HASP v0.35

Documentation/03_Electronics_Assembly.md

@@ -25,11 +25,14 @@ If you are still testing the HASP before complete assembly, continue to the [Hom
 
 ### BOM
 
-* [Mean Well IRM-03-5 AC to 5VDC Power supply](https://amzn.to/2MNF7Gx)
 * [Nextion 2.4" LCD Touchscreen display](https://amzn.to/2DIpahB)
 * [WeMos D1 Mini ESP8266 WiFi microcontroller](https://amzn.to/2Gc92Xs)
+* [Mean Well IRM-03-5 AC to 5VDC Power supply](https://amzn.to/2MNF7Gx)
+* [2N3904 NPN Transistor](https://amzn.to/2TBCBFH)
+* [1k Ohm Resistor](https://amzn.to/2t7UFvF)
 * [4pin 2.54mm JST-XH PCB header](https://amzn.to/2MFV15p) *(note that these are the knockoff 2.54mm versions of the 2.50 XH series from JST.  What they lack for in authenticity they make up for in ubiquity and dirt cheap pricing)*
 * [PCB](../PCB)
+* [6" each of white and black 300V 18AWG stranded power cables](https://amzn.to/2SjXO9G)
 
 > ## WARNING: do not connect AC power and USB at the same time, as there is a chance you could fry your USB ports.  Always disconnect AC before connecting USB or serial to the ESP8266 and Nextion panel (or doing anything else to the device for that matter)
 
@@ -41,22 +44,40 @@ This is what your PCB should look like from the top before you've placed any of
 
 ### PCB Assembled
 
-Now place the components, taking care to orient the WeMos D1 Mini and JST-XH header as shown in the image below.
+Now place the components, taking care to orient the WeMos D1 Mini, Mean Well Power Supply, and JST-XH header as shown in the image below.
 
 ![PCB Assembled](https://github.com/aderusha/HASwitchPlate/blob/master/Documentation/Images/HASP_PCB_Front_Assembled.png?raw=true)
 
+### Transistor soldering
+
+The transistor and resistor act as a switch on the GND connection for the Nextion LCD.  This allows the HASP to reboot the LCD in the event of a failed LCD firmware update.  The pads on the transistor are a little close together, so take care when soldering here and use as little solder as possible.  **The LCD will not power on until the ESP8266 code is flashed and running**, sending power to the "switch" to turn on the LCD.  If you've flashed the ESP8266 code to the WeMos, you;ve connected the LCD, you can see the program running in the serial console, and the display isn't powering on... you almost certainly have a problem with the soldering job on the transistor.  If you just can't make it work, that's OK!  Simply cut the resistor out of the circuit (important!), and then you can bridge the 3 pads for the transistor together with a glob of solder.  This will disable the power switch for the LCD, which might mean pulling the device out of the wall if an LCD firmware update fails but will not otherwise impact daily operation.
+
 ### High voltage AC cabling
 
-The AC power cables should be at least 18AWG 300V stranded cable with a white jacket soldered to the `AC/N` pad on the PCB and a similar wire with a black jacket soldered to `AN/L`.  These are fed through a [rubber push-in grommet](https://amzn.to/2G9y49I) mounted into the rear enclosure.  I've had good luck stripping an existing 3 conductor power cord and using the black/white wires inside.
+The AC power cables should be at least [18AWG 300V stranded cable](https://amzn.to/2SjXO9G) with a white jacket soldered to the `AC/N` pad on the PCB and a similar wire with a black jacket soldered to `AN/L`.  These are fed through a [rubber push-in grommet](https://amzn.to/2G9y49I) mounted into the rear enclosure.  I've had good luck stripping an existing 3 conductor power cord and using the black/white wires inside.
 
 ### Nextion LCD Modification
 
-The Nextion LCD can be modified to give a little extra room around the screw lugs which may help with mounting in some work boxes.  If you have the means to do so, you can use a hot air gun to remove the 4-pin JST XHP connector from the PCB and then use the `lcdmod` rear enclosure model for some extra room in your box.  If you don't have hot air, some careful use of side cutters or a rotary tool may also do the job.  Be careful not to lift any traces as it's easy to do when applying mechanical force the connector.
+The Nextion LCD can be modified to give a little extra room around the screw lugs which may help with mounting in some work boxes.  If you have the means to do so, you can use a hot air gun to remove the 4-pin JST XHP connector from the PCB and then use the [`lcdmod` rear enclosure model](../3D_Printable_Models/HASwitchPlate_rear_lcdmod.stl) for some extra room in your box.  If you don't have hot air, some careful use of side cutters or a rotary tool may also do the job.  Be careful not to lift any traces as it's easy to do when applying mechanical force the connector.
 
-In any event, you're going to need to solder the cable harness included with the Nextion display directly to the pins as shown in the image below.  This demonstrates a panel with the connector removed, but you also solder the cable harness directly to the legs of the existing connector with a simple soldering iron with little trouble.  After soldering the cables in place and confirming everything works, I like to put a bit of epoxy over the wires to provide some measure of strain relief.
+In any event, you're going to need to solder the cable harness included with the Nextion display directly to the pins as shown in the image below.  This demonstrates a panel with the connector removed, but you also solder the cable harness directly to the legs of the existing connector with a simple soldering iron with little trouble.  After soldering the cables in place and confirming everything works, I like to put a bit of hot glue over the wires to provide some measure of strain relief.
 
 ![Nextion_LCD_modification](https://github.com/aderusha/HASwitchPlate/blob/master/Documentation/Images/Nextion_LCD_modification.jpg?raw=true)
 
+### DC Power Option
+
+The [Mean Well IRM-03-5 AC to 5VDC Power supply](https://amzn.to/2MNF7Gx) can be substituted with any of the following [Mean Well SLC03-series DC-DC power supplies](http://www.meanwellusa.com/productPdf.aspx?i=786) if you'd prefer a low-voltage DC option.  This should be suitable for use over existing Cat5 cables, speaker cables, alarm cabling, etc already in your wall.  Check to confirm that the existing cable wire gauge will be safe for the load you will be putting on the system, and try not to put voltage down a wire where other expensive and flammable things might be connected which aren't expecting it.
+
+| Model     | Input Voltage Range |
+|-----------|---------------------|
+| SLC03A-05 | 9-18VDC             |
+| SLC03B-05 | 18-36VDC            |
+| SLC03C-05 | 36-75VDC            |
+
+These DC-DC supplies are smaller than the AC-DC supply and have a different footprint on the board.  Position the supply as shown below.
+
+![PCB_DC_Assembled](https://github.com/aderusha/HASwitchPlate/blob/master/Documentation/Images/PCB_DC_Assembled.jpg?raw=true)
+
 ### Schematic for protoboard assembly
 
 This project was initially built on a [4x6 protoboard](https://amzn.to/2MEnxEy) and the enclosure should still accommodate this approach if you have boards on hand.  Note that this approach is probably dangerous as 120VAC and protoboards are a bad mix.

Documentation/05_Home_Assistant.md

@@ -79,6 +79,9 @@ Finally, you'll need to restart Home Assistant to apply your changes then contin
 
 ## First time setup
 
+> ### NOTICE
+> If you're running Lovelace (now the new default Home Assistant web UI), there [currently is no way for a project like HASP to add panels](https://community.home-assistant.io/t/lovelace-in-ha-package-files/92619).  You'll need to switch to the "states" UI before proceeding.  If your installation is accessed at `http://hassio.local:8123`, navigate to `http://hassio.local:8123/states` to access the states UI.
+
 Upon startup the default HMI display file contains empty buttons with no text.  Launch the Home Assistant web UI and look for a new tab with your chosen device name.  Select that tab and look for the automation titled `hasp_<your_device_name>_00_FirstTimeSetup`.  Select that automation and click "TRIGGER" to apply the basic configuration to your new device.
 
 ![Home_Assistant_FirstTimeSetup](https://github.com/aderusha/HASwitchPlate/blob/master/Documentation/Images/Home_Assistant_FirstTimeSetup.png?raw=true)

PCB/HASwitchPlate-cache.lib

@@ -0,0 +1,200 @@
+EESchema-LIBRARY Version 2.4
+#encoding utf-8
+#
+# Device_R_US
+#
+DEF Device_R_US R 0 0 N Y 1 F N
+F0 "R" 100 0 50 V V C CNN
+F1 "Device_R_US" -100 0 50 V V C CNN
+F2 "" 40 -10 50 V I C CNN
+F3 "" 0 0 50 H I C CNN
+$FPLIST
+ R_*
+$ENDFPLIST
+DRAW
+P 2 0 1 0 0 -90 0 -100 N
+P 2 0 1 0 0 90 0 100 N
+P 5 0 1 0 0 -30 40 -45 0 -60 -40 -75 0 -90 N
+P 5 0 1 0 0 30 40 15 0 0 -40 -15 0 -30 N
+P 5 0 1 0 0 90 40 75 0 60 -40 45 0 30 N
+X ~ 1 0 150 50 D 50 50 1 1 P
+X ~ 2 0 -150 50 U 50 50 1 1 P
+ENDDRAW
+ENDDEF
+#
+# HASwitchPlate-library_Conn_01x08-conn-HASwitchPlate
+#
+DEF HASwitchPlate-library_Conn_01x08-conn-HASwitchPlate J 0 40 Y N 1 F N
+F0 "J" 0 400 50 H V C CNN
+F1 "HASwitchPlate-library_Conn_01x08-conn-HASwitchPlate" 0 -500 50 H V C CNN
+F2 "" 0 0 50 H I C CNN
+F3 "" 0 0 50 H I C CNN
+$FPLIST
+ Connector*:*_??x*mm*
+ Connector*:*1x??x*mm*
+ Pin?Header?Straight?1X*
+ Pin?Header?Angled?1X*
+ Socket?Strip?Straight?1X*
+ Socket?Strip?Angled?1X*
+$ENDFPLIST
+DRAW
+S -50 -395 0 -405 1 1 6 N
+S -50 -295 0 -305 1 1 6 N
+S -50 -195 0 -205 1 1 6 N
+S -50 -95 0 -105 1 1 6 N
+S -50 5 0 -5 1 1 6 N
+S -50 105 0 95 1 1 6 N
+S -50 205 0 195 1 1 6 N
+S -50 305 0 295 1 1 6 N
+S -50 350 50 -450 1 1 10 f
+X Pin_1 1 -200 300 150 R 50 50 1 1 P
+X Pin_2 2 -200 200 150 R 50 50 1 1 P
+X Pin_3 3 -200 100 150 R 50 50 1 1 P
+X Pin_4 4 -200 0 150 R 50 50 1 1 P
+X Pin_5 5 -200 -100 150 R 50 50 1 1 P
+X Pin_6 6 -200 -200 150 R 50 50 1 1 P
+X Pin_7 7 -200 -300 150 R 50 50 1 1 P
+X Pin_8 8 -200 -400 150 R 50 50 1 1 P
+ENDDRAW
+ENDDEF
+#
+# HASwitchPlate-library_IRM-03-5-HASwitchPlate-library
+#
+DEF HASwitchPlate-library_IRM-03-5-HASwitchPlate-library U 0 40 Y Y 1 F N
+F0 "U" 400 250 50 H V C CNN
+F1 "HASwitchPlate-library_IRM-03-5-HASwitchPlate-library" 400 -150 50 H V C CNN
+F2 "HASwitchPlate:ACDC-Converter_MeanWell-IRM-03-x" 400 -250 50 H I C CNN
+F3 "" 400 -350 50 H I C CNN
+$FPLIST
+ ACDC?Converter?MeanWell?IRM?03?x*
+$ENDFPLIST
+DRAW
+S 100 200 700 -100 0 1 0 f
+X AC/L 1 0 100 100 R 50 50 1 1 W
+X AC/N 2 0 0 100 R 50 50 1 1 W
+X +Vout 3 800 100 100 L 50 50 1 1 w
+X -Vout 4 800 0 100 L 50 50 1 1 w
+ENDDRAW
+ENDDEF
+#
+# HASwitchPlate-library_SLC03-series
+#
+DEF HASwitchPlate-library_SLC03-series U 0 40 Y Y 1 F N
+F0 "U" 400 250 50 H V C CNN
+F1 "HASwitchPlate-library_SLC03-series" 400 -150 50 H V C CNN
+F2 "" 400 -250 50 H I C CNN
+F3 "" 400 -350 50 H I C CNN
+DRAW
+S 100 200 700 -100 0 1 0 f
+X -Vin 1 0 0 100 R 50 50 1 1 W
+X -Vout 10 800 0 100 L 50 50 1 1 w
+X +Vin 16 0 100 100 R 50 50 1 1 W
+X +Vout 9 800 100 100 L 50 50 1 1 w
+ENDDRAW
+ENDDEF
+#
+# HASwitchPlate-library_Screw_Terminal_01x02-HASwitchPlate-library
+#
+DEF HASwitchPlate-library_Screw_Terminal_01x02-HASwitchPlate-library J 0 40 Y N 1 F N
+F0 "J" 0 100 50 H V C CNN
+F1 "HASwitchPlate-library_Screw_Terminal_01x02-HASwitchPlate-library" 0 -200 50 H V C CNN
+F2 "" 0 0 50 H I C CNN
+F3 "" 0 0 50 H I C CNN
+$FPLIST
+ Connector*Terminal*Block*:*
+ TerminalBlock*
+$ENDFPLIST
+DRAW
+C 0 -100 25 1 1 6 N
+C 0 0 25 1 1 6 N
+S -50 50 50 -150 1 1 10 f
+P 2 1 1 6 -21 -87 13 -120 N
+P 2 1 1 6 -21 13 13 -20 N
+P 2 1 1 6 -14 -80 20 -113 N
+P 2 1 1 6 -14 20 20 -13 N
+X Pin_1 1 -200 0 150 R 50 50 1 1 P
+X Pin_2 2 -200 -100 150 R 50 50 1 1 P
+ENDDRAW
+ENDDEF
+#
+# HASwitchPlate-library_WeMos_mini-HASwitchPlate
+#
+DEF HASwitchPlate-library_WeMos_mini-HASwitchPlate U 0 40 Y Y 1 F N
+F0 "U" 0 500 60 H V C CNN
+F1 "HASwitchPlate-library_WeMos_mini-HASwitchPlate" 0 -500 60 H V C CNN
+F2 "" 550 -700 60 H V C CNN
+F3 "" 550 -700 60 H V C CNN
+DRAW
+S -300 450 300 -550 0 1 0 N
+X 5V 1 -500 350 200 R 50 50 1 1 W
+X A0 10 500 -250 200 L 50 50 1 1 B
+X D0 11 500 -150 200 L 50 50 1 1 B
+X D5 12 500 -50 200 L 50 50 1 1 B
+X D6 13 500 50 200 L 50 50 1 1 B
+X D7 14 500 150 200 L 50 50 1 1 B
+X D8 15 500 250 200 L 50 50 1 1 B
+X 3.3V 16 500 350 200 L 50 50 1 1 w
+X GND 2 -500 250 200 R 50 50 1 1 W
+X D4 3 -500 150 200 R 50 50 1 1 B
+X D3 4 -500 50 200 R 50 50 1 1 B
+X D2 5 -500 -50 200 R 50 50 1 1 B
+X D1 6 -500 -150 200 R 50 50 1 1 B
+X Rx 7 -500 -250 200 R 50 50 1 1 B
+X Tx 8 -500 -350 200 R 50 50 1 1 B
+X Rst 9 500 -350 200 L 50 50 1 1 B
+ENDDRAW
+ENDDEF
+#
+# HASwitchPlate-library_XH2.54-4P-HASwitchPlate-library
+#
+DEF HASwitchPlate-library_XH2.54-4P-HASwitchPlate-library J 0 40 Y Y 1 F N
+F0 "J" 0 200 50 H V C CNN
+F1 "HASwitchPlate-library_XH2.54-4P-HASwitchPlate-library" 0 -300 50 H V C CNN
+F2 "" 0 0 50 H I C CNN
+F3 "" 0 0 50 H I C CNN
+$FPLIST
+ Connector*:*_??x*mm*
+ Connector*:*1x??x*mm*
+ Pin?Header?Straight?1X*
+ Pin?Header?Angled?1X*
+$ENDFPLIST
+DRAW
+S 34 -195 0 -205 1 1 6 F
+S 34 -95 0 -105 1 1 6 F
+S 34 5 0 -5 1 1 6 F
+S 34 105 0 95 1 1 6 F
+P 2 1 1 6 50 -200 34 -200 N
+P 2 1 1 6 50 -100 34 -100 N
+P 2 1 1 6 50 0 34 0 N
+P 2 1 1 6 50 100 34 100 N
+X GND 1 200 100 150 L 50 50 1 1 I
+X RX 2 200 0 150 L 50 50 1 1 I
+X TX 3 200 -100 150 L 50 50 1 1 O
+X +5V 4 200 -200 150 L 50 50 1 1 P
+ENDDRAW
+ENDDEF
+#
+# Transistor_BJT_S8050
+#
+DEF Transistor_BJT_S8050 Q 0 0 Y N 1 F N
+F0 "Q" 200 75 50 H V L CNN
+F1 "Transistor_BJT_S8050" 200 0 50 H V L CNN
+F2 "Package_TO_SOT_THT:TO-92_Inline" 200 -75 50 H I L CIN
+F3 "" 0 0 50 H I L CNN
+$FPLIST
+ TO?92*
+$ENDFPLIST
+DRAW
+C 50 0 111 0 1 10 N
+P 2 0 1 0 0 0 25 0 N
+P 2 0 1 0 25 25 100 100 N
+P 3 0 1 0 25 -25 100 -100 100 -100 N
+P 3 0 1 20 25 75 25 -75 25 -75 N
+P 5 0 1 0 50 -70 70 -50 90 -90 50 -70 50 -70 F
+X E 1 100 -200 100 U 50 50 1 1 P
+X B 2 -200 0 200 R 50 50 1 1 I
+X C 3 100 200 100 D 50 50 1 1 P
+ENDDRAW
+ENDDEF
+#
+#End Library

PCB/HASwitchPlate-library.dcm

@@ -0,0 +1,3 @@
+EESchema-DOCLIB  Version 2.0
+#
+#End Doc Library

PCB/HASwitchPlate-library.lib

@@ -56,6 +56,22 @@ X -Vout 4 800 0 100 L 50 50 1 1 w
 ENDDRAW
 ENDDEF
 #
+# SLC03-series
+#
+DEF SLC03-series U 0 40 Y Y 1 F N
+F0 "U" 400 250 50 H V C CNN
+F1 "SLC03-series" 400 -150 50 H V C CNN
+F2 "" 400 -250 50 H I C CNN
+F3 "" 400 -350 50 H I C CNN
+DRAW
+S 100 200 700 -100 0 1 0 f
+X -Vin 1 0 0 100 R 50 50 1 1 W
+X -Vout 10 800 0 100 L 50 50 1 1 w
+X +Vin 16 0 100 100 R 50 50 1 1 W
+X +Vout 9 800 100 100 L 50 50 1 1 w
+ENDDRAW
+ENDDEF
+#
 # Screw_Terminal_01x02-HASwitchPlate-library
 #
 DEF Screw_Terminal_01x02-HASwitchPlate-library J 0 40 Y N 1 F N