Migration Reconstruction and Safety Review
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I can’t run auto-layout right now because AI execution is unavailable: the account has no available ACUs. I’m not able to call the placement/routing tools until ACUs are available again.
What has been completed so far:
- Recreated and verified the main schematic documentation set.
- Reconstructed/verified these phase 3 schematic blocks:
- Protected 5S battery input/protection block.
- Raspberry Pi 5.1 V branch.
- LCD 5.0 V branch.
- 12 V KVM branch.
- Preserved intentional no-connects and warnings, including MOD1
VCCas the known TPSM63606 ERC false positive. - No PCB layout work has been started or validated.
What remains before auto-layout is appropriate:
- Finish schematic reconstruction for the USB-C PD charge/interlock subsystem and any remaining blocks.
- Reconcile the expected 44 nets vs current 43 nets.
- Run full ERC and resolve/document all remaining issues.
- Then proceed to PCB placement first, followed by routing. Current state likely needs both placement and routing, but final layout should wait until schematic/ERC reconciliation is complete.
Find net mismatch
Finish USB-C subsystem
List remaining blocks
Review BOM issues
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Migration Triage Report
Date: 2026-07-24
Project: Protected Module-Based 5S Power Distribution Board
Owner of current target project: mansingh33
Project: Protected Module-Based 5S Power Distribution Board
Owner of current target project: mansingh33
Scope
This milestone is a read-only migration triage based on the attached source bundle, native
.flx parsed evidence, BOM excerpts, thread history, and visual/export evidence inventory. No schematic reconstruction, PCB layout, routing, or fabrication approval was performed in this milestone.The native
.flx evidence is treated as the primary machine-readable migration reference. It is an export/backup and not a native re-import. The visual images, seller diagrams, layout drawings, DXF/SVG/PDF exports, and 3D formats are supporting evidence only.Current target-project baseline
The current mansingh33 target project is empty at this triage point:
Table
| Item | Current target | Migration evidence expectation | Status |
|---|---|---|---|
| Schematic components | 0 | 116 visible schematic components / 341 stored elements | Not restored |
| Nets | 0 | 44 nets | Not restored |
| BOM items | 0 | Exact-part metadata plus generic unresolved module blocks | Not restored |
| Project files | 0 | 5 project files | Not restored |
| PCB layout | Empty / not validated | 680 PCB-layout nodes, 465 route vertices, 0 routes | Evidence only; not fabrication-ready |
Exact recoverables from evidence
The following can be restored from the evidence without inventing engineering data:
- Project name, slug intent, owner migration target, and required project description.
- Schematic architecture:
- protected 5S LiPo input path,
- input fuse and master switch path,
- LTC4365-based UV/OV cutoff/protection with back-to-back MOSFETs,
- three low-voltage output branches,
- dedicated fused 5.1 V USB-C Raspberry Pi output,
- fused 5 V USB-C LCD output,
- fused 12 V center-positive KVM barrel output,
- USB-C PD charge-input chain with load-shutdown interlock,
- test points and safety labeling,
- explicit absence of any mapped balance harness.
- The known 44-net expectation and selected net roles from the parsed
.flxevidence. - USB-C role intent:
- J2/J3 are source-only USB-C power outputs using passive Rp and no USB-PD/data role.
- J5 is charge-only / sink-only, no source/OTG, with VBUS to
USB_CHG_VBUS_RAW, CC1/CC2 to the protected PD sink module, and data/SBU intentionally no-connect.
- Verified / resolved part decisions recorded in the source bundle:
- TI TPSM63606RDLR for the 5.1 V rail, configured for 5.100 V with documented passives.
- Pololu D36V28F5 for the 5 V rail.
- Pololu D36V28F12 for the 12 V rail.
- Diodes Inc. SMBJ22CA-13-F input TVS selection, with surge/clamp validation still required.
- Tensility 54-00127 5.5 mm x 2.1 mm KVM barrel jack, center-positive mapping.
- TE Connectivity 282837-2 off-board switch terminal interface.
- Littelfuse 64900001039 5x20 mm PCB fuse holders for serviceable fuses.
- GCT/GST USB4235-03-C_REVA USB-C receptacles.
- Keystone 5002 test points.
- Murata/Yageo/Vishay/Panasonic passive metadata where listed.
- Known documents to recreate:
- Project Specification,
- Design Notes - Power and Safety,
- Board Bring-Up Plan,
- PCB Assembly Notes,
- Connector Pinout Table.
- Safety warnings and release blockers can be preserved exactly in intent.
Must be rebuilt rather than imported
Flux currently treats the
.flx as export/backup evidence, not as a native import. Therefore the following must be reconstructed manually or semi-manually from evidence:- All schematic components and designators.
- All 44 nets and resolved pin-to-net connectivity.
- All component properties, role metadata, MPNs, manufacturers, values, DNI/TBD flags, and functional groups.
- Test points and no-connect annotations.
- All five project files.
- BOM parity against source evidence.
- Any schematic visual organization, portals, labels, and wire geometry that can be reconstructed from stored element data.
44-net accounting status
The parsed
.flx evidence reports exactly 44 nets. The target project currently has 0 nets, so all 44 are presently missing from the reconstruction.Accounting status for this milestone:
Table
| Category | Status |
|---|---|
Total expected nets from parsed .flx | 44 |
| Nets currently in target project | 0 |
| Nets fully reconstructed | 0 |
| Nets not yet reconstructed | 44 |
| Discrepancy status | Complete mismatch because target project is still empty |
Known critical net families that must be accounted for during rebuild include:
- battery and protected-input nets such as
BAT_PROTECTED,BAT_FUSED,VIN_SW, andVIN_PROTECTED, - raw and fused output rails such as
5V1_RAW,+5V1,5V0_RAW,+5V0,12V_RAW, and+12V, - USB-C charge nets such as
USB_CHG_VBUS_RAW,PD_20V,PD_20V_OK, and charger-output/status nets, - common
GND, - CC resistor/source-output nets for J2/J3,
- J5 sink-only CC nets,
- fuse-separated input/output nets,
- test-point nets TP7-TP14 and earlier output/input test points as recorded,
- intentional no-connects for USB data/SBU/unused contacts where applicable.
A future reconstruction pass must extract or replay the exact full 44-net list from the parsed
.flx evidence and document each as restored, intentionally absent, or blocked.Metadata discrepancies
Table
| Field | Source / original evidence | Current target project | Discrepancy |
|---|---|---|---|
| Original owner | manzzy | mansingh33 | Expected migration ownership change |
| Current required owner | mansingh33 | mansingh33 | OK |
| Original description in raw export | Carrier PCB for a 5S 18.5 V LiPo system using proven preassembled DC-DC regulator modules; output-focused wording | Target description includes removable 5S LiPo Raspberry Pi 400 workstation, USB-C PD charging path, and not-fabrication-ready warning | Target description is newer / safer and should be preserved |
| Components | 116 visible / 341 stored elements in evidence | 0 | Not restored |
| Nets | 44 | 0 | Not restored |
| Project files | 5 expected | 0 | Not restored |
| Layout evidence | 680 PCB nodes, 465 route vertices, 0 routes | Not rebuilt/validated | Not fabrication-ready |
ERC / validation status
Evidence from the prior project history reports that earlier ERC passes found no real errors or warnings after schematic work, except one known non-real ERC issue:
Power input not connected: MOD1:VCCon TPSM63606RDLR.- This was identified as a Flux library pin-type defect, because TI requires VCC to remain externally unconnected.
- A part-quality report was previously filed for the TPSM63606RDLR pin classification.
Current target-project ERC status is not meaningful because the schematic is empty. A fresh ERC must be run after reconstruction.
No layout DRC, current-density, thermal, mechanical-clearance, charging, backfeed, or battery-safety validation has been completed in the current target project.
Release blockers preserved
The following must remain visible and unresolved until authoritative evidence is provided:
- Exact MOD4 USB-C PD sink module selection, including compliant sink-only behavior, 20 V / at least 3 A negotiation, no EPR dependency, gated output behavior, and
PD_20V_OKpolarity/level. - Exact MOD5 5S charger module selection, including 21.0 V maximum regulation, preconditioning, termination, safety timer, current limiting, NTC behavior, and status outputs.
- Exact MOD6 reverse-blocker selection or proof that MOD5 blocks reverse current in all powered/unpowered states.
- Final MOD4/MOD5/MOD6 connector pinouts, footprints, mechanical drawings, mounting, and keepouts.
- BMS common-port charging support, charge-current rating, and authoritative orientation/pin information.
- Balance harness must remain unmapped; seller photographs, wire colors, and diagrams must not be used as pin-order proof.
- Optional 2 A charge mode remains disabled/DNI until pack and BMS approval.
- F5 charge-fuse rating/time-current curve and charge-path thermal performance remain charger-dependent.
- TVS clamp coordination and surge margin, especially around the TPSM63606 36 V limit, require validation.
- Final 190 mm x 125 mm rounded outline, mounting holes, strain-relief holes, keepouts, placement, high-current routing, copper planes, and thermal design are not complete.
- Final ERC/DRC closure, current-density analysis, thermal review, mechanical review, backfeed tests, and battery-safety validation are not complete.
- No manufacturing Gerbers, pick-and-place data, or fabrication approval may be claimed from the current evidence.
Visual/export evidence warning
The visual/export inventory includes seller photographs, one seller wiring diagram, pack photographs, layout DXF/SVG/PDF exports, and STEP/BREP/GLB/VRML/XAO 3D exports. These are supporting evidence only.
They do not establish:
- BMS controller identity,
- MOSFET ratings,
- balance-connector orientation,
- verified balance-pin order,
- completed placement,
- completed routing,
- copper-plane adequacy,
- thermal performance,
- mechanical fit,
- DRC/ERC closure,
- charging safety,
- reverse-current blocking,
- fabrication readiness.
The project remains under engineering review and is not fabrication-ready.
Recommended next reconstruction sequence
- Recreate the five project files first, preserving all safety warnings and blockers.
- Rebuild schematic components and properties from the parsed
.flxevidence and BOM. - Recreate all 44 nets and compare pin references against the parsed
.flxevidence. - Run ERC and document real issues, known false positives, and unresolved assumptions.
- Only after schematic/BOM review, decide whether to reconstruct layout evidence or start a new validated PCB layout. Do not treat existing layout exports or 3D geometry as validation proof.
Scope
Current target-project baseline
Exact recoverables from evidence
Must be rebuilt rather than imported
44-net accounting status
Metadata discrepancies
ERC / validation status
Release blockers preserved
Visual/export evidence warning
Recommended next reconstruction sequence
