PCB Design for Coal Boiler Controller
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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:
- Replace the current schematic with the new controller architecture.
- 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
- 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
- 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.
- Run ERC/review and fix all unresolved schematic violations.
- 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.
- 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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