Access Reader Design

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.
Created a project doc

Access Reader Factory Package Run — 2026-07-09

View Document

Full first Rev A prototype preserved: PoE AG9905-MTB, RJ45/W5500 Ethernet, 9-32 V DC LMR16020 branch and ESP32-S3 Wi-Fi are populated. Criti...
Сделал автономный проход и экспортировал артефакты; все ссылки на Gerber+drill, BOM, BOM с DNP-колонкой и Pick-and-Place собраны в Access Reader Factory Package Run — 2026-07-09.
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.
Fix stackup and routing
Fix stackup
Allow larger board
Finish routing
Replace diode OR
Audit exported files

Refine this doc
Ask about this doc
Project Specification - Access Reader
Status
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.
  • 13.56 MHz NFC front-end: NXP CLRC663 plus, SPI interface, tuned PCB antenna.
  • 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


"DC Input\n9 to 32 V" "Reverse-blocking 5 V OR / Power Mux" "PoE Input\n802.3af AG9905-MTB" "5V_SYS Common 5 V Rail" "3.3 V Buck Rail" "ESP32-S3-WROOM-1-N16R2" "GM861 QR Scanner\nUART" "CLRC663 Plus\n13.56 MHz SPI" "EM4095\n125 kHz GPIO RMT" "W5500 Ethernet\nSPI SKU-B" "RS-485 OSDP" "Wiegand Output" "PCF8563 RTC\nI2C" "RGB LEDs and Buzzer" "Two Dry Contact Relays" "Opto Inputs and Tamper"
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.
  • RJ45 PoE path feeds AG9905-MTB 802.3af module output 5V_POE_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.
Interfaces and Connections

Table


InterfaceDirectionElectrical expectationsNotes
DC inputIn9 to 32 VDCFuse/PTC, reverse polarity MOSFET, TVS, EMI filter
PoE RJ45In/DataIEEE 802.3afIsolation boundary and surge/ESD strategy required
USB serviceDataESP32-S3 native USBESD protection and production lock-down policy
QR moduleUART3.3 V TTL targetVerify exact GM861 pinout/current
CLRC663SPI3.3 V logicSeparate CS, IRQ, reset, clean supply
W5500SPI3.3 V logicSKU-B, separate CS, INT, reset
RS-485Half duplexField wiringTVS, termination, bias, DE default receive
WiegandOutputOpen-drain tolerantExternal pull-up may be 5 V or more; protect GPIO
Relay K1/K2Dry contactNO/NC/COMSuppression footprints for inductive loads
InputsInDry contact or 5 to 24 V targetExact 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.
  • 2026-07-09 antenna/mounting update: added requirements for H1–H4 M3 holes, U8 13.56 MHz printed loop antenna, CLRC663 matching/EMC placeholders, J101 external 125 kHz coil connector, LF tuning placeholders, all-layer NFC copper keepout and 120 × 100 mm board-size ceiling.
  • Status

  • Project Overview

  • Intended Use

  • What the Device Should Do

  • Main Features

  • System Architecture

  • Hardware Subsystems

  • Compute and Security

  • Power

  • Identification Channels

  • External I/O

  • Interfaces and Connections

  • Power and Runtime Expectations

  • Power Tree and Power Budget

  • Manufacturing and Assembly Expectations

  • Firmware-Relevant Hardware Requirements

  • Physical Design Expectations

  • Important Design Decisions

  • Assumptions

  • Change Notes

Access Reader

Access Reader thumbnail
Мультиформатный IoT-считыватель доступа на ESP32-S3 с QR, NFC/Mifare, EM-Marine, Wi-Fi/Ethernet/PoE, двумя реле и локальной офлайн-валидацией.

Properties

ESP32-S3 access reader

32

V

50

C

Power-over-Ethernet

Bare metal

Ethernet

Industrial/Manufacturing

Pricing & Availability

Distributor

Qty 1

Arrow

$21.95–$37.63

Digi-Key

$26.41–$27.53

HQonline

$8.44–$9.38

LCSC

$36.86–$48.96

Mouser

$60.41–$60.73

TME

$7.35

Verical

$20.57–$37.56

Controls