PCB Design for Coal Boiler Controller

flux

I can’t execute project changes right now because the session has no remaining execution credits.
Current project state before this request:
  • Project: 7segment driver uyT3
  • Existing design appears to be a 7-segment/TM1637-style board, not the requested boiler controller.
  • Existing components: 46 total, including TM1637-1, resistors, capacitors, connectors, and pin sockets.
  • Existing nets: 18.
  • The requested change is effectively a full redesign/replacement into a 230VAC ESP32-S3 boiler controller PCB.
What remains to be done when execution is available:
  1. Replace the current schematic with the new controller architecture.
  2. Add and wire:
    • Adafruit Feather ESP32-S3 socket
    • HLK-PM01 5V AC/DC module
    • ULN2003A driver
    • 3x PT1000 divider/filter inputs
    • 5x optotriac/triac output channels
    • CH5 fuse, BT138, SRD-05VDC relay, BC547 driver, NE555 watchdog
    • PC817 zero-cross detector
    • All screw terminals, debug header, LEDs, snubbers, decoupling, pullups, and protection parts
  3. Verify all ICs against datasheets before wiring, especially:
    • Feather ESP32-S3 pinout/current limits
    • ULN2003A
    • MOC3041 / MOC3042M
    • BT136 / BT138
    • HLK-PM01
    • NE555
    • PC817
    • SRD-05VDC-SL-C relay
  4. Perform a power budget check for the 5V rail. The HLK-PM01 is only 600mA, and relay coil + optocouplers + LEDs + Feather load may be close enough that this must be verified before committing.
  5. Run ERC/review and fix all unresolved schematic violations.
  6. Only after the schematic is clean, proceed to layout:
    • Set PCB to 100mm x 80mm, 2-layer FR4.
    • Place LV section on left, HV section on right.
    • Keep minimum 4mm creepage between HV and LV copper.
    • Place TRIACs in a bottom-edge row with heatsink/mounting features.
    • Apply HV trace width rules: mains ≥1.5mm, load outputs ≥2mm, LV ≥0.3mm.
    • Add mounting holes, silkscreen zone boundary, warning labels, and connector labels.
  7. Route and run DRC until clean.
Important engineering note: this is a mains-voltage boiler controller, so the design must be reviewed carefully for creepage, clearance, fusing, isolation, thermal behavior, and fail-safe operation before manufacturing.
Check power budget
Save requirements note
Find main parts
Review GPIO map
Identify safety issues
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