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Worked for 2 mins 56 sec

flux

Blocked: I cannot create a true internal Edge.Cuts routed slot with the available PCB edit tools in this session.

What I did:

Removed the earlier pad-style NPTH slot, because you clarified it must not be a pad or drilled hole.
Did not resize, move components, reroute, or modify copper.

Current DRC after cleanup:

Airwires: 0
Overlapping copper: 0
Floating copper / invalid layer / missing footprint errors: 0
Remaining: 3 pre-existing dangling-trace warnings.

Why blocked:

The available line/shape tools only support Top/Bottom layers.
The board-outline tool supports a single closed board outline, not a separate internal Edge.Cuts milling path.
So I cannot safely add the requested internal routed slot as true Edge.Cuts geometry from here.

You’ll need to add this one slot manually in the PCB editor / manufacturing mechanical layer:

Centerline: X = -8.5mm
Start: (-8.5mm, -60mm)
End: (-8.5mm, +60mm)
Routed slot width: 2mm
Non-plated milling / Edge.Cuts layer.

patellllaidxn12

Export the current Gerbers without the slot, and clearly note the manual slot requirement for fabrication.

Thought for 7 sec

flux

I’ll export the current Gerbers as-is, without the slot, and state the manual milling-slot requirement clearly for fabrication.

Worked for 1 min 21 sec

flux

Exported the current Gerbers without the isolation slot: glecs-v4p1-motor-starter-controller-gerbers.zip.

Manual fabrication requirement:

Add a non-plated routed/milled slot on Edge.Cuts, not a drill pad.
Centerline: X = -8.5mm
Start: (-8.5mm, -60mm)
End: (-8.5mm, +60mm)
Slot width: 2mm
Length: 120mm, leaving 10mm solid board bridges at top and bottom.

Pre-export DRC gate was clean: airwires = 0, overlapping copper = 0, missing footprints = 0, invalid layer = 0.

Export assembly package

Create fab note

Check Gerber readiness

Run final HV review

Export all files

Files

Schematic

Layout

Preview

415V Creepage and Clearance Review — GLECS V4.1

Date: 2026-06-26

Scope

Focused review of the routed 2-layer PCB for 415VAC-related creepage and clearance risks. This review is based on Flux layout geometry, schematic net names, visible footprints, and component placement. It is not a formal IEC/UL certification report.

Assumptions Used

System field voltage: 415VAC RMS agricultural motor starter environment.
Review target for production: use at least 6.4mm clearance/creepage between 415VAC conductors of opposite potential and from 415VAC to SELV/control circuitry, with 8mm+ preferred for polluted/agricultural environments or reinforced isolation.
Solder mask is not counted as safety insulation.
Creepage along PCB surface must be measured along copper edges/pads/tracks, not component body outlines.

High-Level Result

Do not fabricate this routed PCB as a 415VAC production board yet. Routing completeness is acceptable electrically, but multiple high-voltage geometry choices are not suitable for 415VAC safety spacing.

Findings

Table

Area	Nets / Parts	Observed / Estimated Spacing	Assessment	Required Change
HV relay output connector	`J_RELAY_CONTACT`, nets `HV_A1` / `HV_A2`	5.08mm pitch footprint with ~2mm pads gives about 3.0mm copper-to-copper between pins	Fail / high risk for 415VAC line-line	Replace with real 630V+ terminal footprint with ≥7.5mm pitch or larger pads/slots that achieve ≥6.4mm copper clearance; preferably ≥8mm.
Voltage sense input connector	`J_VS_IN`, nets `VS_L` / `VS_N`	Same 5.08mm pitch / ~3.0mm copper gap	Fail / high risk for 415VAC input	Replace with ≥7.5mm pitch 630V+ terminal footprint or add certified spacing/slots.
RC snubber across relay contact	`R_SNUB`, `C_SNUB`, nets `HV_A1` / `HV_A2`	0805 pad gap is roughly 0.8mm copper-to-copper	Fail / critical	Do not use 0805 across 415VAC. Use safety-rated through-hole or large SMD parts with certified X2/AC rating and adequate pad spacing; consider series parts or dedicated snubber module footprint.
Relay contact internal footprint	`K1` G5LE contact pads MAIN/NO	Approx. 13mm+ edge clearance between MAIN and NO pads	Likely OK for contact spacing	Verify relay datasheet contact rating for the exact 415VAC load category; PCB spacing around pads appears better than connectors/snubber.
Voltage transformer primary-to-secondary	`T1` ZMPT101B	Primary-secondary pad edge spacing roughly 14mm+	Likely OK geometrically	Verify actual ZMPT101B safety isolation rating/certification; keep low-voltage traces away from primary side copper.
Optocoupler isolation	`U_OPTO1`, `U_OPTO2` PC817C	DIP-4 body gives roughly 6mm-class pad-to-pad isolation path	Marginal/depends on standard	PC817 may be acceptable for low-energy field input isolation, but for harsh/agricultural 415V-adjacent wiring use wide-body/slot or certified reinforced isolator if required.
Bottom/top traces near HV area	HV nets and low-voltage nets	No automated creepage DRC rule was found enforcing 415VAC-specific spacing	Process risk	Add explicit HV keepouts/clearance rules and route HV manually or with constrained net classes.

Specific Production Fixes Recommended

Replace J_RELAY_CONTACT and J_VS_IN footprints with actual 630V+ or 1000V terminal blocks using ≥7.5mm pitch, ideally with datasheet-confirmed creepage/clearance.
Remove 0805 snubber implementation. Replace R_SNUB/C_SNUB with a safety-rated RC snubber footprint intended for mains/415VAC spacing. Do not rely on voltage rating alone; footprint spacing must also pass.
Add PCB isolation slots between HV pins where connector/component spacing is tight, if the chosen manufacturer supports routed slots and the safety standard allows them.
Create HV net classes for HV_A1, HV_A2, VS_L, VS_N, VS_L_LIMITED with clearance at least 6.4mm from SELV/control nets and each other where applicable.
Keep HV and SELV zones separated: connectors/relay/snubber/transformer primary on one board edge, MCU/LTE/logic on the opposite side, with a visible isolation corridor.
Re-export Gerbers only after replacing the footprints and rerouting with the above spacing rules.

Notes on the Existing Gerbers

The previously exported Gerbers are useful as a routing proof-of-concept, but they should be treated as not production-safe for 415VAC until the high-voltage footprint and spacing issues above are corrected.

Open Certification Items

Confirm applicable standard target: IEC 61010-1, IEC 62368-1, IEC 60335, or local agricultural/motor-control standard.
Confirm pollution degree, overvoltage category, altitude, material group/CTI, and whether reinforced or basic isolation is required.
Verify relay load category and terminal block datasheet ratings for 415VAC motor starter duty.

Scope
Assumptions Used
High-Level Result
Findings
Specific Production Fixes Recommended
Notes on the Existing Gerbers
Open Certification Items