Raspberry Pi Zero HAT PCB Design

0:06

Work done

Re-audited the live schematic against the remaining plan.
Added the missing eFuse support parts: C7 = 3.3 nF for U1:dVdt and R10 = 100 kΩ for U1:~FLT pull-up.
Confirmed current remaining schematic issues: L2:1 is still floating, J2:P1 is still floating, U1:dVdt/U1:~FLT and new C7/R10 are not yet wired, J6:C still needs explicit NC, TP3 remains a single-pin net, and 41 Net Portals remain.
Updated the handoff mapping with the current blocked state and exact intended repairs: Schematic Text Mapping for Other LLMs.

Success criteria review

✅ Verified existing corrected intent for VIN_6V, BUCK_5V, PI_5V, motors, LED GPIO JSTs, common GND, and feedback values.
✅ Added C7 and R10 parts needed for the eFuse omissions.
❌ Could not safely apply final wiring repairs due to a schematic data issue that is blocking edits.
❌ ERC is not clean yet; remaining warnings include L2:1, J2:P1, U1:dVdt, U1:~FLT, C7, R10, J6:C, TP3, and expected unused Pi header pins.
❌ PCB layout preparation should wait until the schematic edit issue is cleared and the final schematic repairs are verified.

Next steps

Clear the schematic edit issue, then apply the documented repairs: connect L2:1 to U2:SW/C5:P2, connect J2:P1 to MOTOR1_LOW, wire C7 and R10, mark J6:C NC, resolve TP3, remove stale portals, then rerun ERC/DRC before PCB layout setup.

2 days

bubbaa

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

2 days

flux

1:08

Considering user instructions.

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.

2 days

bubbaa

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

2 days

flux

1:25

Considering tool usage for files.

Running design review.

Analyzing the schematic.

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

2 days

C2 P2 - C3 2

C4 1 - F2 1

H1 Pin_18 - J5 Pin_1

Hole3

C4 2 - C6 2

C3 2 - H1 Pin_34

U1 GND - U1 EP

C4 2 - C6 2

Capacitance

10µF

Hole2

J7 Pin_2 - D1 2

U1 OUT - H1 Pin_2

C4 2 - C6 2

Q1 D - D2 A

C4 2 - C6 2

U1 GND - U1 EP

H1 Pin_22 - J7 Pin_1

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

H1 Pin_11 - R2 2

J5 Pin_2 - D1 2

F2 2 - U1 IN

C4 1 - F2 1

J6 A - U2 VIN

J6 A - D3 K

J6 B - U2 GND

J6 A - U2 VIN

Q2 D - D3 A

J6 A - D3 K

C2 P1 - C6 1

L2 2 - C3 1

U1 OUT - H1 Pin_2

J6 B - U2 GND

R9 2 - C5 P1

H1 Pin_4 - D1 1

J6 B - H1 Pin_9

C4 2 - C6 2

Hole4

C2 P2 - C3 2

L2 2 - C3 1

U2 FB - R6 2

U1 OUT - H1 Pin_2

H1 Pin_19 - R1 1

Q2 D - D3 A

H1 Pin_4 - D1 1

J6 B - H1 Pin_9

C4 2 - C6 2

J7 Pin_2 - D1 2

U1 OUT - H1 Pin_2

C4 1 - F2 1

Hole1

H1 Pin_18 - J5 Pin_1

J6 A - D3 K

J1 P2 - J2 P2

H1 Pin_11 - R2 2

J7 Pin_2 - D1 2

C2 P1 - C6 1

Capacitance

3.3nF

Manufacturer Part Number

54-00166

TP4

Resistance

10000 Ω

R10

Resistance

100kΩ

TP2

TP3

End of Life

Capacitance

0.1uF

End of Life

Capacitance

0.1uF

TP5

Manufacturer Part Number

2.54-2*20

Resistance

76800 Ω

Not Recommended for New Designs

TP1

R_ILM

Resistance

1000 Ω

Reviews

Ground
A common return path for electric current. Commonly known as ground.
jharwinbarrozo
20.5M
Net Portal
Wirelessly connects nets on schematic. Used to organize schematics and separate functional blocks. To wirelessly connect net portals, give them same designator. #portal
jharwinbarrozo
43.0M
Power Net Portal
Wirelessly connects power nets on schematic. Identical to the net portal, but with a power symbol. Used to organize schematics and separate functional blocks. To wirelessly connect power net portals, give them the same designator. #portal #power
jharwinbarrozo
11.4M
Generic Resistor
A generic fixed resistor ideal for rapid circuit topology development. Its footprint automatically adapts based on the selected package case code—supporting 0402, 0603, 0805, 1203, and many other standard SMD packages, as well as axial horizontal and vertical configurations. Save precious design time by seamlessly add more information to this part (value, footprint, etc.) as it becomes available. Standard resistor values: 1.0 ohm, 10 ohm, 100 ohm, 1.0k ohm, 10k ohm, 100k ohm, 1.0M ohm 1.1 ohm, 11 ohm, 110 ohm, 1.1k ohm, 11k ohm, 110k ohm, 1.1M ohm 1.2 ohm, 12 ohm, 120 ohm, 1.2k ohm, 12k ohm, 120k ohm, 1.2M ohm 1.3 ohm, 13 ohm, 130 ohm, 1.3k ohm, 13k ohm, 130k ohm, 1.3M ohm 1.5 ohm, 15 ohm, 150 ohm, 1.5k ohm, 15k ohm, 150k ohm, 1.5M ohm 1.6 ohm, 16 ohm, 160 ohm, 1.6k ohm, 16k ohm, 160k ohm, 1.6M ohm 1.8 ohm, 18 ohm, 180 ohm, 1.8K ohm, 18k ohm, 180k ohm, 1.8M ohm 2.0 ohm, 20 ohm, 200 ohm, 2.0k ohm, 20k ohm, 200k ohm, 2.0M ohm 2.2 ohm, 22 ohm, 220 ohm, 2.2k ohm, 22k ohm, 220k ohm, 2.2M ohm 2.4 ohm, 24 ohm, 240 ohm, 2.4k ohm, 24k ohm, 240k ohm, 2.4M ohm 2.7 ohm, 27 ohm, 270 ohm, 2.7k ohm, 27k ohm, 270k ohm, 2.7M ohm 3.0 ohm, 30 ohm, 300 ohm, 3.0K ohm, 30K ohm, 300K ohm, 3.0M ohm 3.3 ohm, 33 ohm, 330 ohm, 3.3k ohm, 33k ohm, 330k ohm, 3.3M ohm 3.6 ohm, 36 ohm, 360 ohm, 3.6k ohm, 36k ohm, 360k ohm, 3.6M ohm 3.9 ohm, 39 ohm, 390 ohm, 3.9k ohm, 39k ohm, 390k ohm, 3.9M ohm 4.3 ohm, 43 ohm, 430 ohm, 4.3k ohm, 43K ohm, 430K ohm, 4.3M ohm 4.7 ohm, 47 ohm, 470 ohm, 4.7k ohm, 47k ohm, 470k ohm, 4.7M ohm 5.1 ohm, 51 ohm, 510 ohm, 5.1k ohm, 51k ohm, 510k ohm, 5.1M ohm 5.6 ohm, 56 ohm, 560 ohm, 5.6k ohm, 56k ohm, 560k ohm, 5.6M ohm 6.2 ohm, 62 ohm, 620 ohm, 6.2k ohm, 62K ohm, 620K ohm, 6.2M ohm 6.8 ohm, 68 ohm, 680 ohm, 6.8k ohm, 68k ohm, 680k ohm, 6.8M ohm 7.5 ohm, 75 ohm, 750 ohm, 7.5k ohm, 75k ohm, 750k ohm, 7.5M ohm 8.2 ohm, 82 ohm, 820 ohm, 8.2k ohm, 82k ohm, 820k ohm, 8.2M ohm 9.1 ohm, 91 ohm, 910 ohm, 9.1k ohm, 91k ohm, 910k ohm, 9.1M ohm #generics #CommonPartsLibrary
jharwinbarrozo
1.5M
Generic Capacitor
A generic fixed capacitor ideal for rapid circuit topology development. You can choose between polarized and non-polarized types, its symbol and the footprint will automatically adapt based on your selection. Supported options include standard SMD sizes for ceramic capacitors (e.g., 0402, 0603, 0805), SMD sizes for aluminum electrolytic capacitors, and through-hole footprints for polarized capacitors. Save precious design time by seamlessly add more information to this part (value, footprint, etc.) as it becomes available. Standard capacitor values: 1.0pF, 10pF, 100pF, 1000pF, 0.01uF, 0.1uF, 1.0uF, 10uF, 100uF, 1000uF, 10000uF 1.1pF, 11pF, 110pF, 1100pF 1.2pF, 12pF, 120pF, 1200pF 1.3pF, 13pF, 130pF, 1300pF 1.5pF, 15pF, 150pF, 1500pF, 0.015uF, 0.15uF, 1.5uF, 15uF, 150uF, 1500uF 1.6pF, 16pF, 160pF, 1600pF 1.8pF, 18pF, 180pF, 1800pF 2.0pF, 20pF, 200pF, 2000pF 2.2pF, 22pF, 220pF, 2200pF, 0.022uF, 0.22uF, 2.2uF, 22uF, 220uF, 2200uF 2.4pF, 24pF, 240pF, 2400pF 2.7pF, 27pF, 270pF, 2700pF 3.0pF, 30pF, 300pF, 3000pF 3.3pF, 33pF, 330pF, 3300pF, 0.033uF, 0.33uF, 3.3uF, 33uF, 330uF, 3300uF 3.6pF, 36pF, 360pF, 3600pF 3.9pF, 39pF, 390pF, 3900pF 4.3pF, 43pF, 430pF, 4300pF 4.7pF, 47pF, 470pF, 4700pF, 0.047uF, 0.47uF, 4.7uF, 47uF, 470uF, 4700uF 5.1pF, 51pF, 510pF, 5100pF 5.6pF, 56pF, 560pF, 5600pF 6.2pF, 62pF, 620pF, 6200pF 6.8pF, 68pF, 680pF, 6800pF, 0.068uF, 0.68uF, 6.8uF, 68uF, 680uF, 6800uF 7.5pF, 75pF, 750pF, 7500pF 8.2pF, 82pF, 820pF, 8200pF 9.1pF, 91pF, 910pF, 9100pF #generics #CommonPartsLibrary
jharwinbarrozo
1.5M
Generic Inductor
A generic fixed inductor suitable for rapid circuit topology development. The footprint automatically adapts based on the selected package, supporting standard SMD sizes (e.g., 0402, 0603, 0805) as well as well-known inductor packages such as SDR1806, PA4320, SRN6028, and SRR1260. Standard inductor values: 1.0 nH, 10 nH, 100 nH, 1.0 µH, 10 µH, 100 µH, 1.0 mH 1.2 nH, 12 nH, 120 nH, 1.2 µH, 12 µH, 120 µH, 1.2 mH 1.5 nH, 15 nH, 150 nH, 1.5 µH, 15 µH, 150 µH, 1.5 mH 1.8 nH, 18 nH, 180 nH, 1.8 µH, 18 µH, 180 µH, 1.8 mH 2.2 nH, 22 nH, 220 nH, 2.2 µH, 22 µH, 220 µH, 2.2 mH 2.7 nH, 27 nH, 270 nH, 2.7 µH, 27 µH, 270 µH, 2.7 mH 3.3 nH, 33 nH, 330 nH, 3.3 µH, 33 µH, 330 µH, 3.3 mH 3.9 nH, 39 nH, 390 nH, 3.9 µH, 39 µH, 390 µH, 3.9 mH 4.7 nH, 47 nH, 470 nH, 4.7 µH, 47 µH, 470 µH, 4.7 mH 5.6 nH, 56 nH, 560 nH, 5.6 µH, 56 µH, 560 µH, 5.6 mH 6.8 nH, 68 nH, 680 nH, 6.8 µH, 68 µH, 680 µH, 6.8 mH 8.2 nH, 82 nH, 820 nH, 8.2 µH, 82 µH, 820 µH, 8.2 mH #generics #CommonPartsLibrary
jharwinbarrozo
15.8k
Terminal
An electrical connector acting as reusable interface to a conductor and creating a point where external circuits can be connected.
natarius
RMCF0805JT47K0
General Purpose Thick Film Standard Power and High-Power Chip Resistor 47 kOhms ±5% 0.125W, 1/8W Chip Resistor 0805 (2012 Metric) Automotive AEC-Q200 Thick Film Features: - RMCF – standard power ratings - RMCP – high power ratings - Nickel barrier terminations standard - Power derating from 100% at 70ºC to zero at +155ºC - RoHS compliant, REACH compliant, and halogen free - AEC-Q200 compliant
jharwinbarrozo
1.2M
875105359001
10 µF 16 V Aluminum - Polymer Capacitors Radial, Can - SMD 30mOhm 2000 Hrs @ 105°C #commonpartslibrary #capacitor #aluminumpolymer #radialcan
jharwinbarrozo
1.2M
CTL1206FYW1T
Yellow 595nm LED Indication - Discrete 1.7V 1206 (3216 Metric)
jharwinbarrozo
1.1M

Project Name

Stuck Cyan Lightcycle 92e7

Description

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

Audit Report

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.

Net Type

Power

Prune Report

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 Av…ed Types

parts_available

Project Description

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

Airwire Nets

[]

Net: BUC…et Type

Power

Parts Av…y Report

{"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"]}]}

Final Ver…n Report

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.

Feedback…t Value

55000

System Architecture

Diagram

ERC/DRC Report

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

PTC Replacements

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

Voltage

5.2

Net

BUCK_5V

Net: PiVI…Net Type

Power

Domain

Consumer Electronics

ERC/DRC…d Types

design_rule_check_airwires, design_rule_check_floating_copper

DRC Report

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

System Architecture

Diagram

Protecti…umented

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.

5V_USB i…nfirmed

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.

ERC/DRC…d Types

design_rule_check_airwires, design_rule_check_floating_copper

Manufact…fenders

Buck Out… Voltage

5.2

ERC/DRC Status

Clean

Floating…rIslands

[]

Part Type

Portal

Board Size

65.0 mm x 30.0 mm

Manufact… Target

ERC/DRC Report

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

Net: VIN …Net Type

Power

Feedback…) Value

10000

License

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

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bubbaa / Stuck Cyan Lightcycle 92e7

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