Pixel DCSSR

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Pixel DCSSR Version 1.3 - 3 Channel WS2811 DC SSR

PixelDCSSR Production Board.jpg


Disclaimers

The standard disclaimers pertaining to the information contained on this wiki page are listed here.


What is the Pixel DCSSR Version 1.3?

The Pixel DCSSR is a DCSSR that uses a WS2811 IC instead of a traditional Renard controller. The Pixel DCSSR functions just as a normal single pixel allowing the control of dumb LED Strings or Strips on a pixel network. You can mix and match the Pixel DCSSR with normal pixels adding them before, after or even in the middle of pixel strings. The Pixel DCSSR has In/Out pads that allow for standard pixel pigtails to be attached.

How does the Pixel DCSSR work?

Revision History

The Version 1.3 is currently the most recent version of the Pixel DCSSR designed by dlovely in production.

Pixel DCSSR Version 1.3 Parts

PCB

The PCB is available at DIYLEDExpress.com

In addition to the PCB, you will need the following components:

Mouser

Mouser PNDescriptionQty
534-3517Fuseholders, Clips, & Hardware PC FUSE CLIP 5 MM2
660-CF1/4C103JCarbon Film Resistors - Through Hole 10Kohms 5%3
80-C322C104Z5UMultilayer Ceramic Capacitors (MLCC) - Leaded 50volts 0.1uF Z5U3
512-LM78L05ACZXLinear Regulators - Standard TO-92 .1A Pos Volt1
660-CFS1/4CT52R471JCarbon Film Resistors - Through Hole 470 OHM 5% 1/4W3
660-CFS1/4CT52R101JCarbon Film Resistors - Through Hole 100 OHM 5% 1/4W1
660-CFS1/4CT52R330JCarbon Film Resistors - Through Hole 33 OHM 5% 1/4W2
782-K847PHTransistor Output Optocouplers Phototransistor Out Quad CTR 50-600%1
538-39890-0302 Fixed Terminal Blocks 5.0MM ECONOMY 2P 14-24AWG3
571-1-390261-4 IC & Component Sockets 16P ECONOMY TIN1
512-FQPF13N06LMOSFET 60V N-Channel QFET Logic Level3
604-WP7113IDStandard LED - Through Hole HI EFF RED DIFFUSED1
604-WP7113GDStandard LED - Through Hole GREEN DIFFUSED1
71-CCF071K00GKE36 Metal Film Resistors - Through Hole 1/4watt 1Kohms 2% Rated to 1/2watt2
504-GMA-1010A Fuse1
571-5-146281-2Headers & Wire Housings 2 P HEADER single row1
649-65474-002LFHeaders & Wire Housings SHUNT TIN1
NAWS28111

Click here for Mouser Direct Project BOM - You will need to source the WS2811 from another vendor.

The BOM is available at DIYLEDExpress.com and is sold in sets of 4 with PCBs and WS2811 ICs.

Heatsink

The design calls for a heatsink to be attached to the MOSFETS to provide maximum power handling capability. It may be purchased at www.diyledexpress.com.

Housing

The Pixel DCSSR Version 1.3 was designed to fit in the TA-200 Demarcation Enclosure available from numerous vendors including DIYLEDExpress.com
TA-200.jpg

Building the Pixel DCSSR Version 1.3

Assembly

The Pixel DCSSR Version 1.3 is a simple device to assemble and test. It is easiest if you build the units by inserting the various components from smallest to tallest .

  1. Begin by inspecting the PCBs to look for any defects such as cracks or breaks. The holes on the board should be open on both sides. Then inspect and sort out the various parts for the board.
  2. Install the WS2811 IC, make sure to match the dot on the PCB with the small hole on the IC.
    PixelDCSSR1-3-Step-2.jpg
  3. Install the three 0.1 uF capacitors in positions C1-C2 on the bottom left of the board. The capacitors are not polarized so they can go either way.
    PixelDCSSR1-3-Step-2.jpg
  4. Install the resistors:
    1. three 470 ohm resistors (yellow-violet-brown) in positions R1-R3 in the center of the board. The resistors are not polarized so they can go either way.
      PixelDCSSR1-3-Step-3.jpg
    2. three 10K ohm resistors (brown-black-orange) in positions R4-R6 in the center of the board. The resistors are not polarized so they can go either way.
      PixelDCSSR1-3-Step-4.jpg
    3. two 33 ohm resistors (orange-orange-black) in positions R7-R8 on the left center of the board. The resistors are not polarized so they can go either way.
      PixelDCSSR1-3-Step-5.jpg
    4. two 1K ohm resistors (brown-black-red) in positions R9-R10 on the bottom left and bottom right of the board. The resistors are not polarized so they can go either way.
      PixelDCSSR1-3-Step-6.jpg
    5. one 100 ohm resistors (brown-black-brown) in positions R11 on the left center of the board. The resistors are not polarized so they can go either way.
      PixelDCSSR1-3-Step-7.jpg
  5. Install the Install the 16 pin socket in the center of the board. Note that the notch faces the top of the board matching the silkscreen pattern on the PCB.
    PixelDCSSR1-3-Step-8.jpg
  6. Install the light emitting diodes:
    1. Install the Green LED in the position marked Signal near the bottom left of the board. Note that the LED is polarized and long lead should go towards the bottom of the board. (Note: silkscreen shows "FLAT" side of the LED, this can also be used to check for proper orientation)
      PixelDCSSR1-3-Step-9a.jpg
    2. Insert the Red LED in the position marked Power near the bottom center of the board. Note that the LED is polarized and long lead should go towards the bottom of the board. (Note: silkscreen shows "FLAT" side of the LED, this can also be used to check for proper orientation)
      PixelDCSSR1-3-Step-9b.jpg
  7. Install the 5v linear regulator on the top left side of the board. Note that there are two sets of three holes. If you are using the small TO-92 package regulator listed in the BOM then the 7805 will use the holes closest to the caps. Note the regulator is polarized and the flat side should face left to match the orientation on the silkscreen. NOTE: IF YOU PLAN TO USE 5VDC LOADS, SEE THE DESIGN OPTIONS SECTION BELOW BEFORE INSTALLING THE VOLTAGE REGULATOR.
    PixelDCSSR1-3-Step-10.jpg
  8. Install the two fuse clips near the top center of the circuit board. It may be easier to put the fuse in then install them on the PCB to ensure they are installed in the correct direction and line up. Please note that fuse clips may be polarized. Examine them carefully, as they often have extra bends that should be placed on the outside end, to stop the fuse from slipping out. Be careful, the fuse holders require a fair amount of solder and heat to attach them. The FUSE should not be present when installing the clips, as the extra heat may melt the end of the fuse.
    PixelDCSSR1-3-Step-11.jpg Fuse Clip.png
  9. Connect the three 2 position screw terminal strips together by sliding the notches on the sides together. Next solder them to the circuit board with the wire opening side facing the right side of the board.
    PixelDCSSR1-3-Step-12.jpg
  10. Install the 3 MOSFETs in the center of the board. It may be easier to attach them to the heat sink first using heatsink compound and screws and nuts, then soldering them to the PCB so they line up correctly. The MOSFETs are polarized and they should be installed with the tab facing the screw terminals.
    DCSSR2-4-Step-11a.jpgPixelDCSSR1-3-Step-13.jpg
  11. Install the pigtails to the bottom left of the board.
    300px
  12. Install the fuse in the clips if it is not already there.
  13. Gently install the Optoisolator in the socket making sure that the notch faces the top of the board , matching the silkscreen drawing.
  14. Inspect the board to look for any missing solder joints, solder bridges or cold solder joints.

Congratulations! That completes the construction of the Pixel DCSSR Version 1.3 !
PixelDCSSR1-3-Final.jpg

Final Testing

Connect power to the DC IN terminals and the POWER LED should light.
Connect the Pixel DCSSR Version 1.3 to a Pixel controller running 5VDC. The SIGNAL LED should light.
A modification can be made by changing the WS2811 Power input resistor and Signal LED resistor to allow for 12V, information about this will be posted once tested. See this thread for more information on 12V.

Mounting in Housing

The Pixel DCSSR Version 1.3 PCB is designed with attachment holes for #4 sheet metal screws for direct mounting into the TA-200 Demarcation enclosure. The upper bosses in the enclosure may need to be filed down to allow the PCB to sit flush depending on the trimming of the component leads on the bottom of the PCB.

Please note that the small holes on the left above the TA200 mount hole (nearest to the terminal block headers), and on the lower left are intended for use as a strain relief point. Place a small zip tie through this hole and around all incoming/outgoing cables, and tighten until snug. This ensures that any accidental pulling on the cables won't jar the connectors loose from the terminal block headers.

Power Requirements

The Pixel DCSSR4 Version 1.3 can switch DC loads from 7-24VDC. The design provides local power for the optoisolator and the MOSFETs by using a local voltage regulator on the DC IN power. The voltage regulator does not work on the DC loads, so that any voltage applied to the DC IN terminals is fully available at the Output Terminals.

While the MOSFETs are capable of switching up to 10A each, the traces on the board cannot handle that much power. Each channel should be limited to 4 A and the total for all 3 channels should be limited to 10A.


Controlling the Pixel DCSSR Version 1.3

The Pixel DCSSR is control by a Pixel Controller that outputs the 2811 Protocol. This will not work with a normal PWM controller.

Schematic

PCB

PixelDCSSR Production Board.jpg

The PCB is available at DIYLEDExpress.com

Design Options

If you want to drive 5.0V DC loads, you should omit the Voltage regulator and solder in a jumper between the two outer pins where the voltage regulator would go. You must use a well regulated 5.0V DC voltage supply attached to the DC In power terminals.

Other Information

JP1 - JP1 sets the Low/High speed mode of the WS2811. By default no jumper is needed to leave the WS2811 in High Speed mode. If you need to force the WS2811 into Low Speed mode place a jumper wire between the pins of JP1 or install a 2 pin header and shunt. A 2 pin header/shunt is not included in the DIYLEDExpress BOMs to avoid confusion as normal operation should be no jumper.


Pixel DCSSR Version 1.3 Discussion Threads

TBD


FAQ

TBD