02 Parts

PCB assembly

    • naked PCB board
    • 6 plastic distance bolts 4mm for mounting the PCB
  • connector set
    • display 2.4 inch ili9341. 2.2 inch also works. More details.
    • keypad 4x4 matrix
    • 5V power supply, preferably with 35mm DIN rail mounting
    • recommended: USB adaptor for software updates, or configuration without keypad and display

Triac assembly

    • Triac
    • BTA41/800B
    • The part BTA40/800 is electrically the same, but has a casing with blade flat connectors, and is more expensive.
    • Or:
    • Q8040K5
    • If you want to look for other Triacs, consider these parameters:
    • Blocking Voltage V-DRM: minimum 800V
    • Current I-T: minimum 40 A
    • Critical rate of rise of on-state current di/dt: minimum 50 A/us, better 100 A/us
    • Isolated Tab
    • for phase angle triacs: AL800 inductivity
    • terminal strip
    • MOV metal oxide varistor 0,6W, 300VAC =JVR14N471K or similar
    • 470 Ohm or 1k resistor
    • heat conductive paste Kerafol KP92 or similar
    • 4mm screw
    • 4mm washer spring, lock washer
    • MCB miniature circuit breaker
    • heat sink

SSR assembly

    • SSR e.g. carlo gavazzi RA 4850-D12 with 5V DC control voltage input
    • MOV metal oxide varistor
    • heat conductive paste
    • 5mm screws
    • 5mm washer spring, lock washer
    • MCB

Housing

    • metal casing https://www.klibo.de/gehaeuse_metall.html or https://www.schaltschrank-xpress.de or ebay
    • heat sinks
    • optional: fans for forced cooling ventilated heat sink, e.g. Sunon FAN-ML 8025-230 :: Lüfter 80x80x25mm / 230V
    • DIN rails 35mm
    • 2 stage mains filter e.g. Schaffner FN-2090
    • 3 MOVs: S20K275 430 V 12kA 280J Epcos or similar
    • 5 Terminal blocks: Neutral Line1 Line2 Line3 PE
    • optional: aluminum housing for the PCB

Relay Module

If you pick a 4 channel one with the following pin assignment, then wiring is easier. You can connect 2 modules in total, that is 8 relays in total.

The hydrocontrol relay connector comes directly from the microcontroller, so all protection elements like diodes and power transistor/optocoupler need to be present on the relay module.

The module inputs should not pull more than 2mA, because this current has to be delivered directly from the MCU. The above module pulls 1.8mA per input.

You can find the module in the hydrocontrol shop, on ebay etc.

See also PCB connector assignment and Relay wiring

If you intend to switch the mains to the user loads:

Even thought the relays are rated at 10A, which would be 2.3kW at 230V, the contacts may stick after a while, if trying to switch off at the maximum current. For long-lasting safe operation, is recommended to use a separate, stronger mains contactor, which will be controlled by the relay module.

Cabling

    • 1.5 mm2 for Currents up to 16A
    • 2.5 mm2 for currents up to 32 A
    • 4 mm2 for currents up to 40 A
    • 10 mm2 for currents up to 70 A
    • flat ribbon cable 16 strands/conductors 2.54mm spacing

2nd power supply

    • P-mosfet IRF5305 or similar

Ethernet

For easy wiring, choose a module with the below pin layout. These modules are available at ebay, aliexpress, dealxtreme, dx, amazon etc. I won't provide a link here, because these change frequently. Do a search for "w5500" or "w5500 module" or "w5500 ethernet module"

Click images to enlarge.

GSM

    • adafruit fona
    • antenna
    • power and connector adaptor PCB

WLAN

    • ESP-07s module
    • antenna

dump load fault check /current measurement

    • current transformer
    • load resistor
    • terminal plug

Technical specifications: the AD input of the PCB can handle 2.56V max.

Choose your transformer and parallel load resistor, so that the PEAK voltage (not RMS) at maximum electrical current does not exceed 2.5V.

Temperature monitoring

    • NTC resistor 10kOhm
    • R 4.7 kOhm
    • 2 component glue, epoxy or polymer, fast curing 5 - 7 min
    • terminal strip

Sources

Since I live in Germany, for me the german suppliers are the cheapest.

I first go to reichelt.de, then to conrad.de. They also ship international.

heat sinks, high current SSRs and contactors at tme.eu

display, keypad, relay modules, ethernet module, WLAN at ebay, aliexpress, dealxtreme, dx

current transformers, single terminal block at csd electronics or bürklin (obsolete: eibmarkt.de or eibtron.de)

international suppliers:

farnell, digikey, mouser, RS electronics

UK suppliers:

maplin, rapid electronics

Parts checklist for shopping

libre office calc sheet