TRÅDFRI wall switch

This hack will modify the TRÅDFRI remote into an attractive wall switch.

The project homepage (in Danish): https://www.thingiverse.com/thing:3655354

This information is under CC BY-NC-SA 4.0 license.

Photos

63 mm wide. Typical color choices are white or dark gray - silver combo.

The switch are 45 x 45 x 12 mm, and does not require room behind it.

With a smaller bezel the switch can be 50 mm wide.

Both sides of the custom circuit board.

Custom print on plastic is possible.

ZigBee module

The ZigBee module from IKEA can have different functions, depending which firmware is installed.

5-button remote
Mains outlet
2-button remote

Note: The 2-button remote does not have a module you can havest. The IC is soledred directly on th PCB. The picture above shows how the module behaves, if it has the firmware from the 2-button remote.

But why?

Problem, step 1

Using TRÅDFRI on a sofa lamp is great. You can turn it on and off from your phone, and you can place a remote switch where you like.

However when you start using TRÅDFRI to replace existing ceiling lighting, you will soon realize a problem: If the light is turned off by the wall switch, you cannot turn it on by remote or app, because there is no power going to the light.

Solution, step 1

Replace the wall switch with a remote.

Problem, step 2

This looks unattractive, and does not fit into the existing wall switch and socket design.

Solution, step 2

Transfer the electronics from the remote to a switch that fits the design. The the design is so compact, that is does not requires space behind it, and can be mounted directly on the wall.

Problem, step 3

This design is for the FUGA system, which is only used in Denmark.

Solution, step 3

You can use converters to make it converter to fit the size used in the rest of Europe.

Problem, step 4

This does not look as attractive.

Solution, step 4

Be inspired by this hack, to make a solution that fits your wall switch and plug system. Be careful with mains electricity, an the note of the the law and regulations in your country. This hack avoids mains electricity by being mounted directly on the wall.

Building instructions

This guide is for at batch of 200 units. If you want a smaller amount like 20, you can order circuit boards without components, and order all the components at RS Components. However it is much easier and cost effective to follow the guide and make 200 units.

Materials needed

ZigBee module from IKEA TRÅDFRI remote control
Plastic for LK FUGA svagstrømstryk
Circuit board and components
3D printed plastic for the back

Order circuit board with components

Download svagstromstryk_PCB_2019-09-14_4xPannel.zip
Extract IKEA_Button2_BOM_JLCPCB.xlsx and IKEA_Button2-top-pos_JLCPCB.xlsx from it.
Go the the web page https://jlcpcb.com/
Click "QUOTE NOW".
Upload svagstromstryk_PCB_2019-09-10_4xPannel.zip.
Set "PCB Qty" to 50.
Set "Surface Finish" to ENIG-RoHS (not required, if you want to save cost at the expense of the environment).
Change thickness til 1.0 mm.
Enable "SMT Assembly" -> "Assemble your PCB boards".
Pick "Assemble top side".
Click "Confirm".
Upload IKEA_Button2_BOM_JLCPCB.xlsx as BOM file.
Upload IKEA_Button2-top-pos_JLCPCB.xlsx as CPL file.
Click "NEXT".
Review and confirm all the components.
Click "NEXT".
Review Parts Placement.
Click "SAVE TO CART"
Continue the Checkout. DHL is faster for delivery.

Order additional electronic components

Most components are included on the board if you buy them mounted from JLCPCB. The rest can be bought from the resellers below.

Amount	Reference	Picture	RS	Digi-Key Part	Farnell	Mouser	Manufacturer	Manufacturer Part Number
800	S1-4		135-9416 N/A 479-1491	CKN9112TR-ND CKN10880CT-ND CKN10814CT-ND	2320087 N/A 3801287	611-PTS645SM43SMTR92 611-PTS645SL43SMTR92 506-FSM2JSMA	C & K C & K TE	PTS645 SM43 SMTR92 LFS PTS645 SL43 SMTR92 LFS FSM2JSMA / 2-1437565-7
200	S5		135-9404 176-9579	N/A CKN10814CT-ND	N/A N/A	N/A 611-641SP34SMTR2LFS	C & K C & K	PTS641 SM34 SMTR2 LFS PTS641 SP34 SMTR2 LFS
200	S6	N/A	154-2583 154-6145 N/A N/A	CKN10849CT-ND 401-2004-ND N/A N/A	N/A 2435144 N/A N/A	611-JS203011SCQN 611-JS203011CQN N/A N/A	C & K C & K N/A N/A	JS203011SCQN JS203011CQN MSS23D19 MSS-23D19G2-T
1000	C1-5		135-9020
1000	R1-5		679-1459
200	R6		810-1741
200	D1		654-5391
200	Q1		690-0127
200	BT1		N/A 219-7960	BK-888-ND 36-3003-ND	N/A N/A	N/A 534-3003	MPD Keystone	BK-888 3003

When there are multiple choosies for components, the top one is the recommended. If JS203011SCQN is sold out, JS203011CQN can be used as an alternative. You must convert it from thou-hole to SMD, by bending the legs.

In this example I bought:

RS Components
- 200 x 135-9404
DigiKey
- 1000 x CKN9112TR-ND (only 800 is needed)
- 200 x CKN10849CT-ND
- 200 x BK-888-ND

Order original LK FUGA plastic front

The plastic can purchased by these EAN numbers:

Color	Buttons	Center
White	5703302140836	5703302132244
Light gray	5703302140829	5703302132237
Dark gray	5703302140843	5703302132251

You need 400 buttons and 200 center plastic.

If you want laser engraved buttons, they can be ordered at bestil.lk.dk.

Remember to choose "IHC svagstrømstryk", not "IHC wireless". They look similar, but are not compatible.

Print the back side

Download the appropriate model

With support: svagstromstryk_lukket-bagside_med-support.stl
Without support: svagstromstryk_lukket-bagside_uden-support.stl

Tolerances are very small. The space inside must be 41.6 mm wide. Depending you the type of plastic used, the model must be enlarged between 100.2 and 100.8%. The "ironing" feature in Cura is also very useful, because it make assembling easier. Remember to pass this info along, if someone else print the model for you. Teste one, before you print a lot.

Extract the TRÅDFRI ZigBee module

The ZigBee module is inside the TRÅDFRI remote. It can be purchased directly by the number 304.431.24. It is also included in a variety of bundles.

The extraction of the module is quite hard, and the remote is fairly expensive in some regions. Alternatively you can to use the ZigBee module from other TRÅDFRI devices, if you reprogram it.

The TRÅDFRI signal repeater is the easiest product to extract the module from. Just push on the USB plug, and it pops open. It is only soldered on 4 pads.

The bulbs are harder to open, but are easy to desolder, because it is only soldered on one side. The 400 lm white bulb is the cheapest option to the the module.