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120/240 Particle Wifi Switch And Sensor

About the project

After researching the Sonoff WiFi switch, I decided to build my own switch box mountable 120V input IoT switch.

Project info

Difficulty:

Platforms:

Estimated time:

7 days

Published:

2nd August 2019

Items used in this project

Hardware components

Particle Photon x 1

Software app and online services

Particle Build Web IDE

Hand tools and fabrication machines

Soldering iron (generic) x 1

Story

**Important Note**

Before starting this project you should be aware that you are hooking 120/240 volts AC to your shield. These voltages could be deadly and or cause a fire if you overload the relay or solder it wrong. You can also be seriously hurt if you don’t use proper work and safety ethic. Do not work on the shield while it is plugged into power. You should only have the power plug plugged in if it is inside a plastic or insulated box and ready to be tested and/or completed. TEST THE SHIELD BEFORE YOU PLUG IT IN using a voltmeter to ensure that 5 volts DC is the output on the VIN pin of the shield. Be very careful not to come into contact with the high voltage side of the shield. As you can see from the included images, I used silicone to isolate the power pins on the underside of the shield. Hot glue would work as well.

*********************************************************************

Particle 120V switch

PCB from PCBWay

Rear showing status LEDs and sensors

This is the board soldered up and ready for installation.

Soldered and powered by 120V

Particle Code

// This #include statement was automatically added by the Particle IDE.
#include <Adafruit_MPL3115A2.h>
Adafruit_MPL3115A2 baro = Adafruit_MPL3115A2();
#define LTCADDR1 0x69//Table 1 both LOW (7bit address)Feed
#define LTCADDR2 0x67//Table 1 both LOW (7bit address)Circuit1
#define LTCADDR3 0x6f//Table 1 both LOW (7bit address)Circuit2
#define sda D0 
#define scl D1
#define Relay D4
#define COMOk D3
#define CTOn D2
#define MXC6255ADDR 0010101
//================================================================
//Acceleromiter
//================================================================
byte XOUTMSB,XOUTLSB,YOUTMSB,YOUTLSB;
unsigned int SHTH, SHC, ORC;
float XMOT, YMOT, STAT;
//================================================================
//Voltage_Sensor
//================================================================
byte ADCvinMSB, ADCvinLSB, curSenseMSB, curSenseLSB, AinVMSB, AinVLSB;
unsigned int ADCvin, ADCcur, AinV;
float inputVoltage1,  current10, current1, current0p1, current0p01;
int set_port  = 1;
int incomingByte = 0;
const long interval = 10000;
unsigned long previousMillis =  0;
LEDStatus blinkRed(COMOk, LED_PATTERN_BLINK);
void setup() {
  Serial.begin(9600);
  waitFor(Serial.isConnected, 30000);
  Serial.println("Adafruit_MPL3115A2 test!");
  while(! baro.begin()) {
   Serial.println("Couldnt find sensor");
   delay(1000);
   Particle.function("ON", SwitchOn);
   pinMode(D4, OUTPUT);
   pinMode(D3, OUTPUT);
   pinMode(D2, OUTPUT);
   Serial.println(WiFi.localIP());
   blinkRed.setActive(true);
   delay(3000);
   blinkRed.setActive(false);
 }
}
void loop() {
 char message[120];
 char data1[256];
 int sensorValue;
 int    status;
 int8_t result;
 char message1[120];
 int ADCvoltage;
if (millis() - previousMillis >= (interval )) {
 float pascals = baro.getPressure();
 Serial.print(pascals/3377); Serial.println(" Inches (Hg)");
 float altm = baro.getAltitude();
 Serial.print(altm); Serial.println(" meters");
 float tempC = baro.getTemperature();
 Serial.print(tempC); Serial.println("*C");
 sprintf(message, "Temp %f",tempC);
 Particle.publish("Temperature", message,  PRIVATE);
 //=======================================================================
 Wire.beginTransmission(MXC6255ADDR);//first get Input Voltage - 80V max
 Wire.write(0x1E);
 Wire.endTransmission(false);
 Wire.requestFrom(MXC6255ADDR, 2, true);
 delay(1);
 XOUTMSB = Wire.read();
 XOUTLSB = Wire.read();
 SHC = ((unsigned int)(XOUTMSB) << 4) + ((XOUTLSB >> 4) & 0x7F);//formats into 12bit integer
 XMOT = SHC;
 Wire.beginTransmission(MXC6255ADDR);//get ADC Input 2V max
 Wire.write(0x28);
 Wire.endTransmission(false);
 Wire.requestFrom(LTCADDR3, 2, true);
 delay(1);
 YOUTMSB = Wire.read();
 YOUTLSB = Wire.read();
 SHTH = ((unsigned int)(YOUTMSB) << 4) + ((YOUTLSB >> 4) & 0x7F);//12 bit format
 YMOT = SHTH;
 //=======================================================================
 Wire.beginTransmission(LTCADDR1);//first get Input Voltage - 80V max
 Wire.write(0x1E);
 Wire.endTransmission(false);
 Wire.requestFrom(LTCADDR1, 2, true);
 delay(1);
 ADCvinMSB = Wire.read();
 ADCvinLSB = Wire.read();
 ADCvin = ((unsigned int)(ADCvinMSB) << 4) + ((ADCvinLSB >> 4) & 0x0F);//formats into 12bit integer
 inputVoltage1 = ADCvin * 0.025; //25mV resolution
 Wire.beginTransmission(LTCADDR1);//get ADC Input 2V max
 Wire.write(0x28);
 Wire.endTransmission(false);
 Wire.requestFrom(LTCADDR3, 2, true);
 delay(1);
 AinVMSB = Wire.read();
 AinVLSB = Wire.read();
 AinV = ((unsigned int)(AinVMSB) << 4) + ((AinVLSB >> 4) & 0x0F);//12 bit format
 ADCvoltage = AinV * 0.5E-3; //500uV resolution
 Wire.beginTransmission(LTCADDR1);//get sense current
 Wire.write(0x14);
 Wire.endTransmission(false);
 Wire.requestFrom(LTCADDR1, 2, true);
 delay(1);
 curSenseMSB = Wire.read();
 curSenseLSB = Wire.read();
 ADCcur = ((unsigned int)(curSenseMSB) << 4) + ((curSenseLSB >> 4) & 0x0F);//12 bit format
 current10 = ADCcur * (25E-3) / 10.0; //10mA max, unit is mA
 current1 = ADCcur * (25E-3) / 1.0; //100mA max, unit is mA
 current0p1 = ADCcur * (25E-3) / 0.1; //1A max, unit is mA
 current0p01 = ADCcur * (25E-6) / 0.01;//10A max, unit is A
 sprintf(message, "RC %f:RV %f",inputVoltage1,current0p01);
 Particle.publish("String", message,  PRIVATE);
 if(inputVoltage1 < 5 )  {
 digitalWrite(D2 ,HIGH);
 Particle.publish("CT_Active", "1",PRIVATE);
 sprintf(message, "IP %f",WiFi.localIP());
 Particle.publish("IP_Address", message,  PRIVATE);
 sprintf(message, "XMOT %f:YMOT %f",XMOT,YMOT);
 Particle.publish("String", message,  PRIVATE);
}
//========================================================================
  previousMillis = millis(); 
 }
}
int SwitchOn(String command) {
if(command =="1")  {
digitalWrite(D4 ,HIGH);
Particle.publish("Switch_On", "1",PRIVATE);
}
else if(command =="2")  {
digitalWrite(D4,LOW);
Particle.publish("Switch_Off", "0",PRIVATE);
}
return 1;
} 

Node-RED and the App

Schematics

Fritzing File

Particle Gerber FIle

Code

Particle Code

Credits

Jade7272

Journeyman Electrician , Electronics engineer for Penteon Corporation designing wireless sensor Arrays orb the internet of thingsboard


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