Project Status and Action Items

K

kproc

Good job rotating the connectors. Delete CN1. I also want to move the Pico to the top of the board

flux

I’ll remove the extra CN1 connector and move the Pico module up toward the top edge of the PCB, then verify the placement.

flux

Done. I deleted CN1 and moved U_MCU/Pico to the top of the board; it is now centered at about (10 mm, 88 mm) with its top edge just inside the board outline.
Open item: the Pico was clamped at the board edge, so if you want more clearance from the top edge I can drop it slightly lower.
K

kproc

I need a power switch and some output LEDs

flux

I’ll add a low-current front-panel power/enable switch rather than a high-current 12 V path switch, plus output/status LEDs with current-limiting resistors, then verify the schematic changes.

flux

Added the power switch and output LEDs. SW_PWR is a low-current front-panel switch that pulls Pico 3V3_EN to GND to turn logic off, and I added green indicators for BUS_12V and VOUT_19V5 with 4.7kΩ and 8.2kΩ series resistors.
Open items:
  • These are placed near the top/front-panel area but not routed yet.
  • If you intended a true high-current input disconnect instead of a Pico enable switch, that needs a different switch/contactor architecture.
Route controls and verify
Use high-current switch
Route switch and LEDs
Add LED labels
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Schematic

Layout

Preview

Schematic Capture Status — Organized Two-Module Pass
Status
The project schematic has been simplified and organized into two representative modules:
  1. Distribution Board — upstream PSU input protection/control and one representative daughterboard slot.
  2. 19.5V Boost 180W Module — one representative LM5122 boost daughterboard.
This is now a representative architecture schematic, not a 12× replicated schematic.
Distribution Board — Current Representative Blocks
  • Upstream input eFuse: TPS259827ONRGET (U_IN_EFUSE).
  • Input TVS: SMBJ15A (D_IN_TVS).
  • Input bulk/filtering capacitor banks.
  • MCU module: Raspberry Pi Pico 2 (U_MCU).
  • One representative per-slot blade fuse holder (FH_SLOT).
  • One representative slot enable MOSFET scaffold (Q_SLOT_EN).
  • One enable buffer (U_SLOT_BUF).
  • Placeholder 32-pin slot connector (J_SLOT) using X4622WVS-2x16I-C40D64-E60.
  • System status LED and current-limit resistor.
Distribution Board — Removed / Simplified
  • Removed the 11 duplicate slot fuse holders (H1–H11).
  • Removed the 11 duplicate slot MOSFETs (Q2–Q12).
  • Removed the 11 duplicate enable buffers (U4–U14).
  • Removed unused helper resistors (R3, R4, R5, R_MCU_SER).
Representative Slot Pinout
J_SLOT is wired as a placeholder for one full daughterboard slot:
  • Pins 1,3,5,7,9,11,13,15,17,19 → GND.
  • Pins 2,4,6,8,10,12,14,16,18,20 → SLOT1_12V.
  • Pin 21 → SLOT1_GATE / enable path placeholder.
  • Pin 22 → SLOT1_MODE.
  • Pin 23 → SLOT1_SYNC.
  • Pin 24 → SLOT1_FAULT_N.
  • Pin 25 → SLOT1_PGOOD.
  • Pin 26 → IIN_SENSE.
  • Pin 27 → IOUT_SENSE.
  • Pin 28 → TEMP_MOS.
  • Pin 29 → TEMP_IND.
  • Pin 30 → VOUT_CONN as placeholder VOUT sense.
  • Pin 31 → MOD_PRESENT_N.
  • Pin 32 → SLOT_ID_SPARE.
19.5V Boost 180W Module — Current Representative Blocks
  • LM5122 controller (U1).
  • Two BSC010NE2LS MOSFETs (Q1, Q_BOOST_HS).
  • Boost inductor (L_BOOST).
  • Input/output capacitor banks from the user BoM.
  • Input and output current shunts (R_SHUNT_IN, R_SHUNT_OUT).
  • Input/output INA181 current monitors (U2, U3).
  • Feedback and compensation networks.
  • Output TVS (D_OUT_TVS).
  • MOSFET and inductor thermistor telemetry (RT_DB, R1).
  • Placeholder DC output jack (J_DC_OUT) using PJ-037A.
Known Placeholders
  • J_SLOT is not the final ED32BGFBK footprint; it is a usable schematic placeholder with 32 terminals.
  • J_DC_OUT is not the final DC-S007B-D025-15A 15A jack; it is a random usable 2-terminal DC barrel jack placeholder.
  • The imported ED32BGFBK and DC-S007B-D025-15A part projects remain footprint-only until repaired manually.
Validation Notes
  • Current schematic summary: 64 BOM instances, 33 nets.
  • ERC still reports floating MCU GPIO warnings and incomplete support pins, which is expected at this stage.
  • Real engineering validation still needed for TPS259827 support pins, LM5122 compensation/power-stage values, and the final slot enable/high-side switch topology.
  1. Finish TPS259827 support network: ILIM, ITIMER, dVdt, EN/UVLO, PG, retry behavior.
  2. Decide whether Q_SLOT_EN remains, becomes a proper high-side switch, or is removed for fuse-only Rev A.
  3. Validate LM5122 power-stage values with TI calculator/datasheet.
  4. Repair final ED32BGFBK and DC-S007B-D025-15A parts later, then replace placeholders before PCB layout.

  • Status

  • Distribution Board — Current Representative Blocks

  • Distribution Board — Removed / Simplified

  • Representative Slot Pinout

  • 19.5V Boost 180W Module — Current Representative Blocks

  • Known Placeholders

  • Validation Notes

  • Next Recommended Actions