HV Pulse Power Design


The architecture checks out: the HV and low-voltage grounds remain isolated, and the hardware fault line independently disables both charger and inverter enables. Remaining electrical-check items are external module feedback/telemetry stubs plus three pre-existing control-power warnings; I’m documenting these limits and generating firmware, bring-up, and safety files now.
One real inherited issue remains: comparator U2:2IN− is floating. I’m sending a focused correction to tie that unused comparator channel into a defined safe state and to clarify the original 5 V control-source connection, then I’ll re-run only those checks.
Received notification from "Hybrid Power Prototype" that it finished — picking the work back up.
Expanded the schematic from 92 to 172 components with:
  • Six-cell graphene/EDLC supercapacitor interface
  • External 4S LiFePO₄/BMS interface
  • Isolated charger and bidirectional converter interfaces
  • Channel 4 auxiliary self-power path with startup-power ORing
  • ESP32-WROOM-32E and three ADS1115 telemetry ADCs
  • Independent hardware charger/inverter shutdown
  • Protected 40 A-class external inverter interface
  • Separate HV GND and low-voltage LV_GND
Floating comparator and control-power errors were corrected; floating-pin and missing-power checks are now clean.
Open items
  • Exact isolated charger, bidirectional converter, BMS, and active supercapacitor-balancer modules require measured capture voltage, source impedance, and sustainable power.
  • The new components still need PCB placement; routing has not started.
  • The inverter remains an external certified module rather than onboard mains circuitry.
Project files
Next steps
  1. Re-size and place all 172 footprints by power domain.
  2. Select the external converter and BMS modules from measured source data.
  3. Apply HV/high-current layout rules and isolation boundaries.
  4. Review placement before routing.
Place expanded PCB
Select power modules
Set high-voltage rules
Review safety design

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