Step 1 : Creating the Circuit Board


You will first need to create a circuit board to control the four ports. There are links to the image files for the board.

The RJ45 jack is drilled with a #70 wire size drill bit, the relay drill is a 7/64, and the holes for the #12 wire are a 1/8 drill bit.

Photo is of a completed circuit board for the 4 port controller. Note: This board uses a CAT5 wire, and uses negative switching (constant positive)


Circuit Board in ExpressPCB layout.

Circuit Board in PNG format (ready to print)

It would also be easy to use your own SSR's on this.

Step 2 : The SSR Relays


You will need 4 SSR relays for this part. The ones I used are 4 amp ones by electromatic.

Step 3 : Solder in the Relays


You will need to solder in the relays from here. With the soldering, I also did add additional solder along the traces that will be running 120v. I have also soldered in the RJ45 connector.

Step 4 : Add the Output Wires


Next, you will need to solder on the wire that will go to the outlets. I use approx 4" of #12 (stranded) wire for outputs 1 and 2, and 6" of wire for outputs 3 and 4.

I have also drilled two holes into the circuit boards for puting in screws that allow me to mount them into the electical box. I use 10-32 screws, with two nuts for standoffs. Note the electical tape under the one nut to prevent shorting. (even though the nut doesn't touch, I juse want to be safe.) I also drill two mounting holes in the bottom of the box before I put the screws in.

Photo is of two completed SSR assemblys ready to be installed into a box.

Step 5 : Install Into the Electtrical Box


I use a cheap 15' two prong extension cord to provide power to each box. I cut the end off at about 1', and install that end though the box. This allows to chain controllers together as one "long" extension cord.

Solder the power wire into the circuit board, and then attach a crimp on connector on the other end, and then bolt the circuit board into the box.

The relays are installed and mounted into the electical box.

I have also found that I if I tilt the board a little bit up on the left, that it fits together better.