Universal Pellet Stove Controller Design

flux

0:00

Work done
  • Audited the remaining schematic and identified the active fragmented/generated nets and floating pins.
  • Normalized the remaining anonymous net names into functional labels, including Net 6 -> MAINS_L_FILTERED, Net 11 -> MAINS_L_CHOKE, Net 13 -> CH1_MAIN_MT, Net 12 -> CH3_MAIN_MT, Net 10 -> CH4_MAIN_MT, Net 3 -> CH2_GATE_DRIVE, Net 2 -> CH2_GATE_BIAS, Net 1 -> CH34_RETURN, Net 4 -> CH4_MT_UNUSED, and Net 5 -> J1_PIN6_UNUSED.
  • Reconnected the previously floating pins on R11, R12, F1, J2, J3, and J5 based on the currently observable functional grouping.
Success criteria review
  • ⚠️ Fragmented/generated nets were partially normalized, but the connection tool recreated several renamed nets as fresh anonymous nets (Net 1/Net 2/Net 3/Net 4/Net 5/Net 7/Net 8) during reconnection, so the net naming is not yet fully consistent.
  • ⚠️ Several previously floating pins were assigned connectivity, but I could not complete final verification because an issue occurred immediately after the repair pass.
  • ❌ I could not complete the final ERC confirmation that there are no remaining unassigned nets or floating pins.
Next steps The next pass should re-run ERC, then rename the newly recreated anonymous nets (Net 1, Net 2, Net 3, Net 4, Net 5, Net 7, Net 8) to their intended functional names and verify whether any floating pins remain. I can continue from that point once tool execution is available again.
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Design Notes
Schematic cleanup
  • Goal: remove duplicate component designators and normalize fragmented net names before later netlist reconciliation and ERC cleanup.
  • Initial audit found duplicated designators on R13/R14/J5 and fragmented net labels including duplicate +5V entries and Net 1.
  • Large numbers of stale Net Portal components remain from earlier rewiring attempts and will need separate reconciliation.
  • First cleanup batch renames planned:
    • R13 duplicate -> R15
    • R14 duplicate -> R16
    • J5 quick-connect duplicate -> J6
  • Generic net rename planned:
    • Net 1 -> AUX_IO_GND
Follow-up
  • Re-audit the schematic after renames.
  • Determine whether duplicate +5V entries are true separate nets or duplicate labels caused by portal artifacts.
  • Keep naming conventions as close as possible to the existing design.
GND over-collapse recovery - pass 1
  • Snapshot taken before modification, per recovery workflow.
  • Confirmed live failure mode: 16 two-pin parts were reported shorted because both pins had collapsed into GND.
  • Performed first targeted separation pass on these parts:
    • Restored snubber subnets for R1/C2, R2/C3, R3/C4, R4/C5
    • Restored optotriac input current-limit separation for R5, R7, R8
    • Restored gate-drive and gate-bias separation for R9, R13, R14
    • Restored mains surge/protection path separation for RV1 and F1
  • Result after pass 1: ERC no longer reports any shorted two-pin components.
  • Remaining work:
    • Reconnect remaining fragmented/generated nets (Net 10, Net 12, Net 13, etc.) to source-intended names where recoverable
    • Resolve new/remaining floating pins, notably F1:1 and pre-existing orphan references
    • Reduce portal artifacts and continue convergence toward source net names

    Schematic cleanup

    Follow-up

    GND over-collapse recovery - pass 1

Documents

    Design Notes

Assets

Assets are files uploaded to this project which can be used in various ways.

universal pellet stove controller thumbnail
A universal pellet stove controller that uses and arduino uno as the mcu and the

Properties

Diagram



  
    
  
  
    
  



""HV node_120VAC""


""LV Isolated Logic""































"Mains In"
"Fuse"
"Common Mode Choke"
"EMI Filter X2 Caps"
"MOV"
"Isolated AC-DC Supply"
"AC Load Channel 1"
"AC Load Channel 2"
"AC Load Channel 3"
"AC Load Channel 4"
"Isolated DC"
"Arduino IO Connectors"
"Protected Inputs"
"Optotriac LED Drivers"

Pricing & Availability

Distributor

Qty 1

Controls