorting these two pins turns on the SSR. While intended for testing, you can also use it as an extra trigger, especially if you want galvanic insulation between the logic circuit and the SSR trigger – simply use an optocoupler where the secondary side transistor shorts these two pins.
    – Ext: This is for turning on the SSR via an external circuit, i.e. microcontroller or other logic signal.
    – DC out: This has DC output at all time when the board is powered on.
    – DC switched: This has DC output only when the SSR is turned on.
  • I normally do not post BoMs with these circuits, but this time there’s one included since it may not otherwise be logical how to choose the right parts. The BoM is correct as far as I can see, but if you believe you have found an error or if you have a question you are welcome to contact me.
  • Lastly: Always remember that this circuit is mains-powered. Be careful when building, testing and mounting it and always respect your local electrical code of practice. In short: If you’re not sure what you are doing – then stop and ask someone who does!

Downloads:
Download design files here

Related information:
Note: Always read the “intro post” for additional important information about my designs.

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5 Responses to Project files: Mains controller & standby PSU

  1. Frankie says:

    Hi. I downloaded the project files and tried using OSHPARK for the pcbs. They require an outline (GKO) gerber file, is there anyway to add these to the zip packages? Thanks.

    • theslowdiyer says:

      Hi Frankie,

      Have never tried OSHpark, but I think you can unzip the file and just rename the GML layer to GKO and that should do it. Let me know if that works for you 🙂

      Note: I will publish the v1.5 design files for this over the coming weekend so if you are interested in the transformer-based version of the controller you may want to hold off a little bit longer.

      /U.

  2. Frankie says:

    Thanks for the heads up. I will wait then. But I found a use for just the little pcb for the meanwell (MWPSU1) and ordered some from OSHPark. So you suggestion above worked perfect. After I asked I realized that is the advice in their website!

    From the datasheet it seems these meanwells take both ac and dc for input? Or did I misread the datasheet?

    Thanks again for all the great little designs. I may try the multicap board for an unregulated feed to the regs of a dac, just to see how it sounds like.

    • theslowdiyer says:

      Thanks for the heads-up on OSHpark, I might add that to the instructions as their are quite popular with diyers. I have no plans for updates to the basic IRM-psu as that should work fine as-is 🙂

      The DC input is a fairly standard feature on a switching PSU, because the first stage is normally a rectifier anyway and so it doesn’t matter if you feed it AC or DC 🙂

      /U.

  3. Pingback: Project files: Mains controller v1.5 | theslowdiyer

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