Relay Board Schematic Design
Thought for 4 sec
Here’s the schematic plan I’d use for the separate 10-channel 220 VAC relay board.
High-level architecture
Schematic blocks to create 1. AC mains inputText
Control board harness 10x coil drive signals │ ▼ Relay coil interface / flyback protection │ ▼ 10x 24 VDC relay coils AC mains input L / N / PE │ ▼ Main protection ~50 A │ ▼ AC live bus │ ├── CH1 fuse 15 A ─ relay contact ─ output terminal CH1 ├── CH2 fuse 15 A ─ relay contact ─ output terminal CH2 ├── ... └── CH10 fuse 15 A ─ relay contact ─ output terminal CH10 Neutral and protective earth distributed to all output terminals
Use a high-current terminal block for:
AC_L_INAC_N_INPE_IN
For 220 VAC and high current, I would keep this as a physically separated high-voltage section with clear labeling and wide spacing.
2. Main input protection
Add one main protection device before the per-channel distribution.
Recommended options:
- Panel-mount / chassis-mount breaker or fuse, not PCB-only, for ~50 A mains input.
- If represented on the PCB schematic, use a connector or symbol for an external 50 A breaker/fuse.
- Do not rely on a small PCB fuse holder for 50 A mains protection.
Suggested net flow:
3. Ten relay output channelsText
AC_L_IN → MAIN_FUSE_OR_BREAKER → AC_L_PROTECTED AC_N_IN → AC_N_BUS PE_IN → PE_BUS
Each channel should have:
- HANKUK
HR85AKS-DC24relay - Replaceable 15 A fuse on the live output path
- AC output terminal, preferably 3-pin:
- switched live
- neutral
- protective earth
Recommended per-channel topology:
Text
AC_L_PROTECTED → CHx_FUSE_15A → relay COM relay NO → CHx_L_OUT AC_N_BUS → CHx_N_OUT PE_BUS → CHx_PE_OUT
I’d use the relay in normally-open mode unless you explicitly need fail-on behavior.
4. 24 V relay coil power input
Add a low-voltage power connector:
Text
+24V_COIL_IN 0V_COIL_IN
Then distribute:
Text
+24V_COIL → one side of all relay coils coil low side → harness drive signal / transistor driver return path
Important question: are the 10 incoming control signals already low-side coil drivers, or are they just ESP32/logic-level signals?
- If they are already ULN2803/open-drain low-side outputs from the control board, this relay board only needs coil connections and flyback handling.
- If they are logic-level signals, this relay board needs transistor/MOSFET/ULN2803 drivers.
Use a harness connector with at least:
COIL_DRV_1COIL_DRV_2- …
COIL_DRV_100V_COIL- optional
+24V_COILif coil power is also delivered through the harness - optional spare / key / detect pin
For reliability, I’d prefer the 24 V coil supply on a separate higher-current connector, not the signal harness, unless the harness is sized for relay coil current.
6. Coil flyback protection
Each 24 V relay coil needs suppression.
Options:
- Diode across each coil: simple, low-cost, slower relay release.
- TVS or diode + Zener: faster release, better for relay contact timing.
- If the control board already has ULN2803A, note that ULN2803 includes clamp diodes, but the relay board still needs the correct
COMclamp connection to+24V.
For a separate relay board, I’d put local flyback diodes or TVS protection on the relay board so protection stays close to the coils.
Safety/layout constraints to carry into the schematic
- Keep low-voltage harness/24 V coil section physically isolated from 220 VAC contact/output section.
- Use large creepage/clearance between:
- AC live/neutral/PE and low-voltage control
- relay contact pins and coil pins
- adjacent high-current channels
- Use wide copper or copper pours for 15 A paths.
- Consider using slots/cutouts between relay coil/control pins and contact pins.
- Label all high-voltage nets clearly.
- Prefer external/chassis wiring for the full 50 A main feed if PCB copper thickness/width cannot safely support it.
- Are the incoming 10 control signals logic-level inputs or already coil-driver low-side outputs?
- Should each output socket switch live only, or live and neutral?
- Should the board include current sensing or status feedback per channel?
- What connector style/current rating do you want for the AC input and outputs?
- Will the 50 A main protection be on-board, panel-mounted, or external?
My recommended starting schematic is: external/main 50 A breaker → live bus → 10× 15 A fused normally-open relay channels, with neutral and PE distributed directly to each output, and local flyback suppression for all 24 V relay coils.
Use low-side drivers
Add relay drivers
Switch live only
Specify connectors
Create schematic plan
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DS1 OLED Module Selection
Date: 2026-06-15
Selected Part
- Designator: DS1
- Function: user display for status/menu information
- Selected module: Joy-IT SBC-OLED01
- Manufacturer Part Number:
SBC-OLED01 - Manufacturer: Joy-IT
- Display: 0.96 inch OLED, 128 × 64 pixels
- Controller/interface: SSD1306-style I2C OLED module
- Flux package field:
Module - Mount: Through-hole/module header
- Footprint target: approximately 27 mm × 27 mm module outline with 4-pin 2.54 mm header
- Product reference: https://www.joy-it.net/en/products/SBC-OLED01
Schematic Mapping
Current DS1 symbol pins:
Table
| DS1 pin | Project net | Notes |
|---|---|---|
| SDA | I2C_SDA | ESP32 GPIO26 |
| SCL | I2C_SCL | ESP32 GPIO27 |
| 5V | 3V3 | Pin label is inherited from the module symbol, but this design powers the OLED from 3.3 V. |
| GND | GND | Low-voltage ground |
Layout Cautions
- Verify the exact purchased SBC-OLED01 pin order before PCB release; many 0.96 inch OLED modules use the same size but different header order.
- Keep the display accessible for viewing and avoid placing tall parts in front of it.
- If the selected physical module requires 5 V power or has onboard pull-ups to 5 V, do not use it directly with ESP32 I2C; keep the display powered at 3.3 V or add level shifting.
Verification Notes
- DS1 schematic properties now contain MPN, manufacturer, package, mount, product URL, and footprint target.
- The BOM query did not return DS1 even after setting
Exclude from BOM=false; treat this as a BOM-export follow-up before manufacturing output generation.
Selected Part
Schematic Mapping
Layout Cautions
Verification Notes
