View detail for Atmel AT16225: Atmel Smart Plug Hardware User Guide

View detail for Atmel AT16225: Atmel Smart Plug Hardware User Guide

ATSAMW25

AT16225: Atmel Smart Plug Hardware User Guide

Application Note

Introduction

The Atmel ® Smart Plug Reference Design provides a system solution for a Wi-Fi ® enabled power plug that can turn on/off power from the main plug in three ways: using the QTouch ® button, using the Android

™ app with a Wi-Fi connection, or using a scheduled on/off from the Android app. It is an IoT application using the

ATSAMW25 module (a highly integrated module with ATSAMD21, WINC1500,

ECC508A), and an ATM90E26 device to realize ARM

®

Cortex

®

-M0+ MCU control, Wi-Fi connection, CryptoAuthentication with secure hardware key storage, QTouch sensing, and energy metering functions with an optimized BOM.

This document describes the hardware design of the smart plug reference design.

Features

Turnkey solution with small form factor

Three models following either US, EU, or Chinese standards

AC input 90-265V and 50/60Hz

Max output power: 2200W(10A)

Based on ATSAMW25 module

ATSAMD21 Cortex-M0+ MCUWINC1500 IEEE 802.11 b/g/n 2.4G Wi-Fi

Controller

ECC508A hardware Authentication and Encryption

ATM90E26 power and energy metering function

QTouch button

CE/FCC/UL&CUL Certification

Figure 1. Atmel Smart Plug Kits

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Table of Contents

1 Overview ..................................................................................................................... 3

1.1

System Overview .................................................................................................................................. 3

2 MCU Board ................................................................................................................... 4

2.1

MCU Board Overview ............................................................................................................................ 4

2.2

ATSAMW25 .......................................................................................................................................... 5

2.3

Programming Interface .......................................................................................................................... 7

2.4

Header to Touch Board ......................................................................................................................... 7

2.5

Header to Power Board ......................................................................................................................... 8

2.6

DataFlash (Not Mounted) ...................................................................................................................... 8

3 Touch Board ................................................................................................................ 9

3.1

Touch Board Overview .......................................................................................................................... 9

3.2

Touch Sensors ...................................................................................................................................... 9

3.3

LEDs for Wi-Fi and Power ................................................................................................................... 10

3.3.1

Wi-Fi LED ............................................................................................................................... 10

3.3.2

Power LED ............................................................................................................................. 10

3.3.3

LED Pin Definition on SAM W25 ............................................................................................ 10

4 Power Board .............................................................................................................. 10

4.1

Power Board Overview ........................................................................................................................ 10

4.2

AC-DC .............................................................................................................................................. 11

4.3

DC-DC .............................................................................................................................................. 12

4.4

Power Measurement ........................................................................................................................... 12

4.5

Power Measurement Calibration ......................................................................................................... 14

4.5.1

Calculation of the GL .............................................................................................................. 14

4.5.2

Calculation of the Ugain.......................................................................................................... 14

4.5.3

Calculation of the Igain ........................................................................................................... 14

4.5.4

Calculation of the PL_Constant .............................................................................................. 14

4.6

The Relay ............................................................................................................................................ 14

4.7

Plug and Socket .................................................................................................................................. 15

5 PCB Assembly ........................................................................................................... 17

5.1

PCB Stack Structure ........................................................................................................................... 17

6 Reprogram the Kit ..................................................................................................... 18

6.1

Open the Kit ........................................................................................................................................ 18

6.2

Power Supply ...................................................................................................................................... 18

6.2.1

Onboard AC Power ................................................................................................................ 18

6.2.2

External DC power ................................................................................................................. 19

6.3

Programming Tools ............................................................................................................................. 20

6.4

Programming ....................................................................................................................................... 21

7 Revision History ........................................................................................................ 22

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1 Overview

The smart plug consists of three PCBs: Power board, MCU board, and Touch board. The MCU board is vertically mounted to the Power board and the Touch board is connected to the MCU board by a pin connector.

Touch Board: Touch pad and LEDs.

MCU Board: ATSAMW25, 32KHz crystal, DataFlash footprint (not mounted).

Power Board: Socket and Plug, AC-DC, DC-DC, Power Measurement, Relay.

1.1 System Overview

Figure 1-1. System Block Diagram

Output Socket

Input Plug

E

N

L

Fuse

Relay

ATM90E26

AC/DC

DC/DC

12V

3.3V

ATSAMW25

DataFlash

LEDs

Button

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3

Figure 1-2. Overview of the Smart Plug Kit PCBs

2 MCU Board

2.1 MCU Board Overview

Figure 2-1. MCU Board Overview

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2.2 ATSAMW25

The Atmel SmartConnect SAM W25 is a low-power Wi-Fi certified module. This highly integrated module offers the ideal solution for designers seeking Wi-Fi connectivity. The SAM W25 integrates an 802.11 IP stack on top of the Wi-Fi core and fully covers RF certifications.

The SAM W25 module is based on Atmel’s industry-leading WINC1500 Wi-Fi core combined with Atmel’s latest ARM Cortex-M0+ based microcontroller (SAM D21) technology. This turnkey system provides an integrated software solution with application and security protocols such as TLS and integrated network services (TCP/IP stack).

ATSAMW25 is the control center of the smart plug kit. It covers all the intelligent functions including the Wi-Fi connection, touch button, relay control, temperature sensing and protection, LED indicators, and timing.

Figure 2-2. Schematic for ATSAMW25

Table 2-1.

3

4

5

6

0

1

2

Pin #

ATSAMW25 Pinout

SAM W25 function

GND

GND

UART TXD

UART RXD

Wi-Fi Chip En

Wi-Fi GPIO_1

NC

System function

GND

GND

Wi-Fi TXD

Wi-Fi RXD

NC

RTC

NC

Description

Heat sink pads in the bottom

For ATWINC1500 firmware upgrade

For ATWINC1500 firmware upgrade

Not Used

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5

25

26

27

28

21

22

23

24

14

15

16

17

18

19

20

Pin #

10

11

12

13

7

8

9

29

30

31

32

33

34

35

36

37

38

39

40

41

42

VCC

Relay

NC

MCU Reset

MCU SWDCLK

MCU SWDIO

LED PR

LED PG

XIN32

XOUT32

NC

GND

NC

NC

Touch Guard 2

Touch Key

Touch Guard 1

Crypto SDA

Crypto SCL

PM TXD

PM RXD

GND

System function

VCC

Flash SPI MOSI

Flash SPI CLK

GND

Flash SPI SS

Flash SPI MISO

RTC

LED WR

LED WG

LED WY

GND

Test TXD

Test RXD

GND

PA00

PA01

PA02

GND

PA03

PA04

PA05

PA06

PA07

VCC

PB22

PB23

RESET_N

PA30

PA31

PB02

PB03

PA08

PA09

PA10

PA11

GND

SAM W25 function

VBAT

PA16

PA17

GND

PA18

PA19

PA20

PA21

PA22

PA23

GND

PA24

PA25

GND

Power supply

DataFlash Interface

DataFlash Interface

DataFlash Interface

DataFlash Interface

Not Used

Red LED for Wi-Fi

Green LED for Wi-Fi

Yellow LED for Wi-Fi

Fixture test interface

Fixture test interface

Description

Power supply

Relay ON/OFF

SAM D21 reset pin

SWD SWDCLK pin

SWD SWDCLK pin

Red LED for Power

Green LED for Power

32kHz External Crystal

32kHz External Crystal

Touch Guard sensor

Touch key sensor

Touch Guard sensor

Reserved interface for internal crypto

Reserved interface for internal crypto

Interface for Power Measurement device

Interface for Power Measurement device

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46

47

48

49

50

51

Pin #

43

44

45

SAM W25 function

PB10

PB11

Wi-Fi GPIO_15

Wi-Fi GPIO_16

Wi-Fi GPIO_18

Wi-Fi I

2

C SCL

Wi-Fi I

2

C SDA

Wi-Fi Reset_n

GND

System function

NC

NC

NC

NC

NC

I

2

C SCL

I

2

C SDA

NC

GND

Description

Reserved interface for internal WINC1500

Reserved interface for internal WINC1500

2.3 Programming Interface

Since SAM W25 uses the SAM D21 as the controller, the user can use the SWD interface to Program and debug the device.

7

8

5

6

3

4

1

2

9

10

Table 2-2. Pin Definition of SWD Interface

SWD header pin

NC

NC

NC

NC

Pin definition

SWDCLK

GND

NC

VCC

SWDIO

RESET

26

24

25

ATSAMW25 pin

2.4 Header to Touch Board

The Touch Board is connected to MCU Board through a 10-pin header, it contains the tracks for the touch sensors and LEDs. The header also makes it possible to power the MCU externally.

Table 2-3. Header to Touch Board

4

5

2

3

Touch header pin Pin definition

1 GND (External power input if onboard power is not available)

VCC (External power input if onboard power is not available)

Touch Guard Sensor 1

Power LED Green

Touch Key Sensor

ATSAMW25 pin

37

28

36

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7

6

7

8

9

10

Power LED Red

Touch Guard Sensor 2

Wi-Fi LED Red

Wi-Fi LED Yellow

Wi-Fi LED Green

27

35

14

16

15

2.5 Header to Power Board

The MCU Board is mounted directly on the Power Board by a 12-pin header.

Table 2-4. Header to Power Board

8

9

10

11

12

Power header pin Pin definition

1

2

3

4

5

6

7

VCC

GND

Wi-Fi TXD (Reserved for Wi-Fi firmware upgrade on fixture)

Wi-Fi RXD (Reserved for Wi-Fi firmware upgrade on fixture)

Test RXD (Reserved for fixture)

Test TXD (Reserved for fixture)

Power Measurement RXD (Interface for MCU and power measurement device)

Power Measurement TXD (Interface for MCU and power measurement device)

MCU Reset (Reserved for fixture)

Relay Control

MCU SWDIO (Reserved for fixture)

MCU SWDCLK (Reserved for fixture)

40

24

22

26

25

ATSAMW25 pin

2

3

19

18

41

2.6 DataFlash (Not Mounted)

Space for a DataFlash device is reserved (but not mounted) on the board. This can be used to store more data locally if needed.

Figure 2-3. Schematic of DataFlash Part

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Table 2-5. BoM for the DataFlash Part if Mounted

Designator Value

C107 100nF

R111

U102

10k

Vendor

Murata

Yageo

Part Number

RC0402FR-0710KL

1M Byte Winbond W25Q80DVUXIE

Description

GRM155R71H104KE14 Ceramic capacitor, SMD 0402, X7R, 50V, 10%

Thick film resistor, SMD 0402, 1/16W, 1%

Serial Flash, 8-lead USON 2*3mm

Table below shows the pin definition of SAM W25 for DataFlash.

Table 2-6. Pin Definition of DataFlash and SAM W25

Pin name on DataFlash

FLASH_SPI_SS

FLASH_SPI_MISO

FLASH_SPI_MOSI

FLASH_SPI_CLK

Pin name on ATSAMW25

PA18

PA19

PA16

PA17

ATSAMW25 pin

11

12

8

9

3 Touch Board

3.1 Touch Board Overview

The Touch board contains the Touch sensors and the LEDs for Wi-Fi and Power.

Figure 3-1. Touch Board Overview

3.2 Touch Sensors

Touch sensors are designed based on the self-capacitor using the QTouch technology.

Except the Touch Key which handles the ON/OFF/Reset function, another two touch sensors act as the touch guard. The touch guard sensors will prevent some scenarios from spurious triggering.

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Table 3-1. Pin definition of Touch Sensor and SAM W25

Pad name on touch board

Touch Key

Touch Guard 1

Touch Guard 2

Pin name on ATSAMW25

PA06

PA07

PA05

ATSAMW25 pin

36

37

35

3.3 LEDs for Wi-Fi and Power

All LEDs including the Wi-Fi and Power LEDs are driven by the ATSAMW25 GPIOs directly, Logic 1 enables the LEDs.

Note: For better output current performance, the I/O pins needs be set to high drive strength: DRVSTR = 1.

Different color LEDs are used to indicate different status of the plug.

3.3.1 Wi-Fi LED

Yellow blink: Plug in SoftAP mode, not connected (waiting for Phone to connect)

Yellow: Plug in SoftAP mode, connected to a phone (during this period, Phone App sends

SSID/password to plug)

Green blink: Plug in STA mode, connecting to home Access Point (AP)

Green: Plug in STA mode, connected to home AP, connection is good

Red: In error state

3.3.2 Power LED

Green when ON

Red when OFF

3.3.3 LED Pin Definition on SAM W25

Table 3-2. Pin Definition of LEDs and SAM W25

LED name on touch board

Wi-Fi Yellow

Wi-Fi Green

Wi-Fi Red

Power Green

Power Red

Active logic

1

1

1

1

1

Pin name on ATSAMW25

PA23

PA22

PA21

PB03

PB02

ATSAMW25 pin

16

15

14

28

27

4 Power Board

4.1 Power Board Overview

The Power Board contains an AC-DC converter, a DC-DC converter, the power measurement circuit, relay, and the plug and socket.

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Figure 4-1. Power Board Overview

4.2 AC-DC

The AC-DC part transforms the 100V~240V AC input voltage into a 12V/120mA (typical) DC output.

The 12V DC supplies the relay and the DC-DC converter.

Figure 4-2. Schematic of AC-DC Part

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The transformer T301 is a custom component with the parameters below.

Figure 4-3. Transformer Design

Table 4-1.

Wire

N1

N2

N4

Wire Definition of Transformer

Type Start to end

2UEW

Φ 0.15x1P

3-1

2UEW

Φ 0.15x1P

4-5

TRWB

Φ 0.35x1P

7-6

Turns

70Ts

23Ts

24Ts

Tape

1Ts

2Ts

3Ts

4.3 DC-DC

The DC-DC converter converts the DC voltage level from 12V to 3.3V for the SAM W25 module. The MP1470 is a typical buck DC-DC converter, with the output range set to 3.16V to 3.36V.

Figure 4-4. Schematic of DC-DC Part

4.4 Power Measurement

The ATM90E26 works as the power measurement device to get the actual output power.

There are two signals sampled by ATM90E26, one is the voltage which comes from the L line, another is the differential voltage based on the current in sense resistor R311.

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Figure 4-5. Sampled Signal of Power Measurement

The power measurement device will calculate and output the sampled voltage, current, and power to SAM

W25 through the UART port. Considering the different power supply system, 2 optocouplers are used to isolate the SAM W25 and M90E26.

Figure 4-6. Schematic of Power Measurement

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Table 4-2. Pin Definition of Power Measurement and SAM W25

Pin Name for Uart

PWR_PM_TXD

PWR_PM_RXD

Pin name on ATSAMW25

PA10

PA11

ATSAMW25 pin

40

41

4.5 Power Measurement Calibration

Before using the ATM90E26 in user application, some parameters need be calculated, such as GL, Ugain,

Igain, and PL_Contant.

MC: Pulse constant of the energy meter, unit is imp/kWh or imp/kvarh; Assume MC = 10000

Un: Reference voltage, unit is V; Assume Un = 220V

Ib: Basic current, unit is A; Assume Ib = 1A

GL: L line current circuit gain

VL: Sampling voltage of the L line circuit at Ib, unit is mV

VU: Sampling voltage of the voltage circuit at Un, unit is mV

4.5.1 Calculation of the GL

With the s hunt resistor = 1mΩ, Max. current I = 10A.

When, GL = 24

VLsample = 1mΩ * 10A * 24 = 240mV

4.5.2 Calculation of the Ugain

The default Ugain is based on the condition below:

Ugain = 26400 (6720H), Voltage divider coefficient = 880,

Assume Un = 220V, VL = 220 / (880 + 1)

Considering the voltage divider resistors used in smart plug, Voltage divider coefficient = (430 + 430) = 860

So, Ugain = 26400 * (220 / (860 + 1)) / (220 / (880 + 1)) = 27013 (6985H)

4.5.3 Calculation of the Igain

From AN 46102,

R = 200µ

Ω, I = 5A, Lgain = 24 <=> Igain = 31251 (7A13H) by default

In SmartPlug solution,

R = 1mΩ, I = 2A, Lgain = 24 <=> Igain = 31251 * (1000 * 2A * 24) / (200 * 10A * 24) = 62502 (F426H)

4.5.4 Calculation of the PL_Constant

PL_Constant = int (838860800 * GL * VL * Vu / MC * Un * Ib)

= 838860800 * 24 * 1 * (220 / (860 + 1)) / 10000 * 220 * 1 = 2338287(23ADEFH)

4.6 The Relay

The relay is cascaded in the AC input and output. So, the Relay can direct control the ON/OFF of the AC output.

The rated current of the relay is 10A, this means the output power is limited to Max 2200W (@ 220V AC).

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Note: Some electronic devices may generate a surge current far larger than the rated current; damaging the relay by welding the contact shut. When this happens the output will be always ON and the kit will be out of control. If this happens you must cut the input voltage manually immediately. From testing it has been observed that a surge current of less than 50A can make the contactor adhere.

Figure 4-7. Schematic of Relay Control

Table 4-3. Pin Definition of Relay

Relay Contorl Name

PWR_RELAY

Active Logic

1

Pin name on ATSAMW25

PB22

ATSAMW25 pin

22

4.7 Plug and Socket

There are three types of the Plug and Socket: US, EU, and CN. They share the same PCB.

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Figure 4-8. US, EU, and CN standard of Plug and Socket

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5 PCB Assembly

5.1 PCB Stack Structure

The touch board is assembled in the front case of the kit, and the power board together with the MCU board is fixed in the rear case.

When the front and rear case are closed, make sure the touch board connector is aligned with the MCU board pin header.

Figure 5-1. PCB Stack Structure Overview

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6 Reprogram the Kit

6.1 Open the Kit

If the user needs to reprogram the kit with custom code, the kit needs be opened first.

Figure 6-1. Remove the Silica Gel and Screws

Figure 6-2. Open the Kit

6.2 Power Supply

There are two methods to power the Kit while reprogramming: Onboard AC power and external DC power.

6.2.1 Onboard AC Power

At first, connect the programming tools and Kit with the 10-pin SWD connector.

Then, plug the Kit into the AC socket and the kit will be powered by the onboard power supply.

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After programming, the user needs to remove the kit from the AC socket first and then disconnect the programmer/debugger from the SWD header.

Note: The user needs be very carefully during operation and avoid touching any of the components since they are not isolated and can easily lead to an electrical shock.

Figure 6-3. Kit Powered by the Onboard AC Input

6.2.2 External DC power

As described in the MCU board chapter, the kit can also be powered by an external 3.3VDC supply.

Before connecting the 3.3VC, the user needs to make sure the kit is not connected to the AC input.

Connect the 3.3V power supply on pin1 and pin2 of Touch header and make sure the polarity is correct.

Note: It is recommended to use the external DC to power the board while reprogramming since it is far safer than the AC power.

Figure 6-4. Kit Powered by the External DC Input

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Figure 6-5. External Power Input

Note: The Power Pins in on the touch header is connected in parallel with the power supply (3.3V) on the power board. Never connect an external power supply while the onboard power is available.

6.3 Programming Tools

The smart plug uses the SWD as the programming and debug\interface, it supports all tools which supports the

SWD interface. Some tools support a direct connection with the 1.27mm pitch, 10-pin socket. Figures below show the connection example of programming tools.

Figure 6-6. Atmel-ICE Connection

Figure 6-7. JTAGICE3 Connection

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For other programming tools which do not have the 1.27mm pitch, 10-pin socket, the user needs to connect the

SWD lines manually.

6.4 Programming

Connect the kit to a PC with Atmel Studio installed.

Click Tools

→ Device Programming to open the programming dialog. Then, program the kit as show below.

Note: The Device selector must be set to ATSAMD21G18A.

Figure 6-8. Reprogramming Flow by Atmel Studio

Programming steps:

1. Select the programming tool.

2. Choose device (must be ATSAMD21G18A) and select the interface (must be SWD).

3. Apply the setting.

4.

To ensure the correct connection, press ‘Read’ to get the device signature and target voltage.

5. Browse to the folder where the code located, and select it.

6. Program the device. The status can be displayed in the information frame below.

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7 Revision History

Doc Rev.

42689A

Date Comments

03/2016

Initial document release.

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Atmel Corporation 1600 Technology Drive, San Jose, CA 95110 USA T: (+1)(408) 441.0311 F: (+1)(408) 436.4200

www.atmel.com

© 2016 Atmel Corporation. / Rev.: Atmel-42689A-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_03/2016.

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®

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®

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®

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®

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®

logo, and others are the registered trademarks or trademarks of ARM Ltd. Other terms and product names may be trademarks of others.

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