Sensor Wiring Setup
Thought for 3 sec
Work done
- Integrated the two native PC817 homing sensor channels with labeled X/Y sensor terminals, 10kΩ pullups, 100nF filters, 4.7kΩ status LED resistors, Nano D9/D10 outputs, and a single 0Ω star link between
GND_24VandGND_LOGIC. - Preserved the 100 mm × 152 mm, 2-layer board and placed the new/updated sensor parts in the connector area with no placement overlap or out-of-bounds issues.
- Applied the required 1.6 mm copper spacing rule conservatively and documented the implementation in Homing Sensor Integration Audit.
- ✅ Native X/Y sensor circuitry integrated and connected to
+24V_SENSOR/GND_24V. - ✅
LIMIT_X_NETconnects to Nano D9;LIMIT_Y_NETconnects to Nano D10. - ✅ Sensor terminals are documented as BRN/BLU/BLK and filters/status LEDs are included.
- ✅ Board size and 2-layer stackup are preserved.
- ❌ Final layout DRC is not clean: airwires and overlapping copper remain after the stricter spacing rule, so the board is not fabrication-ready yet.
Run routing cleanup/autoroute for the updated board, then re-check DRC until the airwire and copper-clearance issues are cleared. I can continue with PCB routing/cleanup guidance next.
Route sensor nets
Review DRC violations
Verify clearance rule
Prepare Gerbers
Update audit doc
Refine this doc
Ask about this doc
Stuffer Relay Integration Status
Implemented
- Removed the old off-the-shelf relay module connector
RELAY_MODULE_CONNand old command LED partsR17/LED7. - Added onboard active-high stuffer relay subsystem:
STUFFER_OPTOPC817 optocouplerSTUFFER_DRIVERS8050 NPN low-side coil driverSTUFFER_RELAYSRD-05VDC-SL-C 5V SPDT relaySTUFFER_FLYBACK1N4007 flyback diodeSTUFFER_RELAY_LEDred relay-on LED +STUFFER_RELAY_LED_R1k resistorSTUFFER_PWR_LEDgreen +5V LED +STUFFER_PWR_LED_R1k resistorSTUFFER_DECOUPLE100nF andSTUFFER_BULK10uF across +5V/GNDSTUFFER_CONTACT_CONN3-position 5.08mm pluggable terminal for NO/COM/NC
Logic / Wiring
NANO:D11/MOSIdrivesSTUFFER_OPTO_Rthen the PC817 input LED.- PC817 output drives
STUFFER_DRIVER:BthroughSTUFFER_BASE_R, withSTUFFER_BASE_PDas a 10k pulldown. STUFFER_DRIVERsinks the relay coil throughSTUFFER_COIL_NEG.STUFFER_FLYBACKis across the relay coil: cathode to +5V / A1, anode to coil negative / A2.- Contact terminal mapping:
Pin_1 = STUFFER_NO,Pin_2 = STUFFER_COM,Pin_3 = STUFFER_NC.
Safety / Layout Notes
- Treat the relay contact side as potentially 220VAC until the stuffer load is confirmed.
- Keep contact-side traces physically separated from logic with >=3.2mm clearance and >=4mm creepage, preferably more where space allows.
- Place the relay contact terminal at the board edge and orient relay contact pins toward it.
- Place flyback diode adjacent to relay coil pins.
Current Open Items
- PCB placement is complete for the relay subsystem: terminal at the right board edge, relay behind it, driver/flyback/decoupling clustered near the coil, and optocoupler/input resistor near Nano D11.
- Applied available layout rules to the contact-side terminal and relay contact pads:
minKeepOut = 3.2 mmat the terminal andtraceWidth = 1.27 mmon NO/COM/NC contact pads. - ERC floating-pin warnings for unused ESP32 GPIO8/GPIO9 were cleared with no-connect markers.
- Routing still needs final cleanup: airwires remain because traces have not been fully routed after the relay subsystem was added.
- The stuffer load type (220VAC vs low-voltage DC) remains the main open clearance decision; if 220VAC is confirmed, manually verify >=3.2mm clearance and >=4mm creepage around all contact copper after routing.
Implemented
Logic / Wiring
Safety / Layout Notes
Current Open Items
