Ruteo Cuatro Airwires

Trabaja directamente en el proyecto original. NO mover componentes. U2 y T1 están ya separados; no tocar placement. Checks actuales: no hay dangling/floating/overlap/invalid/outside en el filtro, queda SOLO Airwires con 4 errores:

Trace 9c3c uids 9c3cbb2b-afaa-425b-b5ce-d4652c0ff546,22fa4d80-1cd2-4723-97c8-b845671bb7a6
Trace b7ae uids b7ae9ddd-02c9-430b-b15e-4ec3e2abf0d4,1613efc4-46bb-4bd3-88f9-cfd66b1c6e3a__880f28ef-cf41-0acc-4a98-ce0afa37b0c2
Trace 2afa uids 2afaa84b-b464-408d-aa1f-af950c0a7deb,52092b06-ddf0-4867-93dc-2db39dab7c1a__880f28ef-cf41-0acc-4a98-ce0afa37b0c2
Trace 6c9e uids 6c9e5483-2fc2-4ff7-873a-228f2c925c58,2afaa84b-b464-408d-aa1f-af950c0a7deb Objetivo: cerrar SOLO estos 4 airwires con ruteo quirúrgico. No autoroute completo salvo que el enrutador quirúrgico no pueda conectar y solo si es absolutamente necesario para dejar la placa fabricable. Si al rutear aparecen overlaps, elimina/re-rutea solo las trazas recién creadas, no borres grandes partes del board. Al finalizar corre checks de airwires, overlapping copper, dangling, floating, invalid layer, component outside board. Devuelve resumen conciso con resultado limpio o remanentes exactos.

Thought for 6 sec

flux

Voy a trabajar solo sobre esos 4 airwires, sin mover componentes ni hacer autoroute completo; primero inspecciono el estado/rutas afectadas, luego aplicaré ruteo quirúrgico y validaré únicamente los checks indicados.

Worked for 2 mins 13 sec

flux

Bloqueado por falta de ACUs: no pude continuar ejecutando ruteo ni aplicar cambios.

Hecho:

Confirmé con checks actuales que quedan exactamente 4 errores de Airwires: Trace 9c3c, b7ae, 2afa y 6c9e.
Verifiqué que no aparecieron errores en dangling, floating, overlapping copper, invalid layer ni component outside board en el filtro solicitado.
Corrí precheck de ruteo: detectó solo una advertencia de vía duplicada removida automáticamente en (24.9625 mm, 29.0 mm).

Pendiente:

Rutear quirúrgicamente solo esos 4 airwires.
Revalidar los 6 checks finales pedidos.
No se movió ningún componente ni se ejecutó autoroute completo.

Resolver ACUs

Ruteo manual

Ver airwires exactos

Checks finales

Files

Schematic

Layout

Preview

Board Bring-Up Plan — ESP32-S3 IoT Relay Controller

Prerequisites

Current-limited DC supply, isolation transformer/variac for AC tests, multimeter, oscilloscope, USB-C cable, insulated probes.
Treat all AC-side nets as hazardous: AC_L_IN, AC_L_FUSED, AC_N, RELAY_COM_L, LOAD_L_SW.
First power-up should use DC input only; do not connect mains until low-voltage rails and USB programming pass.

1. Visual Inspection

Verify orientation of U2, U3, U5, U6, U7, Q1/Q2, LEDs, D5/D6/D7 and terminal blocks.
Confirm creepage/clearance between mains and SELV zones before applying AC.
Confirm fuse fitted in F1 only with a value appropriate to the target load and inrush.

2. Power Rail Verification

Table

Rail	Source	Expected	Measure At	Current Limit	Pass Criteria
DC_IN_RAW	J4	5 V	J4 pin 1 to GND	300 mA initial	No short / no overheating
DC_5V_PROT	F2 output	~5 V	U7 VIN	300 mA	TVS not conducting during normal input
5V_SYS	U6/U7 outputs	4.8–5.2 V	C10	300 mA initial	Stable before enabling relay
3V3	U3 output	3.267–3.333 V nominal	C2/C3/U1 3V3	300 mA	ESP32 boots, no brownout
ACDC_5V	U2 output	5 V	U6 VIN	AC test only	Isolated output, no SELV-to-mains continuity

3. Critical Signal Verification

Table

Signal	Expected Idle
ESP_EN	High after RC delay
ESP_BOOT / GPIO0	High; BOOT button pulls low
ESP_STRAP_IO45	Low
ESP_STRAP_IO46	Low
RELAY_SET_GPIO / RELAY_RESET_GPIO	Low at boot
ACS_FAULT	High unless overcurrent threshold trips
I2C_SCL / I2C_SDA	Pulled high to 3V3

4. USB and Programming

Power from DC input or verified 5V_SYS.
Connect USB-C to J1.
Confirm USB enumeration of ESP32-S3.
Flash firmware from the Firmware Starter project file.
Confirm serial output at 115200 baud.

5. Functional Validation

Table

Test	Method	Pass Criteria
TMP102	I2C read from 0x48	Plausible board temperature
Relay set/reset	Pulse GPIO4/GPIO5	Contact state changes; coils do not stay energized
Current ADC	Inject known load current	ADC estimate follows current after calibration
AC voltage ADC	Apply isolated/limited AC	Waveform centered around bias; RMS calibration possible
Protection	Trigger ACS fault where safe	Firmware resets relay

6. AC Power Validation

Perform only after visual inspection and DC bring-up pass.
Use isolated test setup and current-limited AC source.
Confirm U2 output isolation and 5V rail stability.
Test relay with low-current lamp/load before 16 A thermal tests.

7. Production Tests

Continuity of PE_PASS_THROUGH, AC_N, AC_L_IN, LOAD_L_SW.
Hipot/isolation testing per target standard and certified component limits.
Thermal run at rated load in enclosure.
RF range test with final antenna.

Prerequisites
1. Visual Inspection
2. Power Rail Verification
3. Critical Signal Verification
4. USB and Programming
5. Functional Validation
6. AC Power Validation
7. Production Tests