commit dbc1f0041f7786eb79761bd0a95982d16e4eee08 Author: MangaValk Date: Sat Oct 24 02:31:50 2026 +0200 Initial commit: plasma DMD driver project - Design docs: 12 V DC power supply, safety and bring-up, ESP32 interface, BOM - PSU schematic (schemdraw) and KiCad 10 carrier-board project with HV net classes - ESP32 PlatformIO firmware skeleton with HV watchdog toggle - Reference schematic of the Stern 520-5138-00 display PSU Co-Authored-By: Claude Opus 5.5 diff --git a/.gitignore b/.gitignore new file mode 100644 index 0000000..9c65e91 --- /dev/null +++ b/.gitignore @@ -0,0 +1,19 @@ +# PlatformIO +firmware/.pio/ +firmware/.vscode/ + +# KiCad backups, caches and local state +*-backups/ +*.kicad_prl +fp-info-cache +*.lck +\#auto_saved_files# +_autosave-* +*.bak + +# Python +__pycache__/ + +# KiCad generated reports +hardware/kicad/erc.rpt +*.net diff --git a/README.md b/README.md new file mode 100644 index 0000000..4184b0b --- /dev/null +++ b/README.md @@ -0,0 +1,41 @@ +# Plasma DMD + +Drive a second-hand 128×32 pinball **plasma** dot-matrix display (originally on a Williams WPC +DMD controller) standalone, from a **Wemos D1 mini ESP32**, powered from a single **12 V DC** brick. + +The display power supply is built from cheap modules plus a copy of the regulator section of the +Stern/Sega display PSU (520-5138-00). The original transformer and AC front end are not used. + +> ⚠️ **High voltage.** The panel runs on about +65 V, −100 V and −112 V, which is about 175 V +> between rails. That can injure you. Read [docs/safety.md](docs/safety.md) before powering anything. + +## The panel + +- Bought second-hand on 18 September 2021 for €37. +- Originally driven by a Williams WPC DMD controller board. No original controller or PSU came with it. + +## Layout + +| Path | Contents | +|---|---| +| [docs/power-supply.md](docs/power-supply.md) | PSU design: block diagram, analysis of the original board, changes | +| [hardware/psu-schematic.svg](hardware/psu-schematic.svg) | PSU schematic (generated by [hardware/psu_schematic.py](hardware/psu_schematic.py)) | +| [hardware/kicad/](hardware/kicad/) | KiCad 10 project for the PSU carrier board (schematic + net classes, PCB not started) | +| [docs/safety.md](docs/safety.md) | Safety design (HV watchdog, fusing, layout, bring-up procedure) | +| [docs/esp32-interface.md](docs/esp32-interface.md) | ESP32 pin plan, 74HCT245 level shifter, panel signals | +| [docs/bom.md](docs/bom.md) | Bill of materials | +| [reference/](reference/) | Original Stern 520-5138-00 display PSU schematic | +| [firmware/](firmware/) | PlatformIO project for the ESP32 | + +## Status + +- [ ] Identify panel: manufacturer/part number from its label +- [ ] Map the panel's power connector pins (WPC panel ≠ Stern CN2 pinout) and check if +12 V is used +- [ ] Map the panel's 14-pin data connector +- [ ] Lay out the PSU PCB in KiCad ([hardware/kicad/](hardware/kicad/README.md)) +- [ ] Order parts ([docs/bom.md](docs/bom.md)) +- [ ] Build and bench-test the PSU **without the panel** ([bring-up](docs/safety.md#bring-up-procedure)) +- [ ] Build HV watchdog and verify that the relay drops when toggling stops +- [ ] Firmware: row scanning with test pattern +- [ ] First power-up with panel (series resistors, current measurement) +- [ ] Firmware: greyscale, content source (Wi-Fi / serial) diff --git a/docs/bom.md b/docs/bom.md new file mode 100644 index 0000000..18429d2 --- /dev/null +++ b/docs/bom.md @@ -0,0 +1,55 @@ +# Bill of materials + +Designators match the KiCad project ([../hardware/kicad/](../hardware/kicad/README.md)). +Footprint choices are in [gen_kicad.py](../hardware/kicad/gen_kicad.py). + +Prices are rough estimates. + +## Modules (AliExpress unless noted) + +| Qty | Part | Notes | About | +|---|---|---|---| +| 1 | 12 V 3 A power brick | **Certified brand, from a local retailer** (e.g. Mean Well GST36A12) | €15 | +| 1 | Mini560 5 V fixed buck module | Fixed output, no trim pot | €2 | +| 2 | NCH6100HV nixie HV boost module | Input 9–16 V, output 85–235 V adjustable | €16 | +| 1 | Isolated DC-DC 12 V → 12 V, 6–10 W | e.g. Mornsun URB1212YMD-6WR3 / -10WR3 | €6 | +| 1 | 5 V 1-channel relay module, with optocoupler | Switches the 12 V feed to the HV modules | €2 | +| 1 | Wemos D1 mini ESP32 | | €5 | + +## Regulator section (from Mouser / Farnell / Reichelt) + +| Qty | Part | Ref (KiCad) | Ref (original Stern board) | +|---|---|---|---| +| 2 | MJE15030 (NPN, TO-220) | Q3, Q6 | Q3, Q5 | +| 1 | MJE15031 (PNP, TO-220) | Q5 | Q4 | +| 1 | MPSA92 (PNP, TO-92) | Q2 | Q1 | +| 1 | MPSA42 (NPN, TO-92) | Q4 | Q2 | +| 2 | 1N5228 (3.9 V zener) | D4, D6 | D3, D4 | +| 1 | 1N4760A (68 V zener) | D5 | D5 | +| 1 | 1N4764A (100 V zener) | D8 | D6 | +| 1 | 1N4743 (13 V zener) | D7 | D7 | +| 2 | 47 kΩ 1 W | R5, R10 | R2, R3 | +| 3 | 1.5 kΩ ½ W | R4, R9, R12 | R4, R5, R10 | +| 2 | 330 kΩ ½ W | R6, R11 | R6, R7 | +| 1 | 2 kΩ 5 W | R13 | R8 | +| 3 | 0.1 µF 500 V film | C6, C8, C9 | C3, C4, C7 | +| 3 | TO-220 heatsink | for Q3, Q5, Q6 | | + +## Additions + +| Qty | Part | Purpose | +|---|---|---| +| 1 | P6KE15A TVS diode (DO-15) | 12 V input surge protection (D1) | +| 1 | 470 µF 25 V electrolytic | 12 V input bulk (C1) | +| 1 | 100 µF 10 V electrolytic | +5 V bulk (C2) | +| 2 | 22 µF 250 V electrolytic (12.5 mm) | Raw HV rail buffer (C5, C7) | +| 2 | 330 kΩ ½ W | Raw HV rail bleeders (R2, R7) | +| 2 | LED + 100 kΩ 1 W | HV-present indicators (LED1/R3, LED2/R8) | +| 1 | 74HCT245 + DIP socket | 3.3 V → 5 V level shifter | +| 1 | 2N7000, 2 × 1N4148, 100 nF, 10 µF, 100 kΩ | HV watchdog charge pump (Q1, D2, D3, C3, C4, R1) | +| 2 | 1 kΩ 1 W | Series resistors for first power-up | +| 5 | 5×20 mm PCB fuse holders + fuses: 3 A T (F1), 2 × 1 A T (F2, F3), 2 × 100 mA F (F4, F5) | | +| — | Phoenix MKDS 5.08 mm screw terminals: 3 × 2-pin (J1, J6, J7), 2 × 3-pin (J5, J8), 1 × 4-pin (J3), 1 × 5-pin (J4) | Module connections | +| 1 | Molex KK-396 8-pin header (J2) + mating housing | Panel power | +| 1 | 2-pin header + jumper (JP1) | +12 V to panel | +| — | M3 standoffs (H1–H4), 300 V-rated wire, plastic enclosure | | diff --git a/docs/esp32-interface.md b/docs/esp32-interface.md new file mode 100644 index 0000000..065517f --- /dev/null +++ b/docs/esp32-interface.md @@ -0,0 +1,35 @@ +# ESP32 interface + +Board: **Wemos D1 mini ESP32**, powered from the 5 V rail. + +## Level shifting + +The panel inputs are 5 V TTL and the ESP32 is 3.3 V. Use a **74HCT245** (HCT only, because it accepts 3.3 V +inputs) powered from 5 V, with DIR tied high (A→B) and OE tied low. + +## Pin plan + +| Signal (to panel, through 74HCT245) | GPIO | Notes | +|---|---|---| +| Dot clock | 18 | VSPI SCK | +| Serial dot data | 23 | VSPI MOSI | +| Column latch | 17 | | +| Row data | 16 | | +| Row clock | 26 | | +| Display enable | 22 | Pull to *off* state at the 245 input | +| HV watchdog toggle | 21 | Charge pump → relay (see safety.md) | +| +65 V monitor (optional) | 34 | ADC, 2 × 1 MΩ + 33 kΩ divider | + +The strapping pins (0, 2, 5, 12, 15) are avoided so nothing twitches during boot. + +## Panel data connector + +- [ ] Map the panel's 14-pin data connector (signal ↔ pin) for this specific panel before wiring. + +## Scanning + +- 128 columns × 32 rows, about 120 Hz frame rate (as on WPC). +- Per row: shift 128 bits of dot data (SPI), latch the columns, advance the row (row data is high + for the first row only, then clock the row once per row). +- The panel must never sit with one row lit. Scanning runs continuously, and the HV watchdog is + toggled once per scanned row (about 2 kHz, so the charge pump stays charged). diff --git a/docs/power-supply.md b/docs/power-supply.md new file mode 100644 index 0000000..6a49404 --- /dev/null +++ b/docs/power-supply.md @@ -0,0 +1,82 @@ +# Power supply design + +## Goal + +Generate every panel rail from one **12 V DC** input, using cheap modules. Panel voltages are set by +**zener references** (copied from the original Stern board), not by module trim pots. A +mis-set or failed module can't push the panel above its rated voltage. + +## The original board (Stern/Sega 520-5138-00) + +See [../reference/stern-520-5138-00-display-psu-schematic.jpg](../reference/stern-520-5138-00-display-psu-schematic.jpg). + +| CN2 pin | Label | How it is produced | Real value | +|---|---|---|---| +| 8 | +60 V | 88 VAC → D1 → C1 (about +120 V raw) → Q3 (MJE15030) emitter follower, base on D5 68 V zener | about +62–67 V | +| 1 | −120 V | 110 VAC → D2 → C2 (about −150 V raw) → Q4 (MJE15031) follower, base on D6 100 V + D7 13 V zeners | about −112 V | +| 2 | −100 V | Q5 (MJE15030) follower from the D6/D7 junction. Collector to GND via R8 2 kΩ 5 W. | about −100 V | +| 7 | +12 V | Passed through from CN1 | | +| 6 | +5 V | Passed through from CN1 | | +| 4, 5 | GND | | | + +- Q1/D3/R2/R4 and Q2/D4/R3/R5: constant-current feeds (about 2 mA) for the zener references. +- R6/R7 (330 kΩ): bleeder resistors. C3/C4/C7: 0.1 µF 500 V decoupling. + +## New design + +Full schematic: [../hardware/psu-schematic.svg](../hardware/psu-schematic.svg) (PNG alongside). +It is generated from [../hardware/psu_schematic.py](../hardware/psu_schematic.py): + +```bash +python -m pip install schemdraw matplotlib +python hardware/psu_schematic.py +``` + +The schematic's reference designators are new; the notes on the sheet map them to the original board. + +Replace the transformer and AC front end (D1, D2, C1, C2, F1, R1) with DC boost modules. Keep the +regulator section as it is. + +``` + Mains ─► [Certified 12V 3A brick] ─► F 3A ─┬──────────────► +12V (only if the panel uses it) + │ + ├─► [Mini560 5V buck] ─► +5V ─► panel logic, ESP32, 74HCT245 + │ + └─► [Relay, NO contact] ◄── HV watchdog (see safety.md) + │ + ┌──────────────┴──────────────┐ + ▼ F 1A slow ▼ F 1A slow + [NCH6100HV #1 set 90V] [Isolated 12→12V DC-DC, 6–10W] + │ │ + │ [NCH6100HV #2 set 130V] + │ out+ ─► GND + ▼ F 100mA, +90V raw ▼ F 100mA, −130V raw + ┌───────────────────────────────────────────────────┐ + │ Copy of original regulator section: │ + │ Q1/Q3/D3/D5/R2/R4 → +62–67V │ + │ Q2/Q4/D4/D6/D7/R3/R5 → −112V │ + │ Q5/R8/R10 → −100V │ + │ R6/R7 bleeders, C3/C4/C7 500V caps │ + └───────────────────────────────────────────────────┘ +``` + +### Why the isolated converter + +A boost module's output negative is shared with its input ground. Powering module #2 through an +isolated DC-DC lets its output float, so its **+ output is tied to GND** and its − output becomes +−130 V. A second certified 12 V wall adapter would also work. + +### Changes compared with the original + +- **Removed:** D1, D2, C1, C2, F1, R1 (the boost modules replace the AC front end; the module current + limit plus a 100 mA fast fuse replaces R1). +- **Added:** 10–22 µF / 250 V cap and a 330 kΩ bleeder across each raw HV rail. +- **Added:** HV-present LED (LED + 100 kΩ 1 W) on each raw HV rail. +- **Headroom:** +90 V raw feeding the 68 V-referenced stage, and −130 V raw feeding the + 113 V-referenced stage, give the followers enough headroom with modest dissipation. Q3/Q4/Q5 get small heatsinks. + +## Open questions + +- [ ] Real HV current draw of the panel, so you can size the isolated DC-DC (6 W vs 10 W) +- [ ] Panel power connector pinout and whether +12 V is used +- [ ] Check that NCH6100HV has a usable enable/shutdown pin (otherwise, switch with the relay only, as drawn) diff --git a/docs/safety.md b/docs/safety.md new file mode 100644 index 0000000..9cf1dac --- /dev/null +++ b/docs/safety.md @@ -0,0 +1,57 @@ +# Safety + +About 175 V sits between the +65 V and −112 V rails. Treat every HV node as live until you have +measured it. + +## Design measures + +1. **Only certified mains equipment.** The 12 V brick is the only mains-connected part. Buy a + certified brand (e.g. Mean Well GST36A12) from a normal retailer, not AliExpress. +2. **Hardware HV watchdog.** The relay on the HV modules' 12 V feed is driven through a charge pump: + + ``` + GPIO21 ──┤├──── A ──►|── B ───┬───────┬──── 2N7000 gate 2N7000 drain ─► relay IN (active-low) + 100nF │ 1N4148 │ │ 2N7000 source ─► GND + ┴ 1N4148 ═ 10µF ▯ 100k + ▲ (anode GND) │ │ + GND GND GND + ``` + + Node A gets a diode to GND (cathode at A), and a diode from A to B (anode at A). This rectifies + the toggling signal into a DC voltage on B. A constant high or low level gives no charge. + + The firmware toggles GPIO21 once per scanned row (about 2 kHz). If it crashes, or the pin sticks high or low, or + the ESP32 resets, the cap discharges and the relay drops within about 1 s. A stuck row can't burn the panel. + (Check the polarity of your relay module's input. Some are active-low.) +3. **Fail-safe defaults.** The relay is normally open. Put a 10 kΩ pull-down on the watchdog + path. Pull the panel ENABLE line to its *off* state at the 74HCT245 input, so a booting ESP32 + can't light anything. +4. **Sequencing.** 5 V comes up, then the ESP32 boots and starts scanning, and only then does the watchdog close the relay. +5. **Fusing.** + + | Where | Fuse | + |---|---| + | 12 V input | 3 A | + | Each HV module input | 1 A slow-blow | + | Each raw HV rail | 100 mA fast | + +6. **Discharge.** 330 kΩ bleeders on raw and regulated rails. HV-present LEDs are a hint only; + always measure before you touch anything. +7. **Layout.** + - Put all HV parts on one side, with ≥ 3 mm clearance between HV tracks. + - Use wire and caps rated for ≥ 300 V/500 V. + - Use a keyed connector to the panel. + - Close it in a plastic enclosure with no exposed HV. + - Tie all grounds at one point. +8. **Semiconductors from real distributors** (Mouser, Farnell, Reichelt). Fake HV transistors are + common on AliExpress. + +## Bring-up procedure + +1. Build the 5 V and 12 V side only. Check the voltages. +2. Connect one HV module at a time, with **no load**. Set NCH6100HV #1 to 90 V and #2 to 130 V. Lock the pots with nail varnish. +3. Connect the regulator section, still without the panel. Check for about +65 V, −112 V and −100 V and that the bleeders discharge them. +4. Test the watchdog: stop toggling GPIO21, and the HV must drop within about 1 s. +5. Map the panel's power connector against the measured rails. Get a second check (photo/label). +6. First power-up with the panel: 1 kΩ in series with each HV rail and a running test pattern. + Measure the current per rail, then remove the series resistors. diff --git a/firmware/platformio.ini b/firmware/platformio.ini new file mode 100644 index 0000000..f9b4e08 --- /dev/null +++ b/firmware/platformio.ini @@ -0,0 +1,5 @@ +[env:wemos_d1_mini32] +platform = espressif32 +board = wemos_d1_mini32 +framework = arduino +monitor_speed = 115200 diff --git a/firmware/src/main.cpp b/firmware/src/main.cpp new file mode 100644 index 0000000..679183e --- /dev/null +++ b/firmware/src/main.cpp @@ -0,0 +1,77 @@ +// Plasma DMD driver skeleton for Wemos D1 mini ESP32. +// Scans a 128x32 plasma panel continuously and toggles the HV watchdog once per row. +// Signal polarities (enable, latch, row data) are NOT yet verified against the panel. + +#include +#include + +// Pins, see docs/esp32-interface.md +constexpr int PIN_DOT_CLK = 18; // VSPI SCK +constexpr int PIN_DOT_DATA = 23; // VSPI MOSI +constexpr int PIN_COL_LATCH = 17; +constexpr int PIN_ROW_DATA = 16; +constexpr int PIN_ROW_CLK = 26; +constexpr int PIN_ENABLE = 22; +constexpr int PIN_HV_WDOG = 21; // charge pump -> HV relay + +constexpr int WIDTH = 128; +constexpr int HEIGHT = 32; +constexpr int ROW_BYTES = WIDTH / 8; + +// TODO: verify polarities on the real panel +constexpr int ENABLE_ON = HIGH; +constexpr int ENABLE_OFF = !ENABLE_ON; + +uint8_t frame[HEIGHT][ROW_BYTES]; + +static void makeTestPattern() { + for (int y = 0; y < HEIGHT; y++) + for (int b = 0; b < ROW_BYTES; b++) + frame[y][b] = ((y / 4 + b) & 1) ? 0xFF : 0x00; // checkerboard +} + +static void pulse(int pin) { + digitalWrite(pin, HIGH); + delayMicroseconds(1); + digitalWrite(pin, LOW); +} + +static void scanFrame() { + for (int y = 0; y < HEIGHT; y++) { + SPI.writeBytes(frame[y], ROW_BYTES); + + digitalWrite(PIN_ENABLE, ENABLE_OFF); // blank while switching rows + pulse(PIN_COL_LATCH); + digitalWrite(PIN_ROW_DATA, y == 0 ? HIGH : LOW); + pulse(PIN_ROW_CLK); + digitalWrite(PIN_ENABLE, ENABLE_ON); + + delayMicroseconds(200); // row on-time, ~120 Hz frame rate incl. overhead + + // Toggle per row (~2 kHz) to keep the charge pump charged. If scanning stops, HV drops. + digitalWrite(PIN_HV_WDOG, !digitalRead(PIN_HV_WDOG)); + } + digitalWrite(PIN_ENABLE, ENABLE_OFF); +} + +void setup() { + // Safe state first: display disabled, watchdog idle (HV stays off). + pinMode(PIN_ENABLE, OUTPUT); + digitalWrite(PIN_ENABLE, ENABLE_OFF); + pinMode(PIN_HV_WDOG, OUTPUT); + digitalWrite(PIN_HV_WDOG, LOW); + pinMode(PIN_COL_LATCH, OUTPUT); + pinMode(PIN_ROW_DATA, OUTPUT); + pinMode(PIN_ROW_CLK, OUTPUT); + + Serial.begin(115200); + SPI.begin(PIN_DOT_CLK, -1, PIN_DOT_DATA, -1); + SPI.setFrequency(4000000); + SPI.setDataMode(SPI_MODE0); + + makeTestPattern(); +} + +void loop() { + scanFrame(); +} diff --git a/hardware/kicad/README.md b/hardware/kicad/README.md new file mode 100644 index 0000000..1b56045 --- /dev/null +++ b/hardware/kicad/README.md @@ -0,0 +1,66 @@ +# 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 | **3.0 mm** | 0.6 mm | +| Power | GND, +12V*, +5V, +12V_PANEL | 0.3 mm | 1.0 mm | +| Default | Watchdog signals | 0.25 mm | 0.4 mm | + +## Making the PCB + +1. Open the PCB editor and choose **Tools → Update PCB from Schematic** (F8). All footprints arrive with ratsnest. +2. Draw the board outline on `Edge.Cuts`. +3. Placement tips: + - Keep the HV area (J5/J7, F4/F5, regulator, J2) on one side and the 12 V/5 V/watchdog on the other. + - Leave room for TO-220 heatsinks on Q3, Q5 and Q6. R13 (5 W) runs warm. + - Consider routed slots between the HV and low-voltage areas. +4. Run DRC. The HV class enforces 3 mm to everything. + +## 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). +- 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. diff --git a/hardware/kicad/check_netlist.py b/hardware/kicad/check_netlist.py new file mode 100644 index 0000000..c30c5d9 --- /dev/null +++ b/hardware/kicad/check_netlist.py @@ -0,0 +1,53 @@ +"""Export the netlist with kicad-cli and compare it with PARTS in gen_kicad.py. + + python hardware/kicad/check_netlist.py [path/to/kicad-cli] +""" +import re +import subprocess +import sys +from pathlib import Path + +from gen_kicad import PARTS, PROJECT, pin_cache_for, read_sexpr_block + +HERE = Path(__file__).parent +CLI = sys.argv[1] if len(sys.argv) > 1 else "C:/Users/patri/AppData/Local/Programs/KiCad/10.0/bin/kicad-cli.exe" +net_file = HERE / f"{PROJECT}.net" +subprocess.run([CLI, "sch", "export", "netlist", "-o", str(net_file), str(HERE / f"{PROJECT}.kicad_sch")], + check=True, capture_output=True) +text = net_file.read_text(encoding="utf-8") +net_file.unlink() + +# actual: (ref, pin number) -> net name +actual = {} +for m in re.finditer(r"\(net\s+\(code", text): + blk = read_sexpr_block(text, m.start()) + name = re.search(r'\(name "([^"]*)"\)', blk).group(1).lstrip("/") + for ref, pin in re.findall(r'\(node\s+\(ref "([^"]+)"\)\s+\(pin "([^"]+)"\)', blk): + actual[(ref, pin)] = name + +errors = 0 +expected = {} +for ref, lib_id, value, fp, conns, g in PARTS: + for num, name, *_ in pin_cache_for(lib_id): + key = num if num in conns else (name if name in conns else None) + if key is None or conns[key] is None: + continue + expected[(ref, num)] = conns[key] + +for k, net in expected.items(): + got = actual.get(k) + if got != net: + errors += 1 + print(f"MISMATCH {k}: expected {net}, got {got}") + +# every net should join at least two pins +by_net = {} +for k, net in actual.items(): + by_net.setdefault(net, []).append(k) +for net, nodes in sorted(by_net.items()): + if len(nodes) < 2 and not net.startswith("unconnected"): + errors += 1 + print(f"SINGLE-PIN NET {net}: {nodes}") + +print(f"{len(expected)} pins checked, {len(by_net)} nets, {errors} problem(s)") +sys.exit(1 if errors else 0) diff --git a/hardware/kicad/gen_kicad.py b/hardware/kicad/gen_kicad.py new file mode 100644 index 0000000..30d31e8 --- /dev/null +++ b/hardware/kicad/gen_kicad.py @@ -0,0 +1,333 @@ +"""Generate the KiCad schematic for the Plasma DMD PSU carrier board. + +The AliExpress modules (Mini560, 2x NCH6100HV, isolated DC-DC, relay) sit off-board and connect +through screw terminals. Symbols are copied from the installed KiCad standard libraries. +Every pin gets a short wire stub and a net label; connectivity is defined in PARTS below. + + python hardware/kicad/gen_kicad.py [path/to/kicad/share] +""" +import re +import sys +import uuid +from pathlib import Path + +HERE = Path(__file__).parent +PROJECT = "plasma_dmd_psu" +SHARE = Path(sys.argv[1] if len(sys.argv) > 1 else "C:/Users/patri/AppData/Local/Programs/KiCad/10.0/share/kicad") +SYMDIR = SHARE / "symbols" + +FP_R = "Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P10.16mm_Horizontal" +FP_R1W = "Resistor_THT:R_Axial_DIN0414_L11.9mm_D4.5mm_P15.24mm_Horizontal" +FP_R5W = "Resistor_THT:R_Axial_Power_L25.0mm_W6.4mm_P30.48mm" +FP_D35 = "Diode_THT:D_DO-35_SOD27_P7.62mm_Horizontal" +FP_D41 = "Diode_THT:D_DO-41_SOD81_P10.16mm_Horizontal" +FP_D15 = "Diode_THT:D_DO-15_P12.70mm_Horizontal" +FP_LED = "LED_THT:LED_D5.0mm" +FP_TO92 = "Package_TO_SOT_THT:TO-92_Inline" +FP_TO220 = "Package_TO_SOT_THT:TO-220-3_Vertical" +FP_FUSE = "Fuse:Fuseholder_Cylinder-5x20mm_Schurter_0031_8201_Horizontal_Open" +FP_CFILM = "Capacitor_THT:C_Rect_L18.0mm_W5.0mm_P15.00mm_FKS3_FKP3" +FP_CDISC = "Capacitor_THT:C_Disc_D5.0mm_W2.5mm_P5.00mm" +FP_CP5 = "Capacitor_THT:CP_Radial_D5.0mm_P2.00mm" +FP_CP63 = "Capacitor_THT:CP_Radial_D6.3mm_P2.50mm" +FP_CP10 = "Capacitor_THT:CP_Radial_D10.0mm_P5.00mm" +FP_CP125 = "Capacitor_THT:CP_Radial_D12.5mm_P5.00mm" +FP_HDR2 = "Connector_PinHeader_2.54mm:PinHeader_1x02_P2.54mm_Vertical" +FP_KK8 = "Connector_Molex:Molex_KK-396_A-41791-0008_1x08_P3.96mm_Vertical" +FP_HOLE = "MountingHole:MountingHole_3.2mm_M3" + + +def tb(n): + return f"TerminalBlock_Phoenix:TerminalBlock_Phoenix_MKDS-1,5-{n}-5.08_1x{n:02d}_P5.08mm_Horizontal" + + +# (ref, lib_id, value, footprint, {pin number or name: net}, group) +PARTS = [ + # 1. Input and +5 V + ("J1", "Connector:Screw_Terminal_01x02", "12V DC in", tb(2), {"1": "+12V_IN", "2": "GND"}, 0), + ("F1", "Device:Fuse", "3A T", FP_FUSE, {"1": "+12V_IN", "2": "+12V"}, 0), + ("D1", "Device:D_TVS", "P6KE15A", FP_D15, {"1": "+12V", "2": "GND"}, 0), + ("C1", "Device:C_Polarized", "470uF 25V", FP_CP10, {"1": "+12V", "2": "GND"}, 0), + ("J3", "Connector:Screw_Terminal_01x04", "Mini560 5V: IN+ IN- OUT+ OUT-", tb(4), + {"1": "+12V", "2": "GND", "3": "+5V", "4": "GND"}, 0), + ("C2", "Device:C_Polarized", "100uF 10V", FP_CP63, {"1": "+5V", "2": "GND"}, 0), + # 2. HV enable + watchdog + ("J8", "Connector:Screw_Terminal_01x03", "ESP32: 5V GND GPIO21", tb(3), + {"1": "+5V", "2": "GND", "3": "WDOG_IN"}, 1), + ("C3", "Device:C", "100nF", FP_CDISC, {"1": "WDOG_IN", "2": "WDOG_A"}, 1), + ("D3", "Device:D", "1N4148", FP_D35, {"K": "WDOG_A", "A": "GND"}, 1), + ("D2", "Device:D", "1N4148", FP_D35, {"A": "WDOG_A", "K": "WDOG_B"}, 1), + ("C4", "Device:C_Polarized", "10uF 16V", FP_CP5, {"1": "WDOG_B", "2": "GND"}, 1), + ("R1", "Device:R", "100k", FP_R, {"1": "WDOG_B", "2": "GND"}, 1), + ("Q1", "Transistor_FET:2N7000", "2N7000", FP_TO92, {"G": "WDOG_B", "S": "GND", "D": "RELAY_IN"}, 1), + ("J4", "Connector:Screw_Terminal_01x05", "Relay module: VCC GND IN COM NO", tb(5), + {"1": "+5V", "2": "GND", "3": "RELAY_IN", "4": "+12V", "5": "+12V_HV"}, 1), + ("F2", "Device:Fuse", "1A T", FP_FUSE, {"1": "+12V_HV", "2": "+12V_HVP"}, 1), + ("F3", "Device:Fuse", "1A T", FP_FUSE, {"1": "+12V_HV", "2": "+12V_HVN"}, 1), + # 3. Positive HV + ("J5", "Connector:Screw_Terminal_01x03", "NCH6100HV #1 (90V): VIN GND HV+", tb(3), + {"1": "+12V_HVP", "2": "GND", "3": "HVP_MOD"}, 2), + ("F4", "Device:Fuse", "100mA F", FP_FUSE, {"1": "HVP_MOD", "2": "+90V_RAW"}, 2), + ("C5", "Device:C_Polarized", "22uF 250V", FP_CP125, {"1": "+90V_RAW", "2": "GND"}, 2), + ("R2", "Device:R", "330k", FP_R, {"1": "+90V_RAW", "2": "GND"}, 2), + ("R3", "Device:R", "100k 1W", FP_R1W, {"1": "+90V_RAW", "2": "N_LED1"}, 2), + ("LED1", "Device:LED", "HV on", FP_LED, {"A": "N_LED1", "K": "GND"}, 2), + ("D4", "Device:D_Zener", "1N5228 3.9V", FP_D35, {"K": "+90V_RAW", "A": "REF_P"}, 2), + ("R5", "Device:R", "47k 1W", FP_R1W, {"1": "REF_P", "2": "GND"}, 2), + ("R4", "Device:R", "1.5k", FP_R, {"1": "+90V_RAW", "2": "Q2_E"}, 2), + ("Q2", "Transistor_BJT:Q_PNP_EBC", "MPSA92", FP_TO92, {"E": "Q2_E", "B": "REF_P", "C": "Q3_B"}, 2), + ("D5", "Device:D_Zener", "1N4760A 68V", FP_D41, {"K": "Q3_B", "A": "GND"}, 2), + ("Q3", "Transistor_BJT:Q_NPN_BCE", "MJE15030", FP_TO220, {"C": "+90V_RAW", "B": "Q3_B", "E": "+65V"}, 2), + ("C6", "Device:C", "0.1uF 500V", FP_CFILM, {"1": "+65V", "2": "GND"}, 2), + ("R6", "Device:R", "330k", FP_R, {"1": "+65V", "2": "GND"}, 2), + # 4. Negative HV + ("J6", "Connector:Screw_Terminal_01x02", "Isolated DC-DC in: VIN GND", tb(2), + {"1": "+12V_HVN", "2": "GND"}, 3), + ("J7", "Connector:Screw_Terminal_01x02", "NCH6100HV #2 (130V) out: HV+ GND", tb(2), + {"1": "GND", "2": "HVN_MOD"}, 3), + ("F5", "Device:Fuse", "100mA F", FP_FUSE, {"1": "HVN_MOD", "2": "-130V_RAW"}, 3), + ("C7", "Device:C_Polarized", "22uF 250V", FP_CP125, {"1": "GND", "2": "-130V_RAW"}, 3), + ("R7", "Device:R", "330k", FP_R, {"1": "GND", "2": "-130V_RAW"}, 3), + ("R8", "Device:R", "100k 1W", FP_R1W, {"1": "N_LED2", "2": "-130V_RAW"}, 3), + ("LED2", "Device:LED", "HV on", FP_LED, {"A": "GND", "K": "N_LED2"}, 3), + ("D6", "Device:D_Zener", "1N5228 3.9V", FP_D35, {"K": "REF_N", "A": "-130V_RAW"}, 3), + ("R10", "Device:R", "47k 1W", FP_R1W, {"1": "GND", "2": "REF_N"}, 3), + ("R9", "Device:R", "1.5k", FP_R, {"1": "Q4_E", "2": "-130V_RAW"}, 3), + ("Q4", "Transistor_BJT:Q_NPN_EBC", "MPSA42", FP_TO92, {"E": "Q4_E", "B": "REF_N", "C": "Q5_B"}, 3), + ("D7", "Device:D_Zener", "1N4743 13V", FP_D41, {"K": "REF_M", "A": "Q5_B"}, 3), + ("D8", "Device:D_Zener", "1N4764A 100V", FP_D41, {"K": "GND", "A": "REF_M"}, 3), + ("Q5", "Transistor_BJT:Q_PNP_BCE", "MJE15031", FP_TO220, {"B": "Q5_B", "C": "-130V_RAW", "E": "-112V"}, 3), + ("C8", "Device:C", "0.1uF 500V", FP_CFILM, {"1": "GND", "2": "-112V"}, 3), + ("R11", "Device:R", "330k", FP_R, {"1": "GND", "2": "-112V"}, 3), + ("R12", "Device:R", "1.5k", FP_R, {"1": "REF_M", "2": "Q6_B"}, 3), + ("Q6", "Transistor_BJT:Q_NPN_BCE", "MJE15030", FP_TO220, {"B": "Q6_B", "C": "Q6_C", "E": "-100V"}, 3), + ("R13", "Device:R", "2k 5W", FP_R5W, {"1": "GND", "2": "Q6_C"}, 3), + ("C9", "Device:C", "0.1uF 500V", FP_CFILM, {"1": "GND", "2": "-100V"}, 3), + # 5. Panel connector (Stern 520-5138 CN2 order; verify against your panel!) + ("J2", "Connector_Generic:Conn_01x08", "Panel power (Stern CN2 order)", FP_KK8, + {"1": "-112V", "2": "-100V", "3": None, "4": "GND", "5": "GND", "6": "+5V", "7": "+12V_PANEL", "8": "+65V"}, 4), + ("JP1", "Connector_Generic:Conn_01x02", "Fit if panel uses +12V", FP_HDR2, + {"1": "+12V", "2": "+12V_PANEL"}, 4), + ("H1", "Mechanical:MountingHole", "M3", FP_HOLE, {}, 4), + ("H2", "Mechanical:MountingHole", "M3", FP_HOLE, {}, 4), + ("H3", "Mechanical:MountingHole", "M3", FP_HOLE, {}, 4), + ("H4", "Mechanical:MountingHole", "M3", FP_HOLE, {}, 4), +] + +GROUP_TITLES = [ + "1. 12 V input and +5 V (Mini560 off-board)", + "2. HV enable relay + hardware watchdog (relay module off-board)", + "3. Positive HV: NCH6100HV #1 off-board + original regulator -> +65 V", + "4. Negative HV: isolated DC-DC + NCH6100HV #2 off-board (FLOATING at -130 V) + regulator -> -112 / -100 V", + "5. Panel connector and mounting", +] +COLS = 7 # parts per row inside a group +DX, DY = 50.8, 27.94 +GROUP_GAP = 12.7 + + +def group_origins(): + """Stack the groups vertically, each as tall as its number of part rows.""" + y, out = 33.02, [] + for g in range(len(GROUP_TITLES)): + n = sum(1 for p in PARTS if p[5] == g) + out.append((25.4, y)) + y += 12.7 + -(-n // COLS) * DY + GROUP_GAP + return out + + +GROUPS = list(zip(GROUP_TITLES, group_origins())) + +NOTES = """Plasma DMD - 12 V DC PSU carrier board (rev 0.1, unverified) +Connectivity is by net labels: every pin has a stub + label. Off-board modules connect via J3-J7. +Panel voltages are set by zeners D5 (68 V -> about +65 V) and D7+D8 (113 V -> about -112 / -100 V), copied from Stern 520-5138-00. +SAFETY: keep >= 3 mm clearance (more is better) between HV nets (+90V_RAW, +65V, -130V_RAW, -112V, -100V, HVN_MOD, HVP_MOD) and low-voltage nets. +J2 pin order follows the Stern CN2 connector: map it to YOUR panel before use. Pin 3 is the key position.""" + + +# --------------------------------------------------------------------------- +def uid(): + return str(uuid.uuid4()) + + +def read_sexpr_block(text, start): + depth, i = 0, start + in_str = False + while True: + ch = text[i] + if in_str: + if ch == "\\": + i += 1 + elif ch == '"': + in_str = False + elif ch == '"': + in_str = True + elif ch == "(": + depth += 1 + elif ch == ")": + depth -= 1 + if depth == 0: + return text[start:i + 1] + i += 1 + + +_libcache = {} + + +def lib_symbol(lib_id): + lib, name = lib_id.split(":") + if lib not in _libcache: + _libcache[lib] = (SYMDIR / f"{lib}.kicad_sym").read_text(encoding="utf-8") + text = _libcache[lib] + m = re.search(r'\(symbol "' + re.escape(name) + r'"', text) + if not m: + raise KeyError(lib_id) + block = read_sexpr_block(text, m.start()) + ext = re.search(r'\(extends "([^"]+)"\)', block) + if ext: + raise ValueError(f"{lib_id} extends {ext.group(1)}; pick a non-derived symbol") + # top-level name gets the library prefix; sub-units keep the bare name + return block.replace(f'(symbol "{name}"', f'(symbol "{lib_id}"', 1) + + +def pins_of(block): + """Return list of (number, name, x, y, angle) from a symbol block (symbol coords, y up).""" + out = [] + for m in re.finditer(r'\(pin \w+ \w+\s*\(at ([-\d.]+) ([-\d.]+) ([-\d.]+)\)', block): + pb = read_sexpr_block(block, m.start()) + name = re.search(r'\(name "([^"]*)"', pb).group(1) + num = re.search(r'\(number "([^"]*)"', pb).group(1) + out.append((num, name, float(m.group(1)), float(m.group(2)), float(m.group(3)))) + return out + + +def pin_cache_for(lib_id): + return pins_of(lib_symbol(lib_id)) + + +def q(s): + return '"' + s.replace("\\", "\\\\").replace('"', '\\"').replace("\n", "\\n") + '"' + + +def snap(v): + return round(round(v / 1.27) * 1.27, 2) + + +HV_NETS = ["+90V_RAW", "+65V", "HVP_MOD", "Q2_E", "REF_P", "Q3_B", "N_LED1", + "-130V_RAW", "-112V", "-100V", "HVN_MOD", "Q4_E", "REF_N", "Q5_B", "REF_M", "Q6_B", "Q6_C", "N_LED2"] +POWER_NETS = ["GND", "+12V", "+12V_IN", "+12V_HV", "+12V_HVP", "+12V_HVN", "+5V", "+12V_PANEL"] + + +def netclass(name, clearance, track, priority): + return {"bus_width": 12, "clearance": clearance, "diff_pair_gap": 0.25, "diff_pair_via_gap": 0.25, + "diff_pair_width": 0.2, "line_style": 0, "microvia_diameter": 0.3, "microvia_drill": 0.1, + "name": name, "pcb_color": "rgba(0, 0, 0, 0.000)", "priority": priority, + "schematic_color": "rgba(0, 0, 0, 0.000)", "track_width": track, "tuning_profile": "", + "via_diameter": 1.0, "via_drill": 0.5, "wire_width": 6} + + +def write_project(): + """Create/update the .kicad_pro with net classes. HV nets get 3 mm clearance to everything.""" + import json + pro = HERE / f"{PROJECT}.kicad_pro" + data = json.loads(pro.read_text(encoding="utf-8")) if pro.exists() else {} + data.setdefault("meta", {"filename": pro.name, "version": 3}) + data["net_settings"] = { + "classes": [ + netclass("Default", 0.25, 0.4, 2147483647), + netclass("Power", 0.3, 1.0, 1), + netclass("HV", 3.0, 0.6, 0), + ], + "meta": {"version": 5}, + "net_colors": None, + "netclass_assignments": None, + "netclass_patterns": [{"netclass": "HV", "pattern": "/" + n} for n in HV_NETS] + + [{"netclass": "Power", "pattern": "/" + n} for n in POWER_NETS], + } + pro.write_text(json.dumps(data, indent=2) + "\n", encoding="utf-8") + + +def main(): + root = uid() + lib_blocks, pin_cache = {}, {} + for p in PARTS: + if p[1] not in lib_blocks: + blk = lib_symbol(p[1]) + lib_blocks[p[1]] = blk + pin_cache[p[1]] = pins_of(blk) + + items = [] + counts = {} + for ref, lib_id, value, fp, conns, g in PARTS: + i = counts.get(g, 0) + counts[g] = i + 1 + gx, gy = GROUPS[g][1] + x = snap(gx + 12.7 + (i % COLS) * DX) + y = snap(gy + 12.7 + (i // COLS) * DY) + pins = pin_cache[lib_id] + # Ref/value go beside the part: above it when a net label sticks out to the right + # (horizontal two-pin parts), otherwise to the right of the body. + if any(int(a) % 360 == 180 for *_, a in pins): + rx, ry, vx, vy, just = x, snap(y - 6.35), x, snap(y - 4.445), "" + else: + rx, ry, vx, vy, just = snap(x + 5.08), snap(y - 1.27), snap(x + 5.08), snap(y + 1.27), " (justify left)" + pin_uuid = "\n".join(f' (pin {q(num)} (uuid {q(uid())}))' for num, *_ in pins) + items.append(f""" (symbol (lib_id {q(lib_id)}) (at {x} {y} 0) (unit 1) + (exclude_from_sim no) (in_bom yes) (on_board yes) (dnp no) (uuid {q(uid())}) + (property "Reference" {q(ref)} (at {rx} {ry} 0) (effects (font (size 1.27 1.27)){just})) + (property "Value" {q(value)} (at {vx} {vy} 0) (effects (font (size 1.27 1.27)){just})) + (property "Footprint" {q(fp)} (at {x} {y} 0) (effects (font (size 1.27 1.27)) (hide yes))) + (property "Datasheet" "" (at {x} {y} 0) (effects (font (size 1.27 1.27)) (hide yes))) +{pin_uuid} + (instances (project {q(PROJECT)} (path {q('/' + root)} (reference {q(ref)}) (unit 1)))) + )""") + used = set() + for num, name, px, py, ang in pins: + key = num if num in conns else (name if name in conns else None) + if key is None: + if conns: + raise KeyError(f"{ref}: pin {num}/{name} not connected in PARTS") + continue + used.add(key) + net = conns[key] + cx, cy = round(x + px, 2), round(y - py, 2) # schematic y is down + # stub points away from the body (pin angle points from connection point toward body) + dx, dy = {0: (-1, 0), 90: (0, 1), 180: (1, 0), 270: (0, -1)}[int(ang) % 360] + ex, ey = round(cx + dx * 2.54, 2), round(cy + dy * 2.54, 2) + if net is None: + items.append(f' (no_connect (at {cx} {cy}) (uuid {q(uid())}))') + continue + items.append(f' (wire (pts (xy {cx} {cy}) (xy {ex} {ey})) (stroke (width 0) (type default)) (uuid {q(uid())}))') + lang, just = {(-1, 0): (180, "right"), (1, 0): (0, "left"), + (0, -1): (90, "left"), (0, 1): (270, "right")}[(dx, dy)] + items.append(f' (label {q(net)} (at {ex} {ey} {lang}) (fields_autoplaced yes)' + f' (effects (font (size 1.27 1.27)) (justify {just} bottom)) (uuid {q(uid())}))') + missing = set(conns) - used + if missing: + raise KeyError(f"{ref}: unknown pins {missing}") + + for title, (gx, gy) in GROUPS: + items.append(f' (text {q(title)} (exclude_from_sim no) (at {gx} {gy} 0)' + f' (effects (font (size 2.54 2.54) (bold yes)) (justify left bottom)) (uuid {q(uid())}))') + items.append(f' (text {q(NOTES)} (exclude_from_sim no) (at 25.4 12.7 0)' + f' (effects (font (size 1.778 1.778)) (justify left top)) (uuid {q(uid())}))') + + libs = "\n".join(" " + b.replace("\n", "\n ") for b in lib_blocks.values()) + sch = f"""(kicad_sch (version 20260101) (generator "plasma_dmd_gen") (generator_version "1.0") + (uuid {q(root)}) + (paper "A2") + (title_block (title "Plasma DMD 12 V DC PSU") (rev "0.1") (comment 1 "Unverified - see notes")) + (lib_symbols +{libs} + ) +{chr(10).join(items)} + (sheet_instances (path "/" (page "1"))) +) +""" + (HERE / f"{PROJECT}.kicad_sch").write_text(sch, encoding="utf-8") + write_project() + print(f"wrote {PROJECT}.kicad_sch with {len(PARTS)} parts") + + +if __name__ == "__main__": + main() diff --git a/hardware/kicad/plasma_dmd_psu.kicad_pro b/hardware/kicad/plasma_dmd_psu.kicad_pro new file mode 100644 index 0000000..7c612be --- /dev/null +++ b/hardware/kicad/plasma_dmd_psu.kicad_pro @@ -0,0 +1,178 @@ +{ + "meta": { + "filename": "plasma_dmd_psu.kicad_pro", + "version": 3 + }, + "net_settings": { + "classes": [ + { + "bus_width": 12, + "clearance": 0.25, + "diff_pair_gap": 0.25, + "diff_pair_via_gap": 0.25, + "diff_pair_width": 0.2, + "line_style": 0, + "microvia_diameter": 0.3, + "microvia_drill": 0.1, + "name": "Default", + "pcb_color": "rgba(0, 0, 0, 0.000)", + "priority": 2147483647, + "schematic_color": "rgba(0, 0, 0, 0.000)", + "track_width": 0.4, + "tuning_profile": "", + "via_diameter": 1.0, + "via_drill": 0.5, + "wire_width": 6 + }, + { + "bus_width": 12, + "clearance": 0.3, + "diff_pair_gap": 0.25, + "diff_pair_via_gap": 0.25, + "diff_pair_width": 0.2, + "line_style": 0, + "microvia_diameter": 0.3, + "microvia_drill": 0.1, + "name": "Power", + "pcb_color": "rgba(0, 0, 0, 0.000)", + "priority": 1, + "schematic_color": "rgba(0, 0, 0, 0.000)", + "track_width": 1.0, + "tuning_profile": "", + "via_diameter": 1.0, + "via_drill": 0.5, + "wire_width": 6 + }, + { + "bus_width": 12, + "clearance": 3.0, + "diff_pair_gap": 0.25, + "diff_pair_via_gap": 0.25, + "diff_pair_width": 0.2, + "line_style": 0, + "microvia_diameter": 0.3, + "microvia_drill": 0.1, + "name": "HV", + "pcb_color": "rgba(0, 0, 0, 0.000)", + "priority": 0, + "schematic_color": "rgba(0, 0, 0, 0.000)", + "track_width": 0.6, + "tuning_profile": "", + "via_diameter": 1.0, + "via_drill": 0.5, + "wire_width": 6 + } + ], + "meta": { + "version": 5 + }, + "net_colors": null, + "netclass_assignments": null, + "netclass_patterns": [ + { + "netclass": "HV", + "pattern": "/+90V_RAW" + }, + { + "netclass": "HV", + "pattern": "/+65V" + }, + { + "netclass": "HV", + "pattern": "/HVP_MOD" + }, + { + "netclass": "HV", + "pattern": "/Q2_E" + }, + { + "netclass": "HV", + "pattern": "/REF_P" + }, + { + "netclass": "HV", + "pattern": "/Q3_B" + }, + { + "netclass": "HV", + "pattern": "/N_LED1" + }, + { + "netclass": "HV", + "pattern": "/-130V_RAW" + }, + { + "netclass": "HV", + "pattern": "/-112V" + }, + { + "netclass": "HV", + "pattern": "/-100V" + }, + { + "netclass": "HV", + "pattern": "/HVN_MOD" + }, + { + "netclass": "HV", + "pattern": "/Q4_E" + }, + { + "netclass": "HV", + "pattern": "/REF_N" + }, + { + "netclass": "HV", + "pattern": "/Q5_B" + }, + { + "netclass": "HV", + "pattern": "/REF_M" + }, + { + "netclass": "HV", + "pattern": "/Q6_B" + }, + { + "netclass": "HV", + "pattern": "/Q6_C" + }, + { + "netclass": "HV", + "pattern": "/N_LED2" + }, + { + "netclass": "Power", + "pattern": "/GND" + }, + { + "netclass": "Power", + "pattern": "/+12V" + }, + { + "netclass": "Power", + "pattern": "/+12V_IN" + }, + { + "netclass": "Power", + "pattern": "/+12V_HV" + }, + { + "netclass": "Power", + "pattern": "/+12V_HVP" + }, + { + "netclass": "Power", + "pattern": "/+12V_HVN" + }, + { + "netclass": "Power", + "pattern": "/+5V" + }, + { + "netclass": "Power", + "pattern": "/+12V_PANEL" + } + ] + } +} diff --git a/hardware/kicad/plasma_dmd_psu.kicad_sch b/hardware/kicad/plasma_dmd_psu.kicad_sch new file mode 100644 index 0000000..bb37e4a --- /dev/null +++ b/hardware/kicad/plasma_dmd_psu.kicad_sch @@ -0,0 +1,5140 @@ +(kicad_sch (version 20260101) (generator "plasma_dmd_gen") (generator_version "1.0") + (uuid "d8fec46f-dde9-4522-8610-66699deb1f29") + (paper "A2") + (title_block (title "Plasma DMD 12 V DC PSU") (rev "0.1") (comment 1 "Unverified - see notes")) + (lib_symbols + (symbol "Connector:Screw_Terminal_01x02" + (pin_names + (offset 1.016) + (hide yes) + ) + (exclude_from_sim no) + (in_bom yes) + (on_board yes) + (in_pos_files yes) + (duplicate_pin_numbers_are_jumpers no) + (property "Reference" "J" + (at 0 2.54 0) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Value" "Screw_Terminal_01x02" + (at 0 -5.08 0) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Footprint" "" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Datasheet" "" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Description" "Generic screw terminal, single row, 01x02, script generated (kicad-library-utils/schlib/autogen/connector/)" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "ki_keywords" "screw terminal" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "ki_fp_filters" "TerminalBlock*:*" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (symbol "Screw_Terminal_01x02_1_1" + (rectangle + (start -1.27 1.27) + (end 1.27 -3.81) + (stroke + (width 0.254) + (type default) + ) + (fill + (type background) + ) + ) + (polyline + (pts + (xy -0.5334 0.3302) (xy 0.3302 -0.508) + ) + (stroke + (width 0.1524) + (type default) + ) + (fill + (type none) + ) + ) + (polyline + (pts + (xy -0.5334 -2.2098) (xy 0.3302 -3.048) + ) + (stroke + (width 0.1524) + (type default) + ) + (fill + (type none) + ) + ) + (polyline + (pts + (xy -0.3556 0.508) (xy 0.508 -0.3302) + ) + (stroke + (width 0.1524) + (type default) + ) + (fill + (type none) + ) + ) + (polyline + (pts + (xy -0.3556 -2.032) (xy 0.508 -2.8702) + ) + (stroke + (width 0.1524) + (type default) + ) + (fill + (type none) + ) + ) + (circle + (center 0 0) + (radius 0.635) + (stroke + (width 0.1524) + (type default) + ) + (fill + (type none) + ) + ) + (circle + (center 0 -2.54) + (radius 0.635) + (stroke + (width 0.1524) + (type default) + ) + (fill + (type none) + ) + ) + (pin passive line + (at -5.08 0 0) + (length 3.81) + (name "Pin_1" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (number "1" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + ) + (pin passive line + (at -5.08 -2.54 0) + (length 3.81) + (name "Pin_2" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (number "2" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + ) + ) + (embedded_fonts no) + ) + (symbol "Device:Fuse" + (pin_numbers + (hide yes) + ) + (pin_names + (offset 0) + ) + (exclude_from_sim no) + (in_bom yes) + (on_board yes) + (in_pos_files yes) + (duplicate_pin_numbers_are_jumpers no) + (property "Reference" "F" + (at 2.032 0 90) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Value" "Fuse" + (at -1.905 0 90) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Footprint" "" + (at -1.778 0 90) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Datasheet" "" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Description" "Fuse" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "ki_keywords" "fuse" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "ki_fp_filters" "*Fuse*" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (symbol "Fuse_0_1" + (rectangle + (start -0.762 -2.54) + (end 0.762 2.54) + (stroke + (width 0.254) + (type default) + ) + (fill + (type none) + ) + ) + (polyline + (pts + (xy 0 2.54) (xy 0 -2.54) + ) + (stroke + (width 0) + (type default) + ) + (fill + (type none) + ) + ) + ) + (symbol "Fuse_1_1" + (pin passive line + (at 0 3.81 270) + (length 1.27) + (name "" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (number "1" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + ) + (pin passive line + (at 0 -3.81 90) + (length 1.27) + (name "" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (number "2" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + ) + ) + (embedded_fonts no) + ) + (symbol "Device:D_TVS" + (pin_numbers + (hide yes) + ) + (pin_names + (offset 1.016) + (hide yes) + ) + (exclude_from_sim no) + (in_bom yes) + (on_board yes) + (in_pos_files yes) + (duplicate_pin_numbers_are_jumpers no) + (property "Reference" "D" + (at 0 2.54 0) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Value" "D_TVS" + (at 0 -2.54 0) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Footprint" "" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Datasheet" "" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Description" "Bidirectional transient-voltage-suppression diode" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "ki_keywords" "diode TVS thyrector" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "ki_fp_filters" "TO-???* *_Diode_* *SingleDiode* D_*" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (symbol "D_TVS_0_1" + (polyline + (pts + (xy -2.54 1.27) (xy -2.54 -1.27) (xy 2.54 1.27) (xy 2.54 -1.27) (xy -2.54 1.27) + ) + (stroke + (width 0.254) + (type default) + ) + (fill + (type none) + ) + ) + (polyline + (pts + (xy 0.508 1.27) (xy 0 1.27) (xy 0 -1.27) (xy -0.508 -1.27) + ) + (stroke + (width 0.254) + (type default) + ) + (fill + (type none) + ) + ) + (polyline + (pts + (xy 1.27 0) (xy -1.27 0) + ) + (stroke + (width 0) + (type default) + ) + (fill + (type none) + ) + ) + ) + (symbol "D_TVS_1_1" + (pin passive line + (at -3.81 0 0) + (length 2.54) + (name "A1" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (number "1" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + ) + (pin passive line + (at 3.81 0 180) + (length 2.54) + (name "A2" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (number "2" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + ) + ) + (embedded_fonts no) + ) + (symbol "Device:C_Polarized" + (pin_numbers + (hide yes) + ) + (pin_names + (offset 0.254) + ) + (exclude_from_sim no) + (in_bom yes) + (on_board yes) + (in_pos_files yes) + (duplicate_pin_numbers_are_jumpers no) + (property "Reference" "C" + (at 0.635 2.54 0) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + (justify left) + ) + ) + (property "Value" "C_Polarized" + (at 0.635 -2.54 0) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + (justify left) + ) + ) + (property "Footprint" "" + (at 0.9652 -3.81 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Datasheet" "" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Description" "Polarized capacitor" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "ki_keywords" "cap capacitor" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "ki_fp_filters" "CP_*" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (symbol "C_Polarized_0_1" + (rectangle + (start -2.286 0.508) + (end 2.286 1.016) + (stroke + (width 0) + (type default) + ) + (fill + (type none) + ) + ) + (polyline + (pts + (xy -1.778 2.286) (xy -0.762 2.286) + ) + (stroke + (width 0) + (type default) + ) + (fill + (type none) + ) + ) + (polyline + (pts + (xy -1.27 2.794) (xy -1.27 1.778) + ) + (stroke + (width 0) + (type default) + ) + (fill + (type none) + ) + ) + (rectangle + (start 2.286 -0.508) + (end -2.286 -1.016) + (stroke + (width 0) + (type default) + ) + (fill + (type outline) + ) + ) + ) + (symbol "C_Polarized_1_1" + (pin passive line + (at 0 3.81 270) + (length 2.794) + (name "" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (number "1" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + ) + (pin passive line + (at 0 -3.81 90) + (length 2.794) + (name "" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (number "2" + (effects + (font + (size 1.27 1.27) + ) + ) + ) + ) + ) + (embedded_fonts no) + ) + (symbol "Connector:Screw_Terminal_01x04" + (pin_names + (offset 1.016) + (hide yes) + ) + (exclude_from_sim no) + (in_bom yes) + (on_board yes) + (in_pos_files yes) + (duplicate_pin_numbers_are_jumpers no) + (property "Reference" "J" + (at 0 5.08 0) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Value" "Screw_Terminal_01x04" + (at 0 -7.62 0) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Footprint" "" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Datasheet" "" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Description" "Generic screw terminal, single row, 01x04, script generated (kicad-library-utils/schlib/autogen/connector/)" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "ki_keywords" "screw terminal" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "ki_fp_filters" "TerminalBlock*:*" + (at 0 0 0) + (show_name no) + (do_not_autoplace no) + (hide yes) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (symbol "Screw_Terminal_01x04_1_1" + (rectangle + (start -1.27 3.81) + (end 1.27 -6.35) + (stroke + (width 0.254) + (type default) + ) + (fill + (type background) + ) + ) + (polyline + (pts + (xy -0.5334 2.8702) (xy 0.3302 2.032) + ) + (stroke + (width 0.1524) + (type default) + ) + (fill + (type none) + ) + ) + (polyline + (pts + (xy -0.5334 0.3302) (xy 0.3302 -0.508) + ) + (stroke + (width 0.1524) + (type default) + ) + (fill + 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"M3" (at 297.18 372.11 0) (effects (font (size 1.27 1.27)) (justify left))) + (property "Footprint" "MountingHole:MountingHole_3.2mm_M3" (at 292.1 370.84 0) (effects (font (size 1.27 1.27)) (hide yes))) + (property "Datasheet" "" (at 292.1 370.84 0) (effects (font (size 1.27 1.27)) (hide yes))) + + (instances (project "plasma_dmd_psu" (path "/d8fec46f-dde9-4522-8610-66699deb1f29" (reference "H4") (unit 1)))) + ) + (text "1. 12 V input and +5 V (Mini560 off-board)" (exclude_from_sim no) (at 25.4 33.02 0) (effects (font (size 2.54 2.54) (bold yes)) (justify left bottom)) (uuid "70cfdd46-d1e5-4d24-9682-ae12348896bf")) + (text "2. HV enable relay + hardware watchdog (relay module off-board)" (exclude_from_sim no) (at 25.4 86.36000000000001 0) (effects (font (size 2.54 2.54) (bold yes)) (justify left bottom)) (uuid "47c0aac3-bb2b-49ec-a5d6-4dfbc6673f28")) + (text "3. Positive HV: NCH6100HV #1 off-board + original regulator -> +65 V" (exclude_from_sim no) (at 25.4 167.64000000000001 0) (effects (font (size 2.54 2.54) (bold yes)) (justify left bottom)) (uuid "0f002229-234a-4373-9719-a6a64e8897dd")) + (text "4. Negative HV: isolated DC-DC + NCH6100HV #2 off-board (FLOATING at -130 V) + regulator -> -112 / -100 V" (exclude_from_sim no) (at 25.4 248.92000000000002 0) (effects (font (size 2.54 2.54) (bold yes)) (justify left bottom)) (uuid "6641c0fe-ef79-4e30-950d-257d0caed8d6")) + (text "5. Panel connector and mounting" (exclude_from_sim no) (at 25.4 358.14000000000004 0) (effects (font (size 2.54 2.54) (bold yes)) (justify left bottom)) (uuid "eef882bc-b452-4fe7-94e7-06dbae79a513")) + (text "Plasma DMD - 12 V DC PSU carrier board (rev 0.1, unverified)\nConnectivity is by net labels: every pin has a stub + label. Off-board modules connect via J3-J7.\nPanel voltages are set by zeners D5 (68 V -> about +65 V) and D7+D8 (113 V -> about -112 / -100 V), copied from Stern 520-5138-00.\nSAFETY: keep >= 3 mm clearance (more is better) between HV nets (+90V_RAW, +65V, -130V_RAW, -112V, -100V, HVN_MOD, HVP_MOD) and low-voltage nets.\nJ2 pin order follows the Stern CN2 connector: map it to YOUR panel before use. Pin 3 is the key position." (exclude_from_sim no) (at 25.4 12.7 0) (effects (font (size 1.778 1.778)) (justify left top)) (uuid "51aecf87-c719-466d-9e1f-46dc457f9439")) + (sheet_instances (path "/" (page "1"))) +) diff --git a/hardware/kicad/plasma_dmd_psu.pdf b/hardware/kicad/plasma_dmd_psu.pdf new file mode 100644 index 0000000..ba205ff Binary files /dev/null and b/hardware/kicad/plasma_dmd_psu.pdf differ diff --git a/hardware/psu-schematic.png b/hardware/psu-schematic.png new file mode 100644 index 0000000..abc7fc7 Binary files /dev/null and b/hardware/psu-schematic.png differ diff --git a/hardware/psu-schematic.svg b/hardware/psu-schematic.svg new file mode 100644 index 0000000..dd26525 --- /dev/null +++ b/hardware/psu-schematic.svg @@ -0,0 +1,7393 @@ + + + + + + + + 2026-10-24T02:22:25.512787 + image/svg+xml + + + Matplotlib v3.11.2, https://matplotlib.org/ + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + 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+ + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + diff --git a/hardware/psu_schematic.py b/hardware/psu_schematic.py new file mode 100644 index 0000000..b4909fc --- /dev/null +++ b/hardware/psu_schematic.py @@ -0,0 +1,319 @@ +"""Generate the PSU schematic (SVG + PNG) with schemdraw. + + python -m pip install schemdraw matplotlib + python hardware/psu_schematic.py +""" +from pathlib import Path + +import schemdraw +import schemdraw.elements as elm + +OUT = Path(__file__).parent +schemdraw.use("matplotlib") + + +def gnd(d, at): + """Ground symbol pointing down (for parts hanging below a node).""" + d.add(elm.Ground().theta(0).at(at)) + + +def gnd_up(d, at): + """Ground symbol pointing up (for parts standing on a negative rail).""" + d.add(elm.Ground().theta(180).at(at)) + + +def vdd(d, at, name): + d.add(elm.Vdd().theta(0).at(at).label(name)) + + +def ic(left, right, label, bottom=(), top=()): + pins = [elm.IcPin(name=n, side="left") for n in left] + pins += [elm.IcPin(name=n, side="right") for n in right] + pins += [elm.IcPin(name=n, side="bottom") for n in bottom] + pins += [elm.IcPin(name=n, side="top") for n in top] + return elm.Ic(pins=pins, pinspacing=1.2, edgepadH=0.6, edgepadW=1.2).right().label(label, "top") + + +def title(d, at, text): + d.add(elm.Label().at(at).label(text, fontsize=12, halign="left", valign="bottom")) + + +def note(d, at, text, size=9, color="black"): + d.add(elm.Label().at(at).label(text, fontsize=size, halign="left", valign="top", color=color)) + + +# For vertical parts schemdraw's "left"/"right" label locations are the part's ends; +# these give the visual side instead. A .reverse()d part swaps its sides again. +R_DOWN, L_DOWN, R_UP, L_UP = "bottom", "top", "bottom", "top" + + +def shunt_down(d, at, part, label): + """part is a factory: elements auto-add when created inside a Drawing.""" + d.add(elm.Dot().at(at)) + d.add(part().at(at).down().label(label, R_DOWN)) + gnd(d, d.here) + + +def shunt_up(d, at, part, label): + d.add(elm.Dot().at(at)) + d.add(part().at(at).up().label(label, R_UP)) + gnd_up(d, d.here) + + +# --------------------------------------------------------------------------- +def block_input(d, ox, oy): + title(d, (ox - 3, oy + 3.5), "1. 12 V input and +5 V") + d.add(elm.Dot(open=True).at((ox, oy)).label("J1 +12V in\n(certified brick)", "left")) + d.add(elm.Fuse().right().label("F1 3A T")) + n1 = d.here + d.add(elm.Line().right().length(3)) + n2 = d.here + d.add(elm.Line().right().length(3)) + n3 = d.here + d.add(elm.Line().right().length(2)) + d.add(elm.Dot()) + d.add(elm.DiodeTVS().at(n1).down().reverse().label("D1\nP6KE15A", L_DOWN)) + gnd(d, d.here) + d.add(elm.Dot().at(n1)) + shunt_down(d, n2, lambda: elm.Capacitor(polar=True), "C1\n470µF 25V") + d.add(elm.Dot().at(n3)) + d.add(elm.Line().at(n3).up().length(1.2)) + vdd(d, d.here, "+12V") + d.add(elm.Dot(open=True).at((ox, oy - 2.5)).label("J1 GND", "left")) + gnd(d, (ox, oy - 2.5)) + + u1 = d.add(ic(["VIN"], ["VOUT"], "U1 Mini560\n5V fixed buck", bottom=["GND"]) + .at((n3.x + 2, oy)).anchor("VIN")) + gnd(d, u1.GND) + d.add(elm.Line().at(u1.VOUT).right().length(2)) + n4 = d.here + d.add(elm.Line().right().length(2)) + vdd(d, d.here, "+5V") + shunt_down(d, n4, lambda: elm.Capacitor(polar=True), "C2\n100µF 10V") + + +def block_enable(d, ox, oy): + title(d, (ox - 3, oy + 3.5), "2. HV enable relay + hardware watchdog") + # charge pump + d.add(elm.Dot(open=True).at((ox, oy)).label("ESP32 GPIO21\n(toggles every\nscanned row)", "left")) + d.add(elm.Capacitor().right().label("C3 100nF")) + a = d.here + d.add(elm.Diode().right().label("D2 1N4148")) + b = d.here + d.add(elm.Line().right().length(2.5)) + c = d.here + d.add(elm.Line().right().length(2.5)) + q1 = d.add(elm.NFet().theta(0).reverse().anchor("gate").label("Q1\n2N7000", "right")) + d.add(elm.Dot().at(a)) + d.add(elm.Diode().at(a).down().reverse().label("D3\n1N4148", L_DOWN)) + gnd(d, d.here) + shunt_down(d, b, lambda: elm.Capacitor(polar=True), "C4\n10µF") + shunt_down(d, c, lambda: elm.Resistor(), "R1\n100k") + gnd(d, q1.source) + + # relay module + k1 = d.add(ic(["IN", "VCC"], ["NO", "COM"], "K1 relay module\n5V, opto, active-low IN", + bottom=["GND"]).at((q1.drain.x + 5, q1.drain.y + 2.5)).anchor("IN")) + d.add(elm.Wire("|-").at(q1.drain).to(k1.IN)) + d.add(elm.Line().at(k1.VCC).left().length(1.5)) + vdd(d, d.here, "+5V") + gnd(d, k1.GND) + d.add(elm.Line().at(k1.COM).right().length(2)) + vdd(d, d.here, "+12V") + d.add(elm.Line().at(k1.NO).right().length(3).label("+12V_HV", "right")) + + note(d, (ox - 6, oy - 4.5), + "Static GPIO (high, low, reset, crash) → no charge on C4 → Q1 off → relay open → HV off.\n" + "Drop-out ≈ 1 s (C4 × R1). Check your relay module's IN polarity.") + + +def block_pos(d, ox, oy): + title(d, (ox - 3, oy + 4.5), "3. Positive HV: boost module + original regulator → +65 V") + d.add(elm.Dot(open=True).at((ox, oy)).label("+12V_HV", "left")) + d.add(elm.Fuse().right().label("F2 1A T")) + d.add(elm.Line().right().length(1)) + u2 = d.add(ic(["VIN"], ["HV+"], "U2 NCH6100HV\nset 90V", bottom=["GND"]).anchor("VIN")) + gnd(d, u2.GND) + y0 = oy + d.add(elm.Line().at(u2.absanchors["HV+"]).right().length(1)) + d.add(elm.Fuse().right().label("F4 100mA F")) + x = d.here.x + d.add(elm.Label().at((x + 0.3, y0 + 0.2)).label("+90V raw", "top", fontsize=9, halign="left")) + + # raw rail: bulk cap, bleeder, HV-present LED + shunt_down(d, (x + 1.5, y0), lambda: elm.Capacitor(polar=True), "C5\n22µF\n250V") + shunt_down(d, (x + 4.5, y0), lambda: elm.Resistor(), "R2\n330k") + d.add(elm.Dot().at((x + 7.5, y0))) + d.add(elm.Resistor().at((x + 7.5, y0)).down().label("R3\n100k 1W", R_DOWN)) + d.add(elm.LED().down().label("LED1", R_DOWN)) + gnd(d, d.here) + + # regulator (original Q1/Q3 section) + xa, xb, xd = x + 12, x + 16, x + 21 + d.add(elm.Resistor().at((xb, y0)).down().label("R4\n1.5k", L_DOWN)) + qa = d.add(elm.BjtPnp(circle=True).theta(0).anchor("emitter").label("Q2\nMPSA92", "right")) + by = qa.base.y + d.add(elm.Dot().at((xa, y0))) + d.add(elm.Zener().endpoints((xa, y0), (xa, by)).reverse().label("D4\n3.9V\n1N5228", R_DOWN)) + d.add(elm.Dot().at((xa, by))) + d.add(elm.Line().at((xa, by)).to(qa.base)) + d.add(elm.Resistor().at((xa, by)).down().label("R5\n47k 1W", L_DOWN)) + gnd(d, d.here) + + qby = qa.collector.y - 1.2 + d.add(elm.Line().at(qa.collector).toy(qby)) + nqb = d.add(elm.Dot()).center + d.add(elm.Zener().at(nqb).down().reverse().label("D5\n68V\n1N4760A", R_DOWN)) + gnd(d, d.here) + q3 = d.add(elm.BjtNpn(circle=True).theta(0).anchor("base").at((xd, qby)) + .label("Q3\nMJE15030\n(heatsink)", "right")) + d.add(elm.Line().at(nqb).to(q3.base)) + d.add(elm.Line().at(q3.collector).toy(y0)) + d.add(elm.Line().at((x, y0)).tox(q3.collector.x)) + + oy2 = q3.emitter.y - 0.8 + d.add(elm.Line().at(q3.emitter).toy(oy2)) + d.add(elm.Line().right().length(2.5)) + o1 = d.here + d.add(elm.Line().right().length(3)) + o2 = d.here + d.add(elm.Line().right().length(3)) + d.add(elm.Dot(open=True).label("+65V to panel", "right")) + shunt_down(d, o1, lambda: elm.Capacitor(), "C6\n0.1µF\n500V") + shunt_down(d, o2, lambda: elm.Resistor(), "R6\n330k") + + +def block_neg(d, ox, oy): + title(d, (ox - 3, oy + 4.5), + "4. Negative HV: isolated converter + floating boost module + original regulator → −112 V / −100 V") + d.add(elm.Dot(open=True).at((ox, oy)).label("+12V_HV", "left")) + d.add(elm.Fuse().right().label("F3 1A T")) + d.add(elm.Line().right().length(1)) + u3 = d.add(ic(["VIN", "GND"], ["−VO", "+VO"], "U3 isolated DC-DC\n12V→12V 6–10W").anchor("VIN")) + d.add(elm.Line().at(u3.GND).left().length(1)) + gnd(d, d.here) + d.add(elm.Line().at(u3.absanchors["+VO"]).right().length(2.5)) + u4 = d.add(ic(["VIN"], ["HV+"], "U4 NCH6100HV\nset 130V", bottom=["GND"]).anchor("VIN")) + jy = u4.GND.y - 1.5 + d.add(elm.Line().at(u3.absanchors["−VO"]).right().length(1.2)) + d.add(elm.Line().toy(jy)) + d.add(elm.Line().tox(u4.GND.x)) + d.add(elm.Dot()) + hv = u4.absanchors["HV+"] + d.add(elm.Line().at(hv).right().length(1.5)) + gnd(d, d.here) + + yb = u4.GND.y - 6 # −130 V raw rail + d.add(elm.Line().at(u4.GND).toy(yb)) + d.add(elm.Fuse().right().label("F5 100mA F", "bottom")) + x = d.here.x + d.add(elm.Label().at((x + 0.3, yb - 0.3)).label("−130V raw", "bottom", fontsize=9, halign="left")) + + d.add(elm.EncircleBox([u4], padx=1.0, pady=1.2).linestyle("--").color("red")) + note(d, (u3.center.x - 3, yb - 0.8), + "⚠ U3's output side, U4 and this whole\nnet sit at −130 V: insulate, never touch.", 8, "red") + + shunt_up(d, (x + 1.5, yb), lambda: elm.Capacitor(polar=True).reverse(), "C7\n22µF\n250V") + shunt_up(d, (x + 4.5, yb), lambda: elm.Resistor(), "R7\n330k") + d.add(elm.Dot().at((x + 7.5, yb))) + d.add(elm.Resistor().at((x + 7.5, yb)).up().label("R8\n100k 1W", R_UP)) + d.add(elm.LED().up().reverse().label("LED2", L_UP)) + gnd_up(d, d.here) + + # regulator (original Q2/Q4/Q5 section) + xa, xb, xz, xd = x + 12, x + 16, x + 19, x + 23 + d.add(elm.Resistor().at((xb, yb)).up().label("R9\n1.5k", L_UP)) + qa = d.add(elm.BjtNpn(circle=True).theta(0).anchor("emitter").label("Q4\nMPSA42", "right")) + by = qa.base.y + d.add(elm.Dot().at((xa, yb))) + d.add(elm.Zener().endpoints((xa, yb), (xa, by)).label("D6\n3.9V\n1N5228", L_UP)) + d.add(elm.Dot().at((xa, by))) + d.add(elm.Line().at((xa, by)).to(qa.base)) + d.add(elm.Resistor().at((xa, by)).up().label("R10\n47k 1W", L_UP)) + gnd_up(d, d.here) + + qby = qa.collector.y + 0.6 + d.add(elm.Line().at(qa.collector).toy(qby)) + d.add(elm.Line().tox(xz)) + nqb = d.add(elm.Dot()).center + d.add(elm.Zener().at(nqb).up().label("D7\n13V\n1N4743", R_UP)) + m = d.add(elm.Dot()).center + d.add(elm.Zener().up().label("D8\n100V\n1N4764A", R_UP)) + gnd_up(d, d.here) + + q4 = d.add(elm.BjtPnp(circle=True).theta(0).anchor("base").at((xd, qby)) + .label("Q5\nMJE15031\n(heatsink)", "right")) + d.add(elm.Line().at(nqb).to(q4.base)) + d.add(elm.Line().at(q4.collector).toy(yb)) + d.add(elm.Line().at((x, yb)).tox(q4.collector.x)) + + # −112 V output + out_x = xd + 17 + y112 = q4.emitter.y + 0.6 + d.add(elm.Line().at(q4.emitter).toy(y112)) + d.add(elm.Line().right().length(6)) + o1 = d.here + d.add(elm.Line().right().length(3)) + o2 = d.here + d.add(elm.Line().tox(out_x)) + d.add(elm.Dot(open=True).label("−112V to panel", "right")) + shunt_up(d, o1, lambda: elm.Capacitor(), "C8\n0.1µF\n500V") + shunt_up(d, o2, lambda: elm.Resistor(), "R11\n330k") + + # −100 V: Q5 follower driven from node M (D6/D7 junction) + yq5 = m.y + 5.5 + d.add(elm.Line().at(m).tox(m.x + 1.5)) + d.add(elm.Line().toy(yq5)) + d.add(elm.Resistor().right().tox(xd + 4.5).label("R12 1.5k", "top")) + q5 = d.add(elm.BjtNpn(circle=True).theta(0).anchor("base").label("Q6\nMJE15030\n(heatsink)", "right")) + d.add(elm.Resistor().at(q5.collector).up().label("R13\n2k 5W", R_UP)) + gnd_up(d, d.here) + y100 = q5.emitter.y - 0.6 + d.add(elm.Line().at(q5.emitter).toy(y100)) + d.add(elm.Line().right().length(6)) + o3 = d.here + d.add(elm.Line().tox(out_x)) + d.add(elm.Dot(open=True).label("−100V to panel", "right")) + shunt_up(d, o3, lambda: elm.Capacitor(), "C9\n0.1µF\n500V") + + +def block_out(d, ox, oy): + title(d, (ox - 4, oy + 3.5), "5. Panel power connector") + names = ["+5V", "+12V", "+65V", "GND", "−100V", "−112V"] + j2 = d.add(ic(list(reversed(names)), [], "J2 to panel\n(keyed, ≥300V rated)").at((ox, oy)).anchor("+5V")) + for n in names: + if n == "+12V": + d.add(elm.Switch().at(j2.absanchors[n]).left().length(3).label("JP1", "top")) + d.add(elm.Label().at(d.here).label(n, "left")) + else: + d.add(elm.Line().at(j2.absanchors[n]).left().length(3).label(n, "left")) + note(d, (ox - 4, j2.absanchors["−112V"].y - 1.5), + "Pin order is a placeholder: map it to YOUR panel's\nconnector before wiring. Fit JP1 only if the\npanel uses +12V.") + + +def block_notes(d, ox, oy): + title(d, (ox, oy), "Notes") + note(d, (ox, oy - 0.4), + "• Panel voltages are set by zeners D5 (68V → about +65V out) and D7+D8 (113V → about −112V / −100V out), copied from Stern 520-5138-00.\n" + " Module trim pots only set the raw rails, so a mis-set module can't over-volt the panel.\n" + "• Original board refs → this design: Q1→Q2, Q2→Q4, Q3→Q3, Q4→Q5, Q5→Q6, D3→D4, D4→D6, D5→D5, D6→D8, D7→D7, R2→R5, R3→R10, R4→R4, R5→R9,\n" + " R6→R6, R7→R11, R8→R13, R10→R12, C3→C6, C4→C8, C7→C9. Designators match the KiCad project.\n" + "• Set U2/U4 with no load, then lock the trim pots. First power-up with the panel: 1 kΩ in series with each HV output, measure current.\n" + "• Q3/Q4/Q5 on small heatsinks. HV transistors and zeners from a real distributor. Raw caps ≥ 250 V, output caps 500 V, ≥ 3 mm HV clearance.\n" + "• Bleeders discharge all rails at power-off; LEDs are a hint only. Always measure before touching.", + size=9) + + +with schemdraw.Drawing(show=False) as d: + d.config(fontsize=9, unit=2.5) + title(d, (-8, 8), "Plasma DMD — 12 V DC input power supply (rev 0.1, unverified)") + block_input(d, 0, 0) + block_enable(d, 42, 0) + block_pos(d, 0, -17) + block_out(d, 58, -14) + block_neg(d, 0, -36) + block_notes(d, -8, -56) + +d.save(str(OUT / "psu-schematic.svg")) +d.save(str(OUT / "psu-schematic.png"), dpi=150) +print("saved") diff --git a/reference/(Pinball DMD Clock) pinball_machine_clock_1.webp b/reference/(Pinball DMD Clock) pinball_machine_clock_1.webp new file mode 100644 index 0000000..e9e7fe8 Binary files /dev/null and b/reference/(Pinball DMD Clock) pinball_machine_clock_1.webp differ diff --git a/reference/dmd display - c9f14626-be7b-4120-a2b2-3ddc91a4284b.jpg b/reference/dmd display - c9f14626-be7b-4120-a2b2-3ddc91a4284b.jpg new file mode 100644 index 0000000..88b210c Binary files /dev/null and b/reference/dmd display - c9f14626-be7b-4120-a2b2-3ddc91a4284b.jpg differ diff --git a/reference/dmd display - s-l300.jpg b/reference/dmd display - s-l300.jpg new file mode 100644 index 0000000..b42e23a Binary files /dev/null and b/reference/dmd display - s-l300.jpg differ diff --git a/reference/stern-520-5138-00-display-psu-schematic.jpg b/reference/stern-520-5138-00-display-psu-schematic.jpg new file mode 100644 index 0000000..3485cf9 Binary files /dev/null and b/reference/stern-520-5138-00-display-psu-schematic.jpg differ