Plasma-DMD/hardware/kicad/README.md

# KiCad project: PSU carrier board

Open `plasma_dmd_psu.kicad_pro` in KiCad 10.

The board carries the fuses, the HV watchdog, both regulators (copied from Stern 520-5138-00) and
the connectors. The AliExpress modules sit **off-board** and connect through Phoenix 5.08 mm screw terminals:

| Connector | Goes to | Pins |
|---|---|---|
| J1 | 12 V DC brick | +12V, GND |
| J3 | Mini560 5 V buck | IN+, IN−, OUT+, OUT− |
| J4 | Relay module | VCC, GND, IN, COM, NO |
| J5 | NCH6100HV #1 (set 90 V) | VIN, GND, HV+ |
| J6 | Isolated DC-DC input | VIN, GND |
| J7 | NCH6100HV #2 (set 130 V) output | HV+ (→ GND), GND (→ −130 V raw) |
| J8 | ESP32 | 5V, GND, GPIO21 (watchdog) |
| J2 | Panel power, Molex KK-396 8-pin | Stern CN2 order: 1 −112V, 2 −100V, 3 key, 4–5 GND, 6 +5V, 7 +12V (via JP1), 8 +65V |

Wire the isolated DC-DC output straight to NCH6100HV #2's input, off-board. Both float at −130 V.

> ⚠️ **J2 pinout is a placeholder.** It follows the Stern supply, not necessarily your WPC panel.
> Map it to your panel before you plug anything in.

## Files

| File | What |
|---|---|
| `gen_kicad.py` | Generates the schematic and the project's net classes from the `PARTS` table. **The source of truth.** |
| `check_netlist.py` | Exports the netlist with kicad-cli and checks every pin against `PARTS` |
| `plasma_dmd_psu.kicad_sch` | Generated schematic (labels-per-pin style: connectivity is by net label) |
| `plasma_dmd_psu.pdf` | Plot of the schematic |

```bash
python hardware/kicad/gen_kicad.py
python hardware/kicad/check_netlist.py
```

Re-running `gen_kicad.py` **overwrites the schematic**. Either keep editing `PARTS` and regenerate, or
stop using the generator once you start editing the schematic in KiCad.

## Net classes (already in the project)

| Class | Nets | Clearance | Track |
|---|---|---|---|
| HV | +90V_RAW, +65V, −130V_RAW, −112V, −100V, HVP/HVN_MOD and all regulator internals | 1.3 mm (3.0 mm to LV via custom rules) | 0.6 mm |
| Power | GND, +12V*, +5V, +12V_PANEL | 0.3 mm | 1.0 mm |
| Default | Watchdog signals, LED cathode/anode nodes | 0.25 mm | 0.4 mm |

## PCB (rev 0.1)

![Top view](pcb-top.png)

The board is 170 × 125 mm, 2 layers, with 4 × M3 holes. It is fully routed with a bottom-layer GND pour.
DRC is clean: 0 violations, 0 unconnected pads, schematic parity OK.

- **Left: low voltage.** 12 V input, Mini560, ESP32 watchdog, relay, F1–F3.
- **Right: high voltage.** +65 V regulator at the top, −112/−100 V regulator at the bottom.
  A dashed silkscreen line marks the boundary, with DANGER text on both sides.
- **J2 (panel)** straddles the boundary. Its LV pins (GND, +5V, +12V) leave towards the left, its HV pins towards the right.
- **Terminal blocks** sit on the top and bottom edges, with wire entries facing outwards.
- **Heatsink space** is left above Q3, Q5 and Q6.

> ⚠️ **The TO-220 tabs are live.** Q3's tab is at +90 V, Q5's at −130 V and Q6's at Q6_C.
> Give each transistor its own heatsink, keep the heatsinks apart, and don't let them touch anything.

### Clearance rules

The classes are in the project, and the custom rules are in `plasma_dmd_psu.kicad_dru`. Later rules win.

| Between | Clearance | Why |
|---|---|---|
| HV and LV (GND, 12 V, 5 V, watchdog) | **3.0 mm** | Keeps HV well away from the touchable side |
| HV and HV | 1.3 mm | IPC-2221 B2 needs 1.25 mm up to 300 V |
| HV and LV, next to a connector pin | 1.8 mm | Fixed pin pitch of J2/J5/J7 |
| HV and HV, next to a transistor pin | 1.0 mm | TO-220 pin escape; same-polarity nets only |
| Pins inside one connector / transistor / HV electrolytic | 0.75 / 0.6 / 2.5 mm | Fixed footprint pitch |

### Regenerating the board

The layout is produced by two scripts, run with KiCad's Python while KiCad is closed:

```bash
"C:/Users/patri/AppData/Local/Programs/KiCad/10.0/bin/python.exe" hardware/kicad/layout_pcb.py
"C:/Users/patri/AppData/Local/Programs/KiCad/10.0/bin/python.exe" hardware/kicad/route_pcb.py
```

- `layout_pcb.py` places every footprint from its `PLACE` table and draws the outline, holes and silkscreen.
  It also swaps in any footprint that changed in the schematic. **It deletes all tracks and zones.**
- `route_pcb.py` autoroutes with Freerouting (`tools/freerouting/`, needs Java 25):
  - It routes with oversized tracks and vias, then shrinks them to their real width. This turns
    the router's smaller clearances into 3 mm for HV to LV and 1.3 mm for HV to HV.
  - It adds fixed escape stubs on J2 and the GND pour.
  - Run DRC afterwards: `kicad-cli pcb drc --schematic-parity --refill-zones hardware/kicad/plasma_dmd_psu.kicad_pcb`.

Once you start hand-editing the board in KiCad, stop running these scripts. They would overwrite your edits.

### Before ordering

- [ ] Check every footprint against the parts you actually buy: fuse holders, the 12.5 mm caps, the R13 5 W size, and the terminal block pitch.
- [ ] Map J2 to your panel's power connector. The current order follows the Stern CN2 connector.
- [ ] Check heatsink size and clearance for Q3/Q5/Q6.
- [ ] Consider conformal coating on the HV side.
- [ ] Get a second pair of eyes on the HV layout.

## Verified so far

- The schematic loads in KiCad 10.0.6, and ERC reports 0 violations.
- `check_netlist.py`: all 122 pins sit on the intended nets (31 nets).
- PCB DRC with schematic parity: 0 violations, 0 unconnected pads.
- All symbols and footprints come from the KiCad 10 standard libraries.
- Transistor pinouts match the footprints: MJE15030/31 are B-C-E (TO-220); MPSA42/92 are E-B-C (TO-92); 2N7000 is S-G-D.

**Not verified:** the circuit itself on real hardware, and the module current ratings.