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 <noreply@anthropic.com>
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mangavalkandClaude Opus 5.5 committed 2026-10-24 02:31:50 +02:00
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# 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.