Access Reader — важная правка по РАЗМЕЩЕНИЮ разъёмов (ты на placement): ВСЕ разъёмы и клеммники ставь ПО КРАЮ платы, ориентированными наружу, с зазором под вставку кабеля/штекера. Сейчас RJ45 Ethernet стоит ПОСЕРЕДИНЕ — в него физически не воткнуть провод, перемести на кромку. На край разъёмной стороной наружу: RJ45 (Ethernet), клеммник входа 9–32В DC, клеммники 2 реле (NO/NC/COM), сервисный USB, клеммники/хедеры RS-485, Wiegand и 2 входов, разъём/шлейф GM861 (QR), 2-pin разъём катушки 125к (J101). Вход кабеля не должен перекрываться компонентами, крепёжными отверстиями или соседними разъёмами (проверь высоту/вылет коннектора наружу за контур). Зону поднесения карт (антенны 13.56/125к) держи свободным краем без разъёмов. Это правило — жёсткое: неудобный доступ к разъёму = брак. Обнови placement и manufacturing notes, отметь этот constraint в ready-to-export чеклисте.
Что не удалось: пакет не order-ready — routing не завершён, DRC всё ещё показывает много airwires; stackup tool принял 4-layer, но readback показывает inner layers как Signal вместо GND/PWR; SS14 diode-OR работает как reverse-blocking fallback, но лучше заменить на ideal-diode/power-mux перед производством. Critical ERC по питанию/GND для W5500, USB ESD, LMR16020 и PoE/DC OR-ing исправлены, placement выполнен на 80×100 мм.
Draft, derived from uploaded technical design PDF Rev 0.1 and updated 2026-07-09 for the first full Rev A prototype. Critical values from PDF OCR should be verified against original datasheets before schematic wiring.
Project Overview
Multiformat IoT access-control reader for doors and turnstiles. The unit identifies users by QR/barcode, Mifare/NFC at 13.56 MHz, EM-Marine at 125 kHz, NFC phones/tags, then decides locally from an on-device access database and drives two dry-contact relays.
Intended Use
Indoor wall or turnstile-mounted access reader, initial target: 0 to 50 C, up to 95 percent RH non-condensing.
Prototype path: MVP on modules, then custom single-PCB Rev A EVT, Rev B DVT/pilot, then certification/series.
Device must keep granting/denying access when network connectivity is lost.
What the Device Should Do
Read QR and 1D/2D barcodes from paper and phone screens.
Read Mifare Classic/Plus/DESFire, ISO14443/ISO15693/NFC tags, and Android/iOS NFC flows where supported.
Read 125 kHz EM-Marine class cards/tags.
Store at least 50000 credentials and 20000 events locally.
Synchronize with a1Aplatform over MQTT/TLS, with WebSocket fallback.
Drive two relay outputs as dry contacts.
Expose Wiegand output and RS-485/OSDP-style integration.
Provide RGB indication, buzzer, tamper detection, service USB, RTC backup.
Main Features
ESP32-S3-WROOM-1-N16R2 module with Wi-Fi/BLE, secure boot and flash encryption.
QR scanner module: GROW GM861 family, UART interface.
125 kHz LF front-end: EM4095 with tuned coil antenna.
First Rev A prototype: one fully populated board with 9 to 32 V DC input, IEEE 802.3af PoE using AG9905-MTB, W5500 Ethernet/RJ45 and ESP32-S3 Wi-Fi all populated.
Two relays, Form C target: NO/NC/COM, at least 2 A at 30 VDC.
System Architecture
Diagram
Hardware Subsystems
Compute and Security
ESP32-S3-WROOM-1-N16R2 preferred because 16 MB flash and 2 MB PSRAM support local database, TLS, OTA and buffering.
Secure boot v2, flash encryption, signed OTA and unique device credentials are required.
GPIO map must avoid ESP32-S3 boot-strapping conflicts and reserve GPIO19/GPIO20 for native USB.
Power
Common internal architecture: selected input source creates 5 V, then a 5 V to 3.3 V buck powers logic/RF.
Protected 9 to 32 V DC input feeds an LMR16020 buck to 5V_DC_PRE_OR.
5V_DC_PRE_OR and 5V_POE_PRE_OR must not be directly paralleled; they merge only through reverse-blocking ideal-diode OR-ing or a priority power mux into 5V_SYS.
Power architecture must prevent backfeed between DC and PoE inputs when either or both sources are connected.
Identification Channels
QR: UART scanner module with MOSFET power switch and trigger/control lines.
NFC: CLRC663 plus with matching/tuning network and RF test points.
LF: EM4095 with coil tuning network and software time-multiplexing against NFC.
External I/O
Two relay outputs, dry contacts only. The device must not power locks or actuators.
RS-485 with TVS, optional termination/bias and preferably isolation for long cable runs.
Wiegand output through voltage-tolerant open-drain drivers, not direct ESP32 GPIO.
Two isolated inputs for door/REX signals plus tamper input.
Isolation boundary and surge/ESD strategy required
USB service
Data
ESP32-S3 native USB
ESD protection and production lock-down policy
QR module
UART
3.3 V TTL target
Verify exact GM861 pinout/current
CLRC663
SPI
3.3 V logic
Separate CS, IRQ, reset, clean supply
W5500
SPI
3.3 V logic
SKU-B, separate CS, INT, reset
RS-485
Half duplex
Field wiring
TVS, termination, bias, DE default receive
Wiegand
Output
Open-drain tolerant
External pull-up may be 5 V or more; protect GPIO
Relay K1/K2
Dry contact
NO/NC/COM
Suppression footprints for inductive loads
Inputs
In
Dry contact or 5 to 24 V target
Exact range must be fixed before schematic
Power and Runtime Expectations
No battery runtime target; RTC backup uses CR1220-class cell.
PoE power target from PDF: less than 6.5 W, intended to fit IEEE 802.3af class 0 to 3.
Firmware should limit WS2812 brightness and time-multiplex RF channels to reduce peak draw and interference.
Power Tree and Power Budget
See separate Preliminary Power Budget project file for current estimates. Current conclusion: 5 V rail should be treated as a 1.3 to 1.5 A peak rail minimum; 3.3 V buck should remain at 2 A class.
Manufacturing and Assembly Expectations
Single 4-layer PCB, signal/GND/power/signal stackup target.
First prototype BOM populates both DC and PoE/Ethernet branches on one PCB; PoE, W5500 and RJ45 are not DNP for this build.
Test pads are required for power rails, ESP32 boot/reset/USB/UART, SPI, I2C, RS-485, relay drives, NFC/LF tuning and QR UART.
RF tuning variants must be supported by DNP capacitors/resistors.
Board outline target is 80 × 100 mm. Size may increase only if required by antenna, keepout or mounting clearance; absolute maximum is 120 × 100 mm.
Four M3 / Ø3.2 mm board mounting holes are required near the corners, with about 5 mm center inset from edges and at least 6 mm copper/component keepout around each.
The 13.56 MHz NFC antenna is required in Rev A as an on-board printed loop, not deferred to EVT; matching/EMC parts remain tuning placeholders for EVT.
The 125 kHz LF antenna is required in Rev A as a 2-pin external coil connector plus tuning placeholders; the external coil is tuned at EVT.
Firmware-Relevant Hardware Requirements
ESP-IDF target recommended.
Partition plan must reserve two OTA slots, NVS, certificates, database, event log, crash dumps and wear-leveling storage.
Firmware should detect active transport/power state where available; Ethernet and Wi-Fi are both present in the first prototype.
Production provisioning must load keys/certificates, enable secure boot/flash encryption and define service USB/debug lock-down.
Physical Design Expectations
Narrow vertical enclosure with top QR window and lower card/phone presentation area.
ESP32 antenna at PCB edge with all-layer antenna keepout.
NFC and LF antenna area must avoid copper planes/components as required by tuning design.
PoE flyback, DC/DC inductors, RJ45 magnetics and relays must be kept away from RF antenna zones.
Indoor v1 target only; outdoor/IP65 version is a separate design pass.
Card presentation edge should contain the 13.56 MHz printed loop and 125 kHz external coil connector/reserved zone, colocated enough for user interaction but kept away from noisy power/Ethernet/relay blocks.
Important Design Decisions
Use module-based ESP32-S3 instead of bare RF chip to reduce radio integration risk.
Use local access decision path rather than cloud-only validation.
Use W5500 for Ethernet because ESP32-S3 has no RMII Ethernet MAC.
Use dry-contact relay outputs only; external lock power is out of scope.
Treat NFC/LF antenna tuning as EVT validation work, not a guaranteed first-pass schematic constant.
Assumptions
GM861 UART-level pinout, current and mechanical details will be verified from datasheet before schematic capture.
Relay contact rating is 2 A at 30 VDC resistive unless updated.
Inputs will support at least dry contact and 5 to 24 V field signaling, but thresholds are not yet frozen.
PoE SKU targets 802.3af class 3 unless the final worst-case budget exceeds margin.
No external memory is used in Rev A unless partition/wear analysis proves internal flash insufficient.
Change Notes
Initial specification created from uploaded PDF and architecture review.
Critical Rev A gates added: GPIO map, power budget, RF floorplan, PoE safety, protection matrix, SKU DNP matrix and memory/partition plan.