Universal Pellet Stove Controller Design
Thought
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, andNet 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.Refine this doc
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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
+5Ventries 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
- Reconnect remaining fragmented/generated nets (
Schematic cleanup
Follow-up
GND over-collapse recovery - pass 1
