Contact person: Universal Indoor-Outdoor AC Bridge USG7007

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Location: Bhopal, India

Budget: Recommended by industry experts

Time to start: As soon as possible

Project description:
"1. Project Purpose and Working Principle

The USG7007 is designed to act as a universal bridge and diagnostic tool between inverter AC indoor and outdoor PCBs of different brands.

When the indoor PCB sends signals, the device captures them, decodes the protocol, and translates it into outdoor-compatible signals.

Outdoor responses are also captured, decoded, and translated back into indoor-compatible format.

It supports automatic signal detection (UART, PWM, DC shift), captures data in real time, and saves configurations automatically in memory.

It works continuously as long as the AC system is ON and provides diagnostic details such as frequency, duty cycle, and baud rate on its LCD.

It can operate in translator mode, simulator mode (indoor-only or outdoor-only), auto-learn mode, and hidden fake signal generator mode for testing.



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2. Run-Time and Operation

The device remains ON continuously as long as the AC system is powered.

Auto-sleep option: After 10 minutes of no activity, the display backlight and buzzer switch OFF to save energy, while the core system remains active.



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3. Application Support

Mobile app via Wi-Fi and BLE: Controls ON/OFF, provides live diagnostics, displays fault logs, and allows OTA firmware updates.

USB-C connection: Supports firmware flashing, debugging, and serial monitoring.



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4. Power System

Internal power: 230V AC to 5V DC SMPS module with full isolation.

External power: 5V DC input jack for bench testing.

Safety features:

Device blocks startup if more than 6V DC is applied.

Reverse polarity protection.

Fuse and NTC inrush limiter on AC side.

MOV and EMI filters for surge protection.


The display shows the current power source (AC or DC).



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5. Microcontrollers

ESP32-WROOM (primary MCU): Handles display menus, app communication, OTA updates, logging, warranty tracking, and security features.

Secondary MCU (STM32F0/ATmega/Nuvoton): Dedicated for timing-critical real-time signal decoding and encoding (UART, PWM, DC-shift).

USB-UART chip (CH340/CP2102): Provides firmware update and debugging capability via USB-C.



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6. Hardware

PCB size: 100 mm × 60 mm.

Display: 16×2 I²C LCD with bilingual support (English + Hindi written in English letters).

Input: 4 push buttons for menu navigation and hidden functions.

Output: Buzzer for alerts, optional status LEDs for power, lock, input, and output.

Isolation: Optocouplers on all signal I/O lines.

Protection: TVS diodes, MOV, and resistors protect against surges and accidental mis-wiring.

USB-C port for firmware and debugging.



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7. Communication and Signal I/O

Protocols supported:

UART: 1200, 2400, 4800, 9600 baud rates (3.3V or 5V levels).

PWM: 1–5 kHz, duty-cycle communication.

DC Shift: 0–12V or 0–15V level modulation.


Full bi-directional indoor-to-outdoor and outdoor-to-indoor translation.

Survives accidental connection of AC phase to signal input without permanent damage.

Connectors: Screw terminals clearly marked for Indoor/Outdoor RX, TX, GND.



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8. Functional Modes

1. Translator Mode: Real-time brand-to-brand communication.


2. Simulator Mode: Acts as indoor-only or outdoor-only with fake signal generation.


3. AI Auto-Learn Mode: Learns and maps unknown brand protocols automatically.


4. Fake Signal Generator: Hidden diagnostic mode to simulate indoor/outdoor signals for testing.




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9. Memory and Security

EEPROM/Flash: Stores last configuration, signal maps, and error logs.

RTC: Tracks 1-year warranty period and shows expiry warning after one year.

PIN lock: Requires PIN entry on first use, visible once for 20 seconds.

Brand lock: Device pairs only with first indoor-outdoor brand and disables further auto-learn.

App lock: If turned OFF through the mobile app, manual ON is disabled until re-enabled from the app.

Firmware and serial details accessible only via hidden service mode.



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10. Diagnostics and Testing

Self-test at boot: RAM, LCD, buzzer, and button check.

Real-time monitoring: Indoor and outdoor frequency, duty cycle, and baud displayed on screen.

Signal presence: Shows which side (indoor or outdoor) is not sending data.

Error handling: Displays human-readable error codes with numeric identifiers.

Fault logging: Last faults stored in EEPROM with time record.



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11. Firmware and Software

ESP32 firmware: Handles user interface, app communication, profile management, logging, RTC warranty, and OTA updates.

Secondary MCU firmware: Manages signal capture, decode/encode, timing, and protocol conversion.

Brand profiles: Contains stored protocol definitions for 18+ AC brands.

Service mode: Provides access to firmware version, device serial number, and built-in test patterns.



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12. Safety and Compliance

Opto-isolation between AC and logic circuits.

Conformal coating for dust and moisture protection.

MOVs and TVS diodes for surge protection.

Thermal rise limited to less than 40°C above ambient temperature.

ESD protection on all input and output lines.



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13. Testing and Quality Control

Factory checklist includes:

Power-on self-test.

Display, button, and buzzer operation.

Indoor/outdoor loopback test.

App lock/unlock functionality.

Over-voltage testing (>6V).

Fault injection (disconnect signals).


AOI/ICT during PCB production for assembly validation.



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14. Packaging

Standard box includes:

One USG7007 device.

AC power cable.

DC bench cable.

Quick Install Guide (English + Hindi).

Warranty Card.

Sticker with QR code linking to app and manual.




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15. Expansion and Future-Proofing

Expansion header for UART/I²C/GPIO with 5V/GND.

Optional adjustable delay + optocoupler support for BLDC feedback circuits.

Auto sleep after 10 minutes of no activity.

Provision for AI waveform recognition and cloud sync in future firmware updates.



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16. Branding

Boot splash screen text: “Sagar Refrigeration Tools – USG7007”.

Display shows contact: Sagar Refrigeration, Sagar: +91 7007940949, Vijay: +91 9598360280.

PCB silk print includes only +91 9598360280.



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17. Supported Brands

Voltas, Daikin, LG, Whirlpool, IFB, Toshiba, Marq, Cruise, Panasonic, Haier, Lloyd, Godrej, Blue Star, Mitashi, Carrier, Hitachi, Samsung, O General, Midea/Gree.



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18. Deliverables

1. EasyEDA project files (schematic and PCB).


2. Gerbers, drill, and assembly files.


3. Bill of Materials with manufacturer part numbers and alternates.


4. Firmware for ESP32 and secondary MCU.


5. Real wiring diagram (with wire-style drawings and pin numbers).


6. USB flashing guide with drivers.


7. Factory test checklist.


8. Quick Install Guide.


9. Serial number format and warranty card.


10. Device sticker/label design with QR code.


11. Final Master PDF document with all details.


12. Box and panel cutout drawings.




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This is the complete and unified detail of the USG7007 project. It covers every requirement from hardware to software, security, safety, branding, application, and deliverables." (client-provided description)