Mosaic Industries, Inc.

AC Relay Wildcard Users Guide

Introduction
This document describes how to use the AC Solid State Relay WildCardTM Module. It provides an
overview of the hardware and software for the module as well as a schematic.

The AC Solid State Relay Module allows you to control up to four, 5 amp AC loads. You can stack up to
eight AC Relay Modules on to the Module Carrier Board or you can mix and match any of the growing
family of WildCard Modules. The following sections guide you through the AC Relay Modules hardware
and software.

AC Relay Wildcard Specifications

Channels Four independent, optically isolated solid state AC relays
Voltage Controls 12 to 280 VAC at 50 or 60 Hz
Current Switches up to 5 amps
Isolation Optically isolated to 4000 V rms
Switching Mode Zero voltage switching
Turn On/Off Times Max turn on/off time of AC cycle
Connections Easy-to-connect-to screw terminals

Hardware
Overview
The AC Relay Module was designed to allow easy control of AC loads. Each AC Relay provides:
Control of 12 to 280 VAC loads operating at 47 to 63 Hz and up to 5 Amps.
Optically isolated control to 4000 Vrms.
Zero voltage switching.
Max turn on/off time of AC Cycle.

The next sections show you how to connect the AC Relay Module to the Module Carrier Board and how to
configure the module for proper operation.

Connecting To The Module Carrier Board

To connect the AC Relay Module to the Module Carrier Board, follow these simple steps:

1. Connect the WildCard Carrier Board to the QED Board as outlined in the WildCard Carrier Board
Users Guide.
2. With the power off, connect the Module Bus on the AC Relay Module to Module Port 0 or Module Port 1
on the Module Carrier Board. The corner mounting holes on the module should line up with the standoffs
on the Module Carrier Board. The Module Bus on the AC Relay Module is located opposite from the
screw terminals. The module ports are shown in Figure 1 of the WildCard Carrier Board Users Guide.
CAUTION: The WildCard Carrier Board does not have keyed connectors. Be sure to insert the module
so that all pins are connected. The Module Carrier Board and the AC Relay Module can be permanently
damaged if the connection is done incorrectly.

AC Relay Module 1
 Mosaic Industries, Inc.

Selecting the Module Address

Once you have connected the AC Relay Module to the WildCard Carrier, you must set the address of the
module using jumper shunts across J1 and J2.

The Module Select Jumpers, labeled J1 and J2, select a 2-bit code that sets a unique address on the module
port of the WildCard Carrier Board. Each module port on the Module Carrier Board accommodates up to
4 modules. Module Port 0 on the WildCard Carrier Board provides access to modules 0-3 while Module
Port 1 provides access to modules 4-7. Two modules on the same port cannot have the same address
(jumper settings). Table 1 shows the possible jumper settings and the corresponding addresses.

Module Port Module Address Installed Jumper Shunts

0 None
0 1 J1
2 J2
3 J1 and J2
4 None
1 5 J1
6 J2
7 J1 and J2
Table 1: Jumper Settings and Associated Addresses

Once you have connected and configured all of the hardware properly, you can use the software drivers to
control AC loads.

Software
This section describes the software that enables you to control the AC Relay Module. We first start with a
description of how modules are addressed, then move on to how the relays are controlled, and finally
present you with example software that initializes and controls the relays.

Initializing the Module

Several bytes of memory on the QED board starting at C000H are used to communicate with the AC Relay
Module. The page used for the memorys extended address corresponds to the module address. For
example, to communicate with module 1 on the WildCard Carrier Board, use the 6 byte memory block
starting at address C000H on page 1.

The AC Relays on the AC Relay Module are controlled by a Xilinx CPLD (Complex Programmable Logic
Device). The AC Relay control lines on the CPLD must be configured as outputs for proper operation (on
power up, the control lines are initialized as inputs). To initialize the module, simply create a function that
is defined as follows. Both C and FORTH versions are presented.

// C Code to initialize the AC Relay Module

#include <allqed.h> // Include QED header files

#define RELAY_CONTROL_LINES 1
#define DIRECTION_REGISTER 0xC005

AC Relay Module 2
 Mosaic Industries, Inc.

#define RELAY_CONTROL_REGISTER 0xC000

#define ALL_RELAYS 0xF

void Init_AC_Relay ( uchar module_number ) // Valid module numbers are 0-7

// Initializes the AC Relay Module by configuring the AC relay control lines
// of the CPLD to outputs. The module number depends on the module select
// jumpers. See Table 1 for the jumper settings and associated addresses.
{
EXTENDED_ADDR module_addr;

module_addr.page16 = module_number;
module_addr.addr16 = RELAY_CONTROL_REGISTER;

// Turn all relays off before initializing control lines to outputs.

// Relays are active low (i.e. writing a 0 to the relay turns it on).
StoreChar( ALL_RELAYS, module_addr.addr32 );

module_addr.addr16 = DIRECTION_REGISTER;

StoreChar( RELAY_CONTROL_LINES, module_addr.addr32);

}

\ Forth Code to initialize the AC Relay Module

HEX

4 USE.PAGE \ Initialize the memory map.

15 WIDTH ! \ Avoid non-unique names.
ANEW ACR.CODE \ Forget marker for easy re-loading.

1 CONSTANT RELAY_CONTROL_LINES
F CONSTANT ALL_RELAYS
C005 CONSTANT DIRECTION_REGISTER
C000 CONSTANT RELAY_CONTROL_REGISTER

: Init_AC_Relay ( byte -- | byte = module num. Valid module numbers are 0-7 )
\ Initializes the AC Relay Module by configuring the AC relay control lines
\ of the CPLD to outputs. The module number depends on the module select
\ jumpers. See Table 1 for the jumper settings and associated addresses.
locals{ &module }

\ Disconnect all relays before initializing control lines to outputs.

\ Relays are active low (i.e. writing a 0 to the relay turns it on).
ALL_RELAYS RELAY_CONTROL_REGISTER &module C!
RELAY_CONTROL_LINES DIRECTION_REGISTER &module C!
;

Controlling A Relay
Once you have initialized the module, use Control_AC_Relay to turn on or off the relays and
Read_AC_Relay_Status to read the status of all the relays. Note that the control lines are active low,
which means that to turn a relay on, you have to write a 0 to the relay.

AC Relay Module 3
 Mosaic Industries, Inc.

// C Code to control the AC Relay Module

// Relays are active low (i.e. writing a 0 to the relay turns it on).
#define RELAY_ON 0
#define RELAY_OFF 1

void Control_AC_Relay ( uchar module_number, uchar relay_num, uchar state )

// Sets the relay number to the appropriate state (on or off).
// Valid relay numbers are 0-3. Valid module numbers are 0-7.
{
EXTENDED_ADDR module_addr;

module_addr.page16 = module_number;
module_addr.addr16 = RELAY_CONTROL_REGISTER;

if(state) // turn relay off

{
state = state << relay_num;
SetBits( state, module_addr.addr32 );
}
else // turn relay on
{
state = 1 << relay_num;
ClearBits ( state, module_addr.addr32 );
}
}

uchar Read_AC_Relay_Status ( uchar module_number )

// Reads the current state of the AC Relays. Valid module numbers are 0-7.
// Returns a character whose least significant nibble represents the four
// relays. For example, if 1 is returned (0001 in binary), then Relay 0 is
// off and the other relays are on. If 12 is returned (1100 in binary),
// then relays 2 and 3 are off and 0 and 1 are on. The four most significant
// bits do not matter.
{
EXTENDED_ADDR module_addr;
Char ac_relay_status;

module_addr.page16 = module_number;
module_addr.addr16 = RELAY_CONTROL_REGISTER;

ac_relay_status = FetchChar( module_addr );

return( ac_relay_status );
}

\ Forth Code to control the AC Relay Module

HEX

\ Relays are active low (i.e. writing a 0 to the relay turns it on).
0 CONSTANT RELAY_ON
1 CONSTANT RELAY_OFF

: Control_AC_Relay ( byte1\byte2\byte3 -- )

AC Relay Module 4
 Mosaic Industries, Inc.

\ Sets the relay number to the appropriate state (on or off).

\ byte1 = Module Number. Valid module numbers are 0-7.
\ byte2 = Relay Number. Valid relay numbers are 0-3.
\ byte3 = Relay State. Valid relay states are RELAY_ON or RELAY_OFF
locals{ &state &relay_num &module }

&state
IF \ turn relay off
&state &relay_num SCALE
RELAY_CONTROL_REGISTER &module SET.BITS
ELSE \ turn relay on
1 &relay_num SCALE
RELAY_CONTROL_REGISTER &module CLEAR.BITS
ENDIF
;

: Read_AC_Relay_Status ( byte -- | byte = module_number )

\ Reads the current state of the AC Relays. Valid module numbers are 0-7.
\ Returns a character whose least significant nibble represents the four
\ relays. For example, if 1 is returned (0001 in binary), then Relay 0 is
\ off and the other relays are on. If 12 is returned (1100 in binary),
\ then relays 2 and 3 are off and 0 and 1 are on. The four most significant
\ bits do not matter.

RELAY_CONTROL_REGISTER SWAP C@
;

Conclusion
Now you are ready to start using your AC Relay Module. All of the software routines listed in this
document are also on the distribution diskette that accompanies each module.

AC Relay Module 5
 1 2 3 4
+5V +5V
H3
TDO
6 TDO
+5V TCK R6
5 TMS TCK 10 k U2
4 TMS
TDI R12 3 1
3 TDI Ctrl + R0+
R11 1k 4
C4 2 R10 1k R0 Ctrl - ~ VR1
D 0.1 uF 1 3-32 VDC 275 VAC VARISTOR D
1k 2
R0-
CON6 AC ERZ-V05D431
+5V PX240D5 VR2

22
21
20
19
18
17
16
15
14
13
12
Pull Down Resistors Are +5V 275 VAC VARISTOR

AC Relay Module
C3 C2 U1 Required To Prevent EMF Noise ERZ-V05D432
0.1 uF 1 uF From Reseting The CPLD
R7

GND
GND
GND
GND
GND
GND
GND
VCC
GND
GND
GND
23 GND TCK 11 TCK 10 k U3
24 10 3 1
TDO TDO TMS TMS Ctrl + R1+
25 9 4
GND TDI TDI R1 Ctrl -
26 VCC GND 8 3-32 VDC ~ VR3 ERZ-V05D438
27 7 2 275 VAC VARISTOR H2
GND GND R1-
28 CHAM RELAY CPLD 6 AC R0+
GND GND VR4 R0+ 1
R3 R3 29 IO3 GND 5 PX240D5 R0- R0- 2
R2 30 4 R1+
R2 IO2 GND 275 VAC VARISTOR R1+ 3
R1 31 3 +5V R1-
R1 IO1 GND R1- 4
R0 R0 32 IO0 J0 2 ERZ-V05D433 R2+ R2+ 5
C 33 1 R2- C
/RST J1 R2- 6
+5V Module Select R8 R3+
R3+ 7
10 k U4 R3-

SEL0
VCC
SEL1
/MOD.CS
E
/OE
/WE
AD3
AD2
AD1
AD0
3 1 R3- 8
J2 J1 Ctrl + R2+ 9
4 AC GND
R3 2 JMP 2 JMP R5 R2 Ctrl - VR5
~ CON9

34
35
36
37
38
39
40
41
42
43
44
+5V (0) (0) 3-32 VDC 2 275 VAC VARISTOR
R2- 120/240 VAC
AC ERZ-V05D435 5A
J1 R2 R4 J0 PX240D5 VR6
C5 10 k 10 k
0.1 uF C7 C6 275 VAC VARISTOR
0.1 uF 0.1 uF +5V ERZ-V05D434

6
R9
10 k U5
3 1
Ctrl + R3+
4
R3 Ctrl - VR7
3-32 VDC ~
B C1 +5V 2 275 VAC VARISTOR B
R1 R3-
AC ERZ-V05D436
(0) PX240D5 VR8
H1 10 uF
1 2 275 VAC VARISTOR
Frame Ground GND +5V
3 /IRQ V+RAW 4 ERZ-V05D437 AC Ground Plane
SEL1 5 6 SEL0
SEL1/XMIT- SEL0/XMIT+
7 8
MOSI/XCV- MISO/XCV+
/RESET 9 10
/MOD.CS 11 /RESET SCK 12 Notes:
/MOD.CS 16MHZ 1. Crydom AC Solid State Relays: 5 amps, 120/240 VAC, Opto Isolated to 4000 Vrms.
E 13 14
E R//W 2. 1500 Ohm nominal input impedance. 2.6 mAdc typical input current.
/OE 15 16 /WE
17 /OE /WE 18 3. 1 V min turn-off voltage, 3 V max turn-on voltage.
AD7 AD6 4. Signals R0-R3 are active low (a 0 written to the corresponding address turns it on).
19 20
AD5 AD4 This was done to make the CPLD design for both AC & DC relay modules identical.
AD3 21 22 AD2
AD1 23 AD3 AD2 24 AD0 5. Resistors with values in parentheses are not installed.
AD1 AD0 6. J1 & J2 select a 2-bit code that sets a unique address (0-3) on the module stack.
7. Place digital ground plane under CPLD and AC ground plane under AC side of
CHAM MODULE BUS, 24 PIN
relays to prevent noise from coupling into the CPLD.
A Title A
AC Solid State Module
Project Wildcard
Mosaic Industries, Inc.

Designer
Size: A Rev: 1
David J. Siu
File: ac_relay.sch
Sheet 1 of 1 Date: 15-Jul-2002 13:50:25 Mosaic Industries
1 2 3 4
 Series PX, MPX
5Amp 120/240 Vac - AC OUTPUT
Advanced features include exceptional
steady state current, plus ultra-high
Ultra High Surge Rating surge ratings utilizing oversized inverse-
parallel SCR chips, together with effi-
Random (R) and Zero cient thermal management for increase
Voltage Sw itching cycle life. Models are available to
switch up to 280 Vrms with either zero-
W ide Range Control cross or random turn-on ("R") switch-
ing versions.
Opto Isolated to 4000 Vrms
Manufactured in Crydom's ISO 9002
Certified facility for optimum product
performance and reliability.

MODEL NUMBERS DC CONTROL PX240D5 PX240D5R

M PX240D5 M PX240D5R
OUTPUT SPECIFICATIONS
Operating Voltage (47-63 Hz) [Vrms] 12-280 12-280
Load Current Range [Arms] .06-5.0 .06-5.0
Transient Overvoltage [Vpk] 600 600
Max. Surge Current, (16.6ms) [Apk] 250 250
Max. On-State Voltage Drop @ Rated Current [Vpk] 1.4 1.4
Maximum I2 t for Fusing, (8.3 msec.) [A2sec] 260 260
Max. Off-State Leakage Current @ Rated Voltage [mArms] 4.0 4.0
Min. Off-State dv/dt @ Max. Rated Voltage [V/sec] 500 500
Max. Turn-On Time 1/2 Cycle 0.02 msec
Max. Turn-Off Time 1/2 Cycle 1/2 Cycle
Power Factor (Min.) with Max. Load 0.5 0.5

INPUT SPECIFICATIONS
Control Voltage Range 3-32 Vdc
Max. Turn-On Voltage 3.0 Vdc
Min. Turn-Off Voltage 1.0 Vdc
Nominal Input Impedance 1500 Ohm
Typical Input Current @ Nominal Voltage 2.6 mAdc
2004 CRYDOM CORP, Specifications subject to change without notice.
GENERAL NOTES
All parameters at 25C unless otherwise specified.
Off-State dv/dt test method per EIA/NARM standard RS-443, paragraph 13.11.1
Voltage applied for 1 minute.

For recommended applications and more information contact:

USA: Sales Support (877) 502-5500 Tech Support (877) 702-7700 FAX (619) 710-8540
Crydom Corp, 2320 Paseo de las Americas, Ste. 201, San Diego, CA 92154
FastFax Document No. 112 Email: sales@crydom.com WEB SITE: http://www.crydom.com
SERIES PX UK: +44 (0)1202 365070 FAX +44 (0)1202 365090 Crydom International Ltd., 7 Cobham
Rev. 020504 Road, Ferndown Industrial Estate, Ferndown, Dorset BH21 7PE, Email: intsales@crydom.com.
PAGE 1 OF 2 GERMANY: +49 (0)180 3000 506
 Series PX, MPX
5Amp 120/240 Vac - AC OUTPUT
GENERAL SPECIFICATIONS
Dielectric Strength 50/60Hz Input/Output/Base 4000 Vrms
Insulation Resistance (Min.) @ 500 Vdc 109 Ohm
Max. Capacitance Input/Output 16 pF
Ambient Operating Temperature Range -30 to 80C
Ambient Storage Temperature Range -40 to 125C
M ECHANICAL SPECIFICATIONS
Weight: (typical) 0.4 oz. (11g)
Encapsulation: Thermally Conductive Epoxy

PIN 1: AC LOAD
PIN 2: AC LOAD
PX PACKAGE PIN 3: +DC CONTROL
.300 (7.6) PIN 4: -DC CONTROL
M PX PACKAGE

BOTTOM VIEW

1.00
MAX.
(25.4)
1 draft
CONTROL LOAD top to base
.300 TYP.
(7.6) 4 3 2 1 .050
.200 TYP.
(1.3) .100 1.00
(5.1) .700 (2.5) (25.4)
(17.8) .025
1.100 (.64)
(27.9) .040 (1.0) DIA. LOAD CONTROL
1.70 (4 PLACES)
(43.1)
.25 TYP. (6.35)
1 2 3 4

CURRENT DERATING CURVE

.20 .16 .015
(5.1) (4.1 0.4)
.70 .40
.040 (1.0) DIA. (17.8) (10.2)
6.0
(4 PLACES) 1.10 .30
5.0 (27.9) (7.6)
1.70
LOAD CURRENT [AMPS]

(43.1)
4.0
All dimensions are in inches (millimeters)
3.0

2.0

1.0

0
20 40 60 80
AMBIENT TEMPERATURE [C]

Max. Load Current vs. Temp.

2004 CRYDOM CORP, Specifications subject to change without notice.

APPROVALS
For recommended applications and more information contact:
UL E116949 USA: Sales Support (877) 502-5500 Tech Support (877) 702-7700 FAX (619) 710-8540
Crydom Corp, 2320 Paseo de las Americas, Ste. 201, San Diego, CA 92154
Email: sales@crydom.com WEB SITE: http://www.crydom.com
FastFax Document No. 112
UK: +44 (0)1202 365070 FAX +44 (0)1202 365090 Crydom International Ltd., 7 Cobham
SERIES PX
Road, Ferndown Industrial Estate, Ferndown, Dorset BH21 7PE, Email: intsales@crydom.com.
Rev. 020504
GERMANY: +49 (0)180 3000 506
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