PCB development - DX air curtains project

INTRODUCTION The purpose of this document is to define the requirements for a new PCB development of a Control Interface for Air Curtains unit. Schematics & PCB design must be made in Protel DXP or Altium Designer software Now we have three different kind of Control Interface for Air Curtains: • BASIC CONTROL INTERFACE: Designed to control the two-speed fan motor. • WATER CONTROL INTERFACE: Designed to control the two-speed fan motor and the water heat electric-valve for temperature regulation. • ELECTRIC CONTROL INTERFACE: Designed to control the two-speed fan motor and the electric heater for temperature regulation (two stages). GENERAL REQUIREMENTS • Two different PCB design: Basic/Water control interface or Electric control Interface. • Universal AC input Power Supply: 100Vac to 260Vac 50/60Hz • SMPS output voltage / power: 24Vdc / 15W • General Overvoltage protection • Overcurrent motor protection, maximum current 1A (PPTC preferred) • Overcurrent/overvoltage/EMC SMPS protection • PCB dimensions: 150mm x 85,5mm • Maximum component height: 28mm • RS485 communication: Two RJ11 connectors CONTROL and AUX in frontal to allow daisy-chain connection. • 4 SMD LED indicators (frontal): • Supply ON (RED) • Status/Alarm indicator (BLUE) • Low FAN speed (GREEN) • Fast FAN speed (GREEN) • AC input connector (Basic/Water): frontal AC receptacle C14 (IEC60320) for Basic/Water air curtains. • AC input connector (Electric): 3-way screwed connector behind PCB. • 4-way connector: Two External digital input signals NO: External OFF and closed-door detector. This connector is in frontal for Electric air curtain and behind for Basic/Water Air curtain. • 2-way connector: External opto-isolated signal indicating FAN is running. This connector is in frontal for Electric air curtain and behind for Basic/Water Air curtain. • Internal 2-way connector for a PTC1000 temperature sensor • Electric valve (Basic/Water): relay output signal to switch-on an external electro-valve. 2-way connector behind PCB. • Electric heater (Electric): 24Vdc Transistor output signals to control external relays for the 2-stage electric heater. 3-way connector behind PCB. HARDWARE REQUIREMENTS There are two PCB designs: one for BASIC or WATER air curtains and the other for ELECTRIC air curtains. Safety standard rules compliance is required in all design process: • primary AC components election (UL/VDE) • Routing considerations (creepage, isolation distances, track with, etc…) PLANNING & MILESTONES We will supply 3 hardware units: BASIC CONTROL INTERFACE, WATER CONTROL INTERFACE and ELECTRIC CONTROL INTERFACE, to be used as reference for the new hardware design. Proposal phases / milestones of hardware project: • 4.1) SMPS PCB design: Translate Schematics to Altium/Protel DXP platform. PCB layout & PCB routing. Deliverables: schematics, BOM, PCB, Gerber fabrication files • 4.2) SMPS PCB design prototype. This prototype will be mounted and assayed in our laboratory to assure the requirements compliance (100Vac to 260Vac 50/60Hz, output voltage / power: 24Vdc / 15W. Modifications will be reported for PCB design corrections. Deliverables: schematics, BOM, PCB, Gerber fabrication files • 4.3) Basic/Water control interface PCB design. Translate Schematics to Altium/Protel DXP platform. PCB layout & PCB routing. Deliverables: schematics, BOM, PCB, Gerber fabrication files • 4.4) Electric control interface PCB design. Translate Schematics to Altium/Protel DXP platform. PCB layout & PCB routing. Deliverables: schematics, BOM, PCB, Gerber fabrication files • 4.5) Protypes validation for Basic, Water & Electric air curtain. Units will be mounted and assayed in our laboratory. Modifications will be reported for PCB design corrections. Deliverables: PCB & schematic project completed. SKILLS REQUIRED (mandatory): • PCB layout • Circuit Board Layout • PCB design