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2 layers69.9 × 106.7 mmLED Strand Interface, the printed circuit board in 3D

Initially when we bought fairy lights (sorry for the amazon link, I hope it stays valid for a while) they came with crappy wall warts which had to be plugged and unplugged daily; these wall warts were of such poor…

Size
69.9 × 106.7 mm
Copper layers
2
Thickness
1.6 mm
Parts
37
Nets
43
Pads
150
Tracks, vias
402, 0
Pours
3
Routed
Yes
KiCad
KiCad 4
Created
14 Apr 2018
Updated
14 Apr 2018

Overview

LED Strand Interface is an open-source printed circuit board by thismatters, from the thismatters/Fairy-Light-Controller repository on GitHub, published under the MIT licence. It is a 2-layer board of 69.9 × 106.7 mm with 37 parts on 43 nets, routed with 402 tracks and 0 vias.

It is built around the ATMEGA328P-PU. Its parts include 11 resistors, 9 connectors, 8 transistors, 4 capacitors and 2 ICs. It belongs with the interfaces and adapters boards and the AVR (ATmega, ATtiny) boards of this library.

Main components

1

README

README.md

Fairy Light Controller

Initially when we bought fairy lights (sorry for the amazon link, I hope it stays valid for a while) they came with crappy wall warts which had to be plugged and unplugged daily; these wall warts were of such poor quality that the barrel plug which recieved the light strand would inevitably break. Totally unacceptable. The goal of this project is to provide an easy interface for controlling and powering many strands of LED fairy lights.

Features

  • 40 Watt Power supply,
  • ATMega328P,
  • IR Reciever and Remote Control [also works with a little white apple remote if you have one laying around],
  • Barrel Plugs for 8 light strands,
  • Laser cut acrylic case.

What's included

  • Code for the ATMega328P,
  • KiCAD files for the control board (OSHPark project for this board),
  • Bill of Materials (below),
  • SVG files for cutting the case parts.

Bill of Materials

Here is what you'll need to order to build this thing. I generally order the parts from a few different suppliers due to availability and price so bear with me. You'll also need a board (obvs), you can order some from OSHPark by following the link above, or you can etch your own. Your choice!

Part #QtyReferenceDescriptionMFR # (link)SupplierNotes
11C1Capacitor 100uF (SMD-1206)GRM31CD80J107ME39LMouser
21C2Capacitor 10uF (SMD-0805)GRM21BC81C106ME15LMouser
31C3Capacitor 100nF (SMD-0805)100nF 50V 0805TaydaIf you order 100 of these they will last you a long time.
41C4Capacitor 1uF (Radial D5L11)105CKR100MMouser
58CON1--CON8Barrel JackKLDX-SMT-0202-APMouserThese are sized to fit the fairy lights linked below.
61IC1MicrocontrollerATMEGA328P-PTaydaAn Arduino chip without the Arduino board. You'll have to have a means to program it (an Arduino board will work nicely for that)
71P1Connector 4POSB4PS-VH(LF) (SN)Digi-keyReceive the power onto the board.
88Q1--Q8NPN Darlinton Pair (SOT-223)FZT600TAMouser
98R1--R8Resistor 0.27 Ohm (Thru-hole)MOSX1CT52RR27JMouser
101R9Resistor 0 Ohm (SMD-0805)0 Ohm 1/8W 1% 0805TaydaIf you order 100 of these they will last you a long time.
111R10Resistor 100 Ohm (SMD-0805)100 Ohm 1/8W 1% 0805TaydaIf you order 100 of these they will last you a long time.
121R11Resistor 10k Ohm (SMD-0805)10K Ohm 1/8W 1% 0805TaydaIf you order 100 of these they will last you a long time.
132RR1--RR2Resistor Array (Bussed) 10k Ohm (SIP-9)4609X-101-103LFMouser8 Resistors
141U1IR Reciever (38 khz)TSOP34438Mouser
151X1Crystal Oscillator (with Caps)CSTLS8M00G53-A0Mouser
161NAPower Supply 40WEPS-45-5-CMouser
1710NAConnector Terminal Crimp-onsSVH-41T-P1.1Digi-keyThose little silver things you have to smash onto your wires.
182NAConnector Housing 4POSVHR-4NDigi-keyTo get power from the power supply to the board
191NAConnector Housing 3POSVHR-3NDigi-keyTo get power from the wall to the power supply
201NARemote ControlCOM-11759SparkfunThe software also supports the little white Apple remote control
211NAPower Cordstayonline.comThe power supply insists on being grounded, and I am happy to oblige it. You can use an old PC power cable with one end cut off (choose wisely), or you can order to length.
228NAFairy LightsB00I7M7C40AmazonIt is pretty vital to get the ones with the barrel power connector that matches the barrel jacks (Item 5). Minimum 1, maximum 8
231NABattery for Remote ControlCR2025Lots of placesYou figure it out
241NA28 pin DIP IC Socket28 pin DIP IC SocketTaydaThis is what you'll actually solder to the board. Cram the ATMega328 into this.

The Case

The case is cut from 0.177 inch thick acyrlic sheet using a laser cutter. The specific laser cutter I used is at the ATX Hackerspace; it does not compensate for kerf so the files themselves compensate for the laser width. The case parts should fit together snugly so no adhesive is needed for assembly, although the little bits for wall mounting will need to be bonded onto the bottom so a little cyanoacrylate adhesive will be useful.

Parts

37
QtyValueFootprintReferences
80.27Resistors_ThroughHole:Resistor_Horizontal_RM10mmR1, R2, R3, R4, R5, R6, R7, R8
8BARREL_JACKsmd_parts:KLDX-SMTCON1, CON2, CON3, CON4, CON5, CON6, CON7, CON8
8Darl_NPN_pssmd_parts:SOT-223-TransistorQ1, Q2, Q3, Q4, Q5, Q6, Q7, Q8
10Resistors_SMD:R_0805_HandSolderingR9
1100Resistors_SMD:R_0805_HandSolderingR10
1100UCapacitors_SMD:C_1206_HandSolderingC1
1100nCapacitors_SMD:C_0805_HandSolderingC3
110UCapacitors_SMD:C_0805_HandSolderingC2
110kResistors_SMD:R_0805_HandSolderingR11
11usmd_parts:C_Radial_D5_L11_P2.5_bigpadC4
1ATMEGA328P-Psmd_parts:DIP-28__300IC1
1CONN_4wafer:Socket_VH-RM3-96mm_Lock_4pin_straightP1
1CRYSTAL_WITH_CAPSsmd_parts:Crystal_Vertical_3PinX1
1IR_RECEIVERsmd_parts:TSOPxxU1
1PD_RR8_10ksmd_parts:Resistor_Array_SIP8RR1
1PU_RR8_10ksmd_parts:Resistor_Array_SIP8RR2

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Questions

How big is the LED Strand Interface PCB?

It measures 69.9 × 106.7 mm and has 2 copper layers, 1.6 mm thick.

What parts does the LED Strand Interface use?

37 parts, built around the ATMEGA328P-PU. The full list of its parts is on this page, with links to each part's symbol and footprint where PCBKit's library has them.

Where can I download the LED Strand Interface KiCad files?

From the thismatters/Fairy-Light-Controller repository on GitHub, at the commit this page was made from: the board is hardware/LED_Strand_Interface.kicad_pcb. PCBKit opens the board in the browser, with nothing to install.

Can I use the LED Strand Interface design in my own project?

Its repository publishes it under the MIT licence: you may reuse it on that licence's terms (keep the author's notice, and for a copyleft licence share your changes alike).