Contact person: AC Communication Translator & Simulator

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Location: Bhopal, India

Budget: Recommended by industry experts

Time to start: As soon as possible

Project description:
"Project Overview – USG7007

Universal AC Communication Translator & Simulator


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1. Hardware

MCU Options:

1. ESP32-WROOM (default: WiFi/Bluetooth, fast prototyping, easy coding).


2. STM32 Series MCU (optional: industrial-grade reliability, advanced timers, better UART/PWM handling).



Memory: External EEPROM/Flash IC for storing signal data and brand profiles.

RTC Module: For warranty time tracking and logging.

Display: 16x2 LCD with I²C interface.

Input/Output:

Indoor PCB signal input/output

Outdoor PCB signal input/output


USB-C (CH340/CP2102): For firmware programming, debugging, and updates.

Buttons: Push buttons for manual menu navigation and brand saving.

Buzzer: For alerts, fault warnings, and feedback.

Protection: Reverse polarity, over-voltage cutoff (>6V), miswiring protection, and optocoupler-based signal isolation.

PCB Size: 10 cm × 6 cm.

Enclosure: ABS plastic box labeled “Sagar Refrigeration – USG7007.”



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2. Power Supply

AC-DC Micro SMPS: 230V AC input, converted to 5V regulated DC.

External 5V DC Input: For portable or external power operation.

Power Mode Indicator: LCD shows “AC Mode” or “DC Mode.”



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3. Software & Firmware Functions

Signal Capture: Reads UART, PWM, and DC-Shift signals from AC PCBs.

Signal Translation: Converts one brand’s signal into another brand’s format.

Simulation Modes:

1. Indoor-only mode – provides fake compressor, fan, and sensor signals.


2. Outdoor-only mode – provides fake indoor communication and sensor values.



Auto Recognition: Saved brand data is auto-detected when reconnected.

Security Features:

PIN activation on first-time setup.

Signal lock to first saved brand profile.


Diagnostic Features:

Startup self-test routine.

Real-time signal frequency display.

Fault log storage in EEPROM.

Last working brand profile auto-load.




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4. Application (Optional Mobile App)

Remote ON/OFF control.

Manual brand selection and signal saving.

Firmware update via USB or WiFi.

Status monitoring and error log display.



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5. Workplace Usage Examples

Example 1 – Cross-Brand Communication

Case: Daikin Indoor PCB + LG Outdoor PCB.

Action: Connect both through USG7007.

Result: Indoor signals are translated to LG format and vice versa.

Outcome: Both work together smoothly.


Example 2 – Indoor PCB Testing Without Outdoor

Case: Panasonic Indoor PCB available, no outdoor unit.

Action: Connect to USG7007 in Indoor Simulation Mode.

Result: Device provides fake compressor, fan, and sensor signals.

Outcome: Indoor PCB works standalone for testing.


Example 3 – Outdoor PCB Testing Without Indoor

Case: Voltas Outdoor PCB available, no indoor unit.

Action: Connect to USG7007 in Outdoor Simulation Mode.

Result: Device simulates indoor signals and sensors.

Outcome: Outdoor PCB works standalone for testing.



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6. Benefits in the Field

Supports both MCU options (ESP32 for easy development, STM32 for industrial use).

Works for indoor-only or outdoor-only testing.

Enables cross-brand communication between different PCBs.

Reduces dependency on complete AC units during repair.

Saves time, improves accuracy, and increases workshop efficiency.



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Do you want me to make two separate cost estimations also – one if project is built with ESP32 and another if it is built with STM32 – so you can compare and discuss with the developer?" (client-provided description)