Atmel AT16225 Hardware User's Manual

Atmel-42689B-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_07/2016

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

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 The Fuse ............................................................................................................................................. 12

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

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

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

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

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

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

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

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

4.8 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

AT16225: Atmel Smart Plug Hardware User Guide [APPLICATION NOTE]

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ATSAMW25

Output Socket

AC/DC

3.3V

DC/DC

LEDs

12V

Button

Relay

Fuse

Input Plug

DataFlash

ATM90E26

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

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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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Pin #

SAM W25 function

System function

Description

GND

Heat sink pads in the bottom

GND

2 UART TXD

Wi-Fi TXD

For ATWINC1500 firmware upgrade

UART RXD

Wi-Fi RXD

For ATWINC1500 firmware upgrade

Wi-Fi Chip En

Wi-Fi GPIO_1

RTC

Not Used

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. ATSAMW25 Pinout

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Pin #

SAM W25 function

System function

Description

VBAT

VCC

Power supply

PA16

Flash SPI MOSI

DataFlash Interface

PA17

Flash SPI CLK

DataFlash Interface

GND

PA18

Flash SPI SS

DataFlash Interface

PA19

Flash SPI MISO

DataFlash Interface

PA20

RTC

Not Used

PA21

LED WR

Red LED for Wi-Fi

PA22

LED WG

Green LED for Wi-Fi

PA23

LED WY

Yellow LED for Wi-Fi

GND

PA24

Test TXD

Fixture test interface

PA25

Test RXD

Fixture test interface

GND

VCC

Power supply

PB22

Relay

Relay ON/OFF

PB23

NC 24

RESET_N

MCU Reset

SAM D21 reset pin

PA30

MCU SWDCLK

SWD SWDCLK pin

PA31

MCU SWDIO

SWD SWDCLK pin

PB02

LED PR

Red LED for Power

PB03

LED PG

Green LED for Power

PA00

XIN32

32kHz External Crystal

PA01

XOUT32

32kHz External Crystal

PA02

GND

PA03

NC 34

PA04

NC 35

PA05

Touch Guard 2

Touch Guard sensor

PA06

Touch Key

Touch key sensor

PA07

Touch Guard 1

Touch Guard sensor

PA08

Crypto SDA

Reserved interface for internal crypto

PA09

Crypto SCL

Reserved interface for internal crypto

PA10

PM TXD

Interface for Power Measurement device

PA11

PM RXD

Interface for Power Measurement device

GND

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Pin #

SAM W25 function

System function

Description

PB10

NC 44

PB11

NC 45

Wi-Fi GPIO_15

NC 46

Wi-Fi GPIO_16

NC 47

Wi-Fi GPIO_18

NC 48

Wi-Fi I2C SCL

I2C SCL

Reserved interface for internal WINC1500

Wi-Fi I2C SDA

I2C SDA

Reserved interface for internal WINC1500

Wi-Fi Reset_n

NC 51

GND

SWD header pin

Pin definition

ATSAMW25 pin

SWDCLK

GND

NC 4

VCC

5 SWDIO

26 6 RESET

24 7 NC 8

NC 9

NC 10

Touch header pin

Pin definition

ATSAMW25 pin

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

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

Touch Guard Sensor 1

Power LED Green

28 5 Touch Key Sensor

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.

Table 2-2. Pin Definition of SWD Interface

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

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Power LED Red

Touch Guard Sensor 2

35 8 Wi-Fi LED Red

14 9 Wi-Fi LED Yellow

Wi-Fi LED Green

Power header pin

Pin definition

ATSAMW25 pin

VCC

GND

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

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

3 5 Test RXD (Reserved for fixture)

Test TXD (Reserved for fixture)

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

41 8

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

40 9

MCU Reset (Reserved for fixture)

Relay Control

MCU SWDIO (Reserved for fixture)

MCU SWDCLK (Reserved for fixture)

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

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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Designator

Value

Vendor

Part Number

Description

C107

100nF

Murata

GRM155R71H104KE14

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

R111

10k

Yageo

RC0402FR-0710KL

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

U102

1M Byte

Winbond

W25Q80DVUXIE

Serial Flash, 8-lead USON 2*3mm

Pin name on DataFlash

Pin name on ATSAMW25

ATSAMW25 pin

FLASH_SPI_SS

PA18

FLASH_SPI_MISO

PA19

FLASH_SPI_MOSI

PA16

FLASH_SPI_CLK

PA17

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

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

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

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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Pad name on touch board

Pin name on ATSAMW25

ATSAMW25 pin

Touch Key

PA06

Touch Guard 1

PA07

Touch Guard 2

PA05

LED name on touch board

Active logic

Pin name on ATSAMW25

ATSAMW25 pin

Wi-Fi Yellow

PA23

Wi-Fi Green

PA22

Wi-Fi Red

PA21

Power Green

PB03

Power Red

PB02

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

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

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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Wire

Type

Start to end

Turns

Tape

2UEW Φ 0.15x1P

3-1

70Ts

1Ts

2UEW Φ 0.15x1P

4-5

23Ts

2Ts

TRWB Φ 0.35x1P

7-6

24Ts

3Ts

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

Figure 4-3. Transformer Design

Table 4-1. Wire Definition of Transformer

4.3 The Fuse

If broken, the fuse F301 (12A) should be changed by the professional person.

4.4 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

4.5 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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Pin Name for Uart

Pin name on ATSAMW25

ATSAMW25 pin

PWR_PM_TXD

PA10

PWR_PM_RXD

PA11

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

4.6 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

4.6.1 Calculation of the GL

With the shunt resistor = 1mΩ, Max. current I = 10A. When, GL = 24 VLsample = 1mΩ * 10A * 24 = 240mV

4.6.2 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)

4.6.3 Calculation of the Igain

From AN 46102, R = 200µΩ, 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)

4.6.4 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)

4.7 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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Relay Contorl Name

Active Logic

Pin name on ATSAMW25

ATSAMW25 pin

PWR_RELAY

PB22

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 bigger than 50A can make the contactor adhere.

Figure 4-7. Schematic of Relay Control

Table 4-3. Pin Definition of Relay

4.8 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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Doc Rev.

Date

Comments

42698B

07/2016

A new section 4.3 (The Fuse) is added. In section 4.7, the “Note”. “less than” has been corrected to “bigger than”.

42689A

03/2016

Initial document release.

7 Revision History

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© 2016 Atmel Corporation. / Rev.: Atmel-42689B-Atmel-Smart-Plug-Hardware-User-Guide_AT16225_ApplicationNote_07/2016. Atmel®, Atmel logo and combinations thereof, Enabling Unlimited Possibilities®, QTouch®, and others are registered trademarks or trademarks of Atmel Corporation

in U.S. and other countries. ARM®, ARM Connected® 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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Atmel AT16225 Hardware User's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

Features

1 Overview

1.1 System Overview

2 MCU Board

2.1 MCU Board Overview

2.2 ATSAMW25

2.3 Programming Interface

2.4 Header to Touch Board

2.5 Header to Power Board

2.6 DataFlash (Not Mounted)

3 Touch Board

3.1 Touch Board Overview

3.2 Touch Sensors

3.3 LEDs for Wi-Fi and Power

3.3.1 Wi-Fi LED

3.3.2 Power LED

3.3.3 LED Pin Definition on SAM W25

4 Power Board

4.1 Power Board Overview

4.2 AC-DC

4.3 The Fuse

4.4 DC-DC

4.5 Power Measurement

4.6 Power Measurement Calibration

4.6.1 Calculation of the GL

4.6.2 Calculation of the Ugain

4.6.3 Calculation of the Igain

4.6.4 Calculation of the PL_Constant

4.7 The Relay

4.8 Plug and Socket

5 PCB Assembly

5.1 PCB Stack Structure

6 Reprogram the Kit

6.1 Open the Kit

6.2 Power Supply

6.2.1 Onboard AC Power

6.2.2 External DC power

6.3 Programming Tools

6.4 Programming

7 Revision History