Raspberry Pi Zero HAT PCB Design

bubbaa

bubbaa

give a text instructions of exactly what to wire but dont wire yourself.

flux

I created a detailed copy-pasteable wiring checklist here: Manual Wiring Instructions - Pi Zero 2 W Power HAT.
It lists the exact pin-to-pin/net wiring for VIN_6V, GND, TPS56339 buck/BOOT/SW/FB, TPS259531 eFuse, motor MOSFET channels, LED JSTs, TP3, and the final ERC checklist.
bubbaa

bubbaa

I think I wired everything. check my work. do not wire anything yourself but call out what is needed.

flux

Your main functional wiring looks mostly correct now: VIN_6V, buck/eFuse-to-PI_5V, motor low-side switching, LED GPIO connectors, and common GND are all largely in place. Remaining issues are cleanup/ERC hygiene: label the unnamed VIN_6V, BUCK_5V, and GND nets, rename AUTO_NAME to Q2_GATE, mark J6:C NC, resolve/assign TP1–TP4 and 6V:P1, then route the PCB airwires. Full audit is in Schematic Audit — Check My Work.
Run ERC/DRC
List net labels
Check BOM completeness
Inspect airwires
F2
C2 P2 - C3 2
C4 1 - F2 1
H1 Pin_18 - J5 Pin_1
C4 2 - C6 2
C4 2 - C6 2
C3 2 - H1 Pin_34
U1 GND - U1 EP
C4 2 - C6 2
H1 Pin_19 - R1 1
U2 GND - H1 Pin_6
J7 Pin_2 - D1 2
U1 OUT - H1 Pin_2
C4 2 - C6 2
Q1 D - D2 A
C4 2 - C6 2
C4 2 - C6 2
U1 GND - U1 EP
H1 Pin_22 - J7 Pin_1
J6 A - U2 VIN
C4 2 - C6 2
J7 Pin_2 - D1 2
C2 P1 - C6 1
U2 FB - R6 2
H1 Pin_22 - J7 Pin_1
C4 2 - C6 2
R9 2 - C5 P1
U2 SW - L2 1
H1 Pin_11 - R2 2
J5 Pin_2 - D1 2
F2 2 - U1 IN
F2 2 - U1 IN
U1 GND - U1 EP
C2 P1 - C6 1
C4 1 - F2 1
J6 A - U2 VIN
J6 A - U2 VIN
J6 A - D3 K
J6 B - U2 GND
J6 A - U2 VIN
Q2 D - D3 A
J6 A - D3 K
J6 B - U2 GND
J1 P2 - J2 P2
C2 P1 - C6 1
L2 2 - C3 1
Q1 D - D2 A
U1 OUT - H1 Pin_2
J6 B - U2 GND
R9 2 - C5 P1
H1 Pin_4 - D1 1
J6 B - H1 Pin_9
C2 P1 - C6 1
C4 2 - C6 2
C4 2 - C6 2
C4 2 - C6 2
C2 P2 - C3 2
L2 2 - C3 1
U2 FB - R6 2
C4 2 - C6 2
U1 OUT - H1 Pin_2
C4 2 - C6 2
H1 Pin_19 - R1 1
Q2 D - D3 A
H1 Pin_4 - D1 1
J6 B - H1 Pin_9
C4 2 - C6 2
C4 2 - C6 2
J7 Pin_2 - D1 2
U1 OUT - H1 Pin_2
C4 1 - F2 1
H1 Pin_18 - J5 Pin_1
J6 A - D3 K
J1 P2 - J2 P2
U2 SW - L2 1
H1 Pin_11 - R2 2
J7 Pin_2 - D1 2
C2 P1 - C6 1
R4
J2
Hole3
6V
6V
C1
Capacitance
10µF
U1
Hole2
C7
Capacitance
3.3nF
6V
J6
Manufacturer Part Number
54-00166
R3
TP4
J5
R7
Resistance
10000 Ω
D2
D1
R1
R10
Resistance
100kΩ
6V
6V
TP2
TP3
6V
C4
Hole4
C5
End of Life
Capacitance
0.1uF
C2
End of Life
Capacitance
0.1uF
6V
R2
TP5
J1
C3
H1
Manufacturer Part Number
2.54-2*20
6V
J7
Hole1
TP1
D3
R_ILM
Resistance
1000 Ω
C6
L2
R6
Resistance
76800 Ω
Q2
Q1
D5
R9
U2

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Schematic Audit — Check My Work
Date: 2026-05-02
Scope: Read-only audit of the current Pi Zero 2 W Power HAT schematic after the user’s manual wiring pass. No project edits were made.
Overall Status
The main topology is close, but the schematic is not yet clean. Key rails and signal paths are mostly present, but there are several items that still need attention before layout:
  • 39 PCB airwire DRC errors remain. These are layout/routing issues, not necessarily schematic connectivity errors.
  • ERC floating-pin warnings remain for J6:C, several test points, expected-unused Pi header pins, and a 6V:P1 object.
  • TP3 / Net 22 is still a single-pin net.
  • Some net names are still unnamed or generic even though the connections appear correct.
  • Q2_GATE rename did not take; the actual Q2 gate net is still called AUTO_NAME.
What Looks Correct
Barrel Jack and Raw 6 V Rail
Current live netlist shows:
  • J6:A is on the raw 6 V input rail with U2:VIN, U2:EN, input capacitors, D5:K, D2:K, J1:P2, J2:P2, and C6:1.
  • J6:B is on the common ground net.
This matches the intended Tensility mapping:
  • J6:A -> VIN_6V
  • J6:B -> GND
  • J6:C -> NC / plug-detect if used
Issue: the raw 6 V rail is currently shown as an unnamed net in the live schematic output, even though the intent is VIN_6V. Rename/label this net back to VIN_6V if it is not visibly labeled in the editor.
Buck Switch Node
The SW node is now present and correctly contains:
  • U2:SW
  • C5:P2
  • L2:1
This addresses the earlier L2:1 floating issue.
Bootstrap Network
Bootstrap wiring appears structurally correct:
  • BOOT: U2:BOOT, R9:1
  • BOOT_CAP: R9:2, C5:P1
  • SW: U2:SW, C5:P2, L2:1
This means the bootstrap path is:
U2:BOOT -> R9 -> C5 -> SW
Buck Output / BUCK_5V
The post-inductor buck output node is present as an unnamed net containing:
  • L2:2
  • C3:1
  • C4:1
  • F2:1
  • R6:1
This is the intended BUCK_5V rail. Rename/label this unnamed net to BUCK_5V if it is not visibly labeled.
Ground side of output capacitors:
  • C3:2 -> GND
  • C4:2 -> GND
Feedback Divider
Feedback net is correct:
  • FB: U2:FB, R6:2, R7:P1
  • R7:P2 -> GND
  • R6:1 -> BUCK_5V node
Values/properties:
  • R6 = 76.8 kΩ
  • R7 = 10 kΩ
This matches the ~5.2 V target from the corrected topology.
eFuse / Pi 5 V Path
The Pi power path appears correct:
  • BUCK_5V node -> F2:1
  • F2:2 -> U1_IN
  • U1_IN: F2:2, U1:IN pins, U1:EN/UVLO
  • PI_5V: U1:OUT, H1:Pin_2, H1:Pin_4, D1:1, R10:P2
This matches the intended path:
BUCK_5V -> F2 -> TPS259531 eFuse input -> PI_5V -> H1 pins 2 and 4
eFuse dVdt and FLT Support
The newly added support networks now exist:
  • U1:dVdt connected to C7:P2
  • C7:P1 -> GND
  • U1:~FLT connected to R10:P1
  • R10:P2 -> PI_5V
This resolves the previous real omissions for dVdt and ~FLT.
Motor Low-Side Switches
Motor channel low-side topology is present:
Channel 1:
  • MOTOR1_LOW: Q1:D, D2:A, J2:P1
  • D2:K is on raw 6 V rail
  • Q1:S -> GND
  • Q1_GATE: Q1:G, R1:2, R3:1
  • R3:2 -> GND
  • PWM10: H1:Pin_19, R1:1
Channel 2:
  • MOTOR2_LOW: Q2:D, D3:A, J1:P1
  • D3:K is on raw 6 V rail
  • Q2:S -> GND
  • Q2 gate net: AUTO_NAME: R2:1, R4:1, Q2:G
  • R4:2 -> GND
  • PWM17: H1:Pin_11, R2:2
This is electrically correct. Only the Q2 gate net name needs cleanup.
LED GPIO Connectors
LED connector nets are correct:
  • GPIO24_LED: H1:Pin_18, J5:Pin_1
  • GPIO25_LED: H1:Pin_22, J7:Pin_1
  • J5:Pin_2 -> GND
  • J7:Pin_2 -> GND
Role notes correctly state these are for LED modules with built-in current limiting; bare LEDs need series resistors or drivers.
Common Ground
The common ground net includes:
  • J6:B
  • U2:GND
  • U1:GND, U1:EP
  • Q1:S, Q2:S
  • Pi ground pins including H1:Pin_6, Pin_9, Pin_14, Pin_25, Pin_34, Pin_39
  • C1:P2, C2:P2, C3:2, C4:2, C6:2
  • R3:2, R4:2, R7:P2, R_ILM:P2
  • J5:Pin_2, J7:Pin_2
This matches the single common ground requirement.
What Still Needs Attention
1. Net Names / Labels Need Cleanup
The live schematic still shows these important rails as unnamed nets:
  • Raw input rail containing J6:A, U2:VIN, U2:EN, D5:K, D2:K, J1:P2, J2:P2, etc. This should be labeled VIN_6V.
  • Buck output node containing L2:2, C3:1, C4:1, F2:1, R6:1. This should be labeled BUCK_5V.
  • Main ground net is unnamed in the live output, although it is functionally GND. Make sure it is labeled GND in the editor.
2. Q2 Gate Net Name
Electrical connection is correct, but the net name is still AUTO_NAME:
  • AUTO_NAME: R2:1, R4:1, Q2:G
Rename this net to Q2_GATE after removing any conflicting duplicate Q2_GATE portal/label.
3. J6:C Floating
ERC reports:
  • Floating pin: J6:C
If unused, place a No-Connect marker on J6:C. Do not tie it to VIN or GND unless you intentionally use the jack switch/contact behavior.
4. Test Points / Single-Pin Nets
ERC reports floating test points:
  • TP1:-
  • TP2:-
  • TP4:-
Single-pin net warning:
  • Net 22 has only one pin connected: TP3:-
Action: either connect each test point to the intended rail/signal or mark/remove it. Likely assignments could be:
  • TP1 -> VIN_6V
  • TP2 -> BUCK_5V
  • TP3 -> PI_5V
  • TP4 -> GND
But verify intended labels/placement before wiring.
5. 6V:P1 Floating
ERC reports:
  • Floating pin: 6V:P1
This appears to be a leftover power symbol/portal/object. Either connect it to VIN_6V intentionally or remove/NC it if it is a stale artifact.
6. Pi Header Floating Pins
Many unused Pi header pins are floating. That is expected if they are not used, but ERC will continue warning unless you mark unused H1 pins as No-Connect or accept the warnings.
Used H1 pins currently include:
  • Pin_2, Pin_4: PI_5V
  • Pin_6, Pin_9, Pin_14, Pin_25, Pin_34, Pin_39: GND
  • Pin_11: PWM17
  • Pin_18: GPIO24_LED
  • Pin_19: PWM10
  • Pin_22: GPIO25_LED
7. DRC Airwires
DRC reports 39 airwire errors. These are PCB layout routing issues, not necessarily schematic net problems. Once the schematic cleanup items above are handled, the board still needs physical routing or autorouting.
8. Parts Availability
Manufacturer Part Number review passes. Parts Available review is currently unrun, so availability has not been reconfirmed after the latest changes.
  1. Label unnamed rails:
    • raw input rail -> VIN_6V
    • buck output node -> BUCK_5V
    • common ground -> GND
  2. Rename AUTO_NAME -> Q2_GATE after clearing duplicate label conflict.
  3. Mark J6:C No-Connect.
  4. Resolve test points:
    • connect them to intended rails/signals or remove/NC them.
  5. Remove or connect 6V:P1 artifact.
  6. Decide whether to mark unused H1 pins NC or accept warnings.
  7. Re-run ERC.
  8. Run Parts Available review.
  9. Proceed to PCB routing to clear 39 airwires.
Bottom Line
Your main functional wiring looks correct now. The remaining work is mostly cleanup and ERC hygiene: net labels, NC markers, stale artifacts/test points, Q2 gate naming, and then PCB routing.

  • Overall Status

  • What Looks Correct

  • Barrel Jack and Raw 6 V Rail

  • Buck Switch Node

  • Bootstrap Network

  • Buck Output / BUCK_5V

  • Feedback Divider

  • eFuse / Pi 5 V Path

  • eFuse dVdt and FLT Support

  • Motor Low-Side Switches

  • LED GPIO Connectors

  • Common Ground

  • What Still Needs Attention

  • 1. Net Names / Labels Need Cleanup

  • 2. Q2 Gate Net Name

  • 3. J6:C Floating

  • 4. Test Points / Single-Pin Nets

  • 5. `6V:P1` Floating

  • 6. Pi Header Floating Pins

  • 7. DRC Airwires

  • 8. Parts Availability

  • Recommended Fix Order

  • Bottom Line

Documents

  • Schematic Text Mapping for Other LLMs

  • Manual Wiring Instructions - Pi Zero 2 W Power HAT

  • Schematic Audit — Check My Work

Assets

No assets added.

Stuck Cyan Lightcycle 92e7

Stuck Cyan Lightcycle 92e7 thumbnail
Pi Zero 2 W Power HAT – 6 V Input, 5.2 V Buck to Pi 5 V Header via 1.85 A Fuse, Enhanced Input & Pi Rail Protection (TVS + High-Hold PTC + 5 A Schottky)

Properties

Retained: PJ-037A barrel jack; input fuse F1 (RUEF500); Schottky D1 (VS-MBRS340); TVS D2 (SMAJ6.0A); buck converter U1 (TPS56339DDC) with L1 (4.7 µH), C3/C4 (22 µF, CC1206KKX5R6BB226, 1206), C5 (100 nF), divider resistors R_FB_H (75 kΩ) and R_FB_L (10 kΩ); output fuse F2 (RUEF500); USB-A J3; TVS D7 (SP0502BAHT); motor driver Q1/Q2 (AO3400A) with gate resistors R1/R2 (100 Ω), pulldowns R3/R4 (100 kΩ) and flyback diodes D3/D4 (MBR540); RP40 header (PPPC202LFBN-RC 2x20 TH) with test points T10/T17; JST-PH connectors J1/J2. Removed: duplicate net portals; ESD diodes D5 and D6. Net optimizations: consolidated all ground symbols into a single GND net; removed stray portal blocks; validated VIN and 5V_USB rails; ensured PWM10 and PWM17 nets correctly isolated and connected.

Power

Net standardization: Confirmed VIN net (VIN) and buck output net (5V_USB) are correctly named and delineated, with Pi 5V remaining isolated from 5V_USB. PWM control nets verified and labeled via RP40 (PPPC202LFBN-RC 2x20 TH): GPIO 10 -> T10 (PWM10) and GPIO 17 -> T17 (PWM17). Pruning: Removed stray/duplicate net portals and non-topology ESD parts; retained only agreed functional blocks (BJ, F1, D1, D2, U1=TPS56339DDC, L1, C1–C5, RFB_H, RFB_L, RBOOT=ERJ-3GEYJ300V, C3/C4=CC1206KKX5R6BB226, F2, D7, J3, Q1/Q2, D3/D4, MT1/MT2, RP40=PPPC202LFBN-RC, J1/J2, T10/T17, mounting holes). Wiring fixes: D4 rewired as flyback between motor node and VIN; EN line implemented with R5 pull-up to 5V_USB and correctly tied to U1:EN; feedback chain and all input/output decoupling capacitors verified against buck topology. Validation: Latest ERC/DRC checks (airwires, missing footprints) are clean with no remaining warnings; parts availability review run for key BOM items with results stored under `Parts Availability Report`. Design is considered pruned, net-standardized, and production-ready for PCB layout and manufacturing.

parts_available

Pi Zero 2 W Power HAT – Buck Converter Feeds Pi 5V Header via ~1.85 A PTC Fuse (USB Power Output Removed)

[]

Power

{"reviewType":"parts_available","results":[{"designator":"C3","available":true,"stock":12500,"distributors":["Digi-Key","Mouser"]},{"designator":"C4","available":true,"stock":13000,"distributors":["Digi-Key","Arrow"]},{"designator":"RBOOT","available":true,"stock":54000,"distributors":["Digikey"]},{"designator":"RP40","available":true,"stock":8500,"distributors":["Mouser"]}]}

BOOT path modification passed without errors; C3/C4 set to CC1206KKX5R6BB226 (1206), RBOOT set to ERJ-3GEYJ300V (0603), RP40 set to PPPC202LFBN-RC (2x20 TH) with no connectivity changes.

55000

Ω
Diagram



  
    
  
  
    
  



InputStage


BuckStage


PiPowerPath


MotorDrivers




















































"Barrel Jack IN"
"Polyfuse F1 (input)"
"Schottky D1"
"TVS D2"
"10uF C1"
"100nF C2"
GND
"TPS56339 U2"
"4.7uH L2"
"22uF C3"
"22uF C4"
"100nF C5"
"R6: FB_H node_55kΩ"
"R7: FB_L node_10kΩ"
"("BUCK_5V ≈ 5.2V")"
"PTC F2 ≈1.85A (A16-185)"
"("PI_5V / H1 pins 2,4")"
H1
"PWM10 from H1"
"100R R1"
"AO3400A Q1"
"PWM17 from H1"
"100R R2"
"AO3400A Q2"
"MBRS540 D3 to VIN"
"MBRS540 D4 to VIN"

ERC/DRC checks run for: design_rule_check_airwires, design_rule_check_floating_copper. No remaining warnings.

F1 (1206L050/15YR): HoldCurrent 0.5 A, Package 1206; F2 (ASMD1206-200): HoldCurrent 1.85 A, Package 1206

5.2

V

BUCK_5V

Power

Consumer Electronics

design_rule_check_airwires, design_rule_check_floating_copper

ERC/DRC checks run for: design_rule_check_airwires, design_rule_check_floating_copper. No remaining warnings.

Diagram



  
    
  
  
    
  



InputStage


BuckStage


USBOutput


MotorDrivers


GPIOBreakouts































































"Barrel Jack IN"
"Polyfuse F1"
"Schottky D1"
"TVS D2"
"10uF C1"
"100nF C2"
GND
"TPS56339 U1"
"4.7uH L1"
"22uF C3 (CC1206KKX5R6BB226)"
"22uF C4 (CC1206KKX5R6BB226)"
"100nF C5"
"R_FB_H"
"R_FB_L"
"30R BOOT RBOOT (ERJ-3GEYJ300V)"
"Polyfuse F2"
"TVS5 SP0502BAHT"
"USB-A J3"
"PWM10"
"100R R1"
"AO3400A Q1"
"PWM17"
"100R R2"
"AO3400A Q2"
"MBR540 D3"
VIN
"MBR540 D4"
"RPi 40 Header (PPPC202LFBN-RC node_2x20 TH)"
"GPIO24 J1"
"GPIO25 J2"
"PWM10 Test T10"
"PWM17 Test T17"

Input and USB protection paths updated; VIN and PI_5V net names verified; USB-A output and USB_VBUS path removed; buck output now feeds Pi 5V header (H1 pins 2/4) via ~1.85 A PTC fuse F2 with common GND, maintaining ~5.2 V BUCK_5V output.

Revised: USB-A VBUS path removed; buck output BUCK_5V now routed through ~1.85 A PTC F2 onto PI_5V (H1 pins 2/4). Previous 5V_USB isolation note superseded by new topology.

design_rule_check_airwires, design_rule_check_floating_copper

R6

5.2

V

Clean

[]

Portal

65.0 mm x 30.0 mm

10

ERC/DRC checks run for: design_rule_check_airwires, design_rule_check_floating_copper. No remaining warnings.

Power

10000

Ω

solderpad.org/licenses/SHL-2.1/

Pricing & Availability

Distributor

Qty 1

Arrow

$2.51–$3.01

Digi-Key

$1.98–$3.39

LCSC

$3.43–$3.79

Mouser

$3.14–$3.44

TME

$1.46

Verical

$1.58–$91.06

Controls