AC SSR board

Switch a specified AC mains load with galvanically isolated low-voltage control. The selected v12 is an engineering study targeting 20 A, not a qualified 20 A product or a verified Fotek-compatible assembly.

Development status

Baseline documentation snapshot: 2026-10-11, before the requested connector/protection/usability revision program. New revision features require their own reviewed source and qualification evidence.

This page documents an unqualified engineering study, not a released or tested product. Saved CAD, renders and automated checks do not establish a safe assembly, compatible cable, firmware support or a usable current rating.

Board-specific qualification limits: v12 retained; no new revision; no fabrication/energizing; mains spacing/cooling/signoff open.

Interfaces and wiring

Inputs

  • X socket low-voltage command or standard single-output signal interface.
  • AC line/load terminals at voltage/frequency TBD.

Outputs

  • Switched AC load path.

Connection contract

The following is the repository-canonical 10-pin mapping used in the selected study. Pin 1 is +3.3 V, pin 2 is +5 V, and pin 10 is GND. The previously recorded V2 Prime physical rail-placement discrepancy remains unresolved; the existing CAD does not qualify the real connector or cable. Do not fabricate or connect it until the real target hardware is inspected.

Pin Function
1 +3.3 V logic
2 +5 V control supply
3 AC_ENABLE with pull-down
4 Unused
5 Unused
6 Unused
7 Unused
8 Unused
9 Unused
10 SELV GND only

Power off before connecting or changing jumpers. Verify pin 1, signal direction, supply voltage and ground at both ends of every cable. A mechanically fitting connector is not proof of electrical compatibility. If a host pin mapping or current allocation remains unresolved in the design record, do not connect the board until it is resolved.

Electrical design requirements

The following are specification requirements or study assumptions; they are not measured operating ratings. A newer selected-revision note takes precedence over historical draft options.

  • 20 A requires stated ambient, heat sink and derating.
  • The selected v12 uses a zero-cross MOC3083 optotriac and BTA41-800BRG triac for resistive-load burst firing. Random-fire/phase-angle operation is outside this selected design.
  • Off-state leakage, minimum load and surge current must be specified.
  • Mains creepage/clearance and fuse standard are design blockers.

Protection in the design record

The design describes the following protection intent. Check the selected schematic and remaining qualification gates before relying on it:

Replaceable branch fuse, MOV/snubber selected for load and mains category, reinforced isolation, thermal cutoff/sensor and touch-safe terminal spacing.

Configuration and commissioning

Use the configuration and firmware contract for the exact selected revision. Do not copy another module’s socket assignments or assume that an unused pin is available. First-article work must verify source selection, reset/unplug behavior, cable orientation and the actual load or sensor interface before normal operation.

Requested connector and usability upgrades

The following are requirements for the next design iterations; this page does not claim they are already fitted:

  • On electrically suitable three/four-pin low-voltage ports, provide compact alternative 2.54 mm header/Molex-style and keyed STEMMA-family footprints. Populate one connector option per shared position and document its pin order. Use STEMMA QT only for compatible four-wire I²C; connector appearance does not make another signal protocol I²C-compatible.
  • Render each supported connector population separately. Document clearances, cable access and the exact fitted option.
  • Use uppercase titles in a consistent Montserrat-style face, labels on both sides, visible domain boundaries, a revision-specific wiring guide and this page’s URL on the silk where readable.
  • Keep mounting-hole centers on a documented 10 mm lattice; add cable-tie holes where space and electrical clearances permit. Place status LEDs near accessible edges and give every indicator its own disable solder jumper. Provide labeled test pads and a ground observation point.
  • Review applicable DC power entries for reverse-polarity cutoff with a blinking warning, overvoltage cutoff/indication, controlled startup and electronic overcurrent protection. Indicator and protection circuits must work in the fault state without defeating isolation or safe output defaults. Thermal protection belongs only where the power/thermal analysis justifies it.
  • Electronic protection does not automatically replace a required mains/branch safety fuse. Backfeed blocking and inductive-load flyback clamps are separate design functions. Do not add identity EEPROMs, fault memory, calibration storage or paid self-test hardware under this upgrade program.

Design sources

Documentation route: smoothieware.org/extensions/ac-ssr-board.

Additive design studies

The 2026-10-11 upgrade program has saved additional candidates v13, v14, v15. These studies preserve the historical design described above. Their connector, LED, mechanical and protection changes are revision-specific and remain unqualified.

See the per-board changes, failures and remaining work and mandatory family specification. Use the source hash and native check for the exact candidate being reviewed; do not infer hardware ratings from a rendered population.

Upgrade candidate readback

The three additional revisions are v13, v14, v15. They are engineering studies; saved CAD and renders do not release the hardware. The latest candidate is described below. Older baseline notes above remain historical.

ac-ssr-board

  • Latest PCB source, SHA-256 3771c5bb4eea64f3a795cdb001975397160cc353ddcc02ff38675004c6ef688e.
  • Last native check: 0 errors, including 0 open connections. This is a CAD result, not electrical, assembly or firmware qualification.
  • No alternative connector population is recorded for this physical role. Any applicable connector conversion remains an explicit design-review item.
  • normal population/render record: 6 images; source current; image hashes match; 0 unresolved models.
  • Changes, failed trials and remaining work.

Applicable protection, current-path, thermal, pinout, cable access and physical tests remain open wherever the linked board record has not verified them. A zero native-error count does not close those gates.

Second-round annotation readback v16 — 2026-10-13

Protected source v15; current PCB SHA-256 6f279ab247119fa06aa1d7984a69929e6176267c45ee3be765f312090d5609f0. Fresh checks: zero enabled PCB errors/opens/parity and ERC errors; 6 PCB warnings. Electrical geometry, project rules and 29 historical files unchanged. Verified 18 model entries, 17 exports and 6 current population views, all inspected. Full documentation URL readable. Five inherited ignored PCB categories remain; 1.9mm copper neck, cooling, fuse coordination, protective earth and heatsink qualification failures remain open; not for mains use or fabrication Inherited native warnings and enabled-rule exclusions remain explicit Physical/thermal/current/connector-fit qualification open No priced or area savings established by annotation candidate.

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