You may have seen this topic: http://www.cocoontech.com/index.php?showtopic=4629&st=15&hl=
Well I decided to modify an Icon Appliance Module to turn it into a contact closure.
Disclaimer: Do NOT do this modification! There are line voltages on this pcb and you could cause damage to connected equipment and/or a fire hazard.
This is documented for educational purposes only.
Ok so here is the inside of the appliance module:
I removed the relay to see what traces were hidden underneath:
Now we want to isolate the relay contacts from the line voltage, so I drilled out the through holes that connect it to the board. By doing this, I broke the connection to a trace (shown in red) that fed the 120V hot wire through to the rest of the circuit. Also there are some other traces that I had to be careful not to break (shown in yellow).
I reconnected the broken trace to 120V hot with a wire. Then I connected wires to the switched relay contacts. These were covered in heat shrink tubing to keep them from coming into contact with the board. There is still 120V flowing around in that area!
I disconnected the wires leading to the switched outlet because I won't be using that. I then secured all loose wires with hot glue, replaced the PCB, and put it all back together. The wire is routed out through the ground hole of the receptacle.
Final shot of the new insteon contact closure module.
Well I decided to modify an Icon Appliance Module to turn it into a contact closure.
Disclaimer: Do NOT do this modification! There are line voltages on this pcb and you could cause damage to connected equipment and/or a fire hazard.
This is documented for educational purposes only.
Ok so here is the inside of the appliance module:


I removed the relay to see what traces were hidden underneath:

Now we want to isolate the relay contacts from the line voltage, so I drilled out the through holes that connect it to the board. By doing this, I broke the connection to a trace (shown in red) that fed the 120V hot wire through to the rest of the circuit. Also there are some other traces that I had to be careful not to break (shown in yellow).
I reconnected the broken trace to 120V hot with a wire. Then I connected wires to the switched relay contacts. These were covered in heat shrink tubing to keep them from coming into contact with the board. There is still 120V flowing around in that area!

I disconnected the wires leading to the switched outlet because I won't be using that. I then secured all loose wires with hot glue, replaced the PCB, and put it all back together. The wire is routed out through the ground hole of the receptacle.
Final shot of the new insteon contact closure module.
