• Existing working prototype uses a ZhiPu 95W IEEE 802.3bt splitter as the PoE PD front end, producing a regulated 24V rail into a Philips Hue Perifo track lighting system while bypassing the OEM AC driver.
• An Olimex ESP32-PoE-ISO board currently handles wired Ethernet control through the splitter passthrough and switches the 24V rail through a relay chain.
• Measured full prototype load is 72.21W sustained from a UniFi USW Pro XG 48 PoE switch, powering four cylinder spotlights plus two gradient light bars, with stable PoE+++ negotiation and nominal splitter thermal performance.
• The custom Flux PCB is intended to integrate the Silvertel AG59824 PoE PD front end, 24V rail output, LMR33630 24V-to-3.3V logic buck, STM32G473 MCU, W5500 Ethernet, MOSFET PWM output, and DALI interface.
• Physical product intent: fixture-location module with RJ45 input and 4-conductor rail output terminal block — Cat6 in, lighting rail out, no additional power/data wiring.
• Target applications: small medical offices, restaurants, and retail spaces where low-voltage Cat6 retrofit, centralized PoE backup power, per-fixture sensing, lux compensation, and wired network control are strong differentiators.

• Prototype-to-production lighting rail controller for Ethernet-powered lighting installations.
• Intended to replace relay-style switching with solid-state PWM-capable dimming.
• Ethernet-only control; no WiFi/BLE antenna assumed.
• Product may be wired by installers, so output/field-wiring protection is required.

• Negotiate PoE power from an Ethernet switch/injector.
• Generate a 24V output rail for lighting/rail power.
• Generate a regulated 3.3V rail for control electronics.
• Switch/dim the 24V lighting output with a MOSFET.
• Communicate over wired Ethernet.
• Support DALI two-wire lighting control.
• Read a lux sensor over I2C and occupancy via GPIO/PIR input.
• Provide development/debug access.

• Integrated isolated PoE PD module for first revision.
• 24V rail output terminals sized around measured load plus headroom.
• 3.3V control rail.
• MCU + W5500 Ethernet controller architecture preferred for production.
• PWM MOSFET output stage.
• DALI interface.
• I2C sensor header and PIR input.
• Programming/debug header and test points.
• Reverse-polarity/output miswire protection on field terminals where practical.

Diagram

• Power: integrated PoE PD module, isolated 24V conversion, 24V-to-3.3V regulator, protection, bulk capacitance, and test points.
• Compute/control: STM32-class MCU with GPIO for SPI Ethernet, PWM, DALI control, I2C, PIR, reset, and debug.
• Ethernet: W5500 Ethernet controller and RJ45 with magnetics.
• Lighting output: MOSFET dimming path sized for the expected lighting current and thermal margin.
• DALI: DALI bus interface connected to the rail conductors or dedicated output pins as finalized.
• Sensors: I2C lux sensor header, PIR input header, optional temperature monitoring.

• PoE/Ethernet input: RJ45.
• Lighting rail output: 24V+, 24V-, DALI+, DALI- terminal block.
• Sensor input: 3.3V I2C header for lux sensor.
• PIR input: power, ground, and GPIO signal header.
• Debug: SWD/programming header.

• Input source: PoE switch or injector.
• Output rail target: 24V lighting rail.
• Logic rail target: 3.3V.
• Runtime: continuous powered operation; no battery.

• Measured 24V system draw: 22.90W, about 0.95A at 24V.
• User-selected design target: 24V output rail with 2–3A production headroom.
• Practical 24V power target: true 3A headroom at 24V, which requires an 89W-class 802.3bt module or equivalent rather than a 60W-only module.
• The existing Ag5324 module is now considered prototype-only/undersized for this target.
• Leading production-headroom candidate: Silvertel AG59824-LPB, IEEE 802.3bt Class 8, 24V 89W-class isolated output.
• Lower-power fallback candidate: Silvertel Ag5810, IEEE 802.3bt Type 4 Class 7, 60W, configurable 12V/24V isolated output, suitable only if the rail is capped around 2.5A.
• 3.3V electronics: provisional 250–500mA peak budget.

Diagram

• Production-intent PCB, but first revision should favor known-good integrated blocks where possible.
• Use test points on 24V, 3.3V, GND, reset, and programming signals.
• Ethernet and PoE layout will need controlled impedance and careful isolation/creepage review.

• PWM output for dimming MOSFET gate control.
• SPI for W5500 Ethernet controller.
• I2C for lux sensor.
• GPIO interrupt/input for PIR.
• DALI transmit/receive control pins.
• Debug/programming header.

• Board size not yet specified.
• RJ45 and rail terminal block should be board-edge accessible.
• Keep high-voltage/high-current PoE and 24V switching areas separated from low-level logic.

• Use an integrated isolated PoE PD module for revision 1 instead of a discrete PoE PD controller plus custom flyback.
• Size the production-intent 24V rail for 2–3A headroom, not only the measured 0.95A load.
• Replace the current Ag5324 power module before layout. Use AG59824-LPB or equivalent for true 3A headroom; use Ag5810 only for a deliberate 2.5A/60W cap.
• Use Ethernet-only architecture; no WiFi/BLE antenna.
• Prefer W5500 + separate STM32-class MCU for production supportability.
• Relay replaced by MOSFET to support PWM dimming.
• Add reverse-polarity/output protection for field wiring mistakes.
• Rev 1 DALI scope: protected DALI terminals only; full DALI PHY/transceiver and firmware commissioning are deferred to rev 2.
• Rev 1 output abuse scope: protect against reversed passive load wiring only; externally powered reverse polarity, cable shorts, hot-plug capacitance, and inductive kick remain production/rev-2 protection requirements.
• Layout may not proceed until AG59824-LPB has a correct reusable footprint/STEP association.

• The 24V load is currently about 22.90W / 0.95A based on measured data.
• The design target is now 2–3A lighting-output headroom; exact PoE module footprint and thermal design must be confirmed before layout.
• 3.3V control current is provisionally 500mA peak.
• DALI bus details are provisional until rail wiring and compliance requirements are finalized.
• This is not yet a certified safety/compliance design.

• Initial project specification created from the pasted architecture on 2026-07-04.
• Updated with measured 22.90W load, 2–3A growth-headroom note, W5500 + STM32 direction, and reverse-polarity protection requirement.
• Updated after follow-up module research: AG59824-LPB is the leading true-3A production candidate; Ag5810 remains a 60W/2.5A fallback. Both require library part creation/import and footprint verification before layout.
• Implemented AG59824-LPB in the schematic as PS1, added AG59824 output/input capacitors, upgraded the 24V output PTC to 3A hold, and wired DALI terminal TVS protection. Remaining production caveats: replace provisional DF01S PoE input bridges with MOSFET rectification or higher-current bridges, verify Schottky output reverse-protection thermals at 3A, and verify exact AG59824-LPB footprint before PCB layout release.