The board needs both placement and routing: it has 91 airwires, 14 copper-overlap errors, and several parts extend beyond the circular outline. I’m correcting full-board placement first—preserving ENC1 exactly at the origin and the ESP32 antenna edge/keepout—then I’ll route the cleaned layout.
Thought for 9 mins 53 sec
28 days ago
2/4 Determine and execute required placement cleanup
Inspect current board geometry, placement, connectivity, routing, and DRC state
Determine and execute required placement cleanup
Determine and execute required PCB routing
Independently verify final placement, routing, constraints, and DRC
Accessed knowledge for the next task.
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PCB Placement Cleanup
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Received notification from "PCB Placement Cleanup" that it finished — picking the work back up.
The placement executor has finished; I’m reconciling its applied result against the hard centered-encoder, antenna, edge-access, overlap, and board-bound constraints now. If placement is valid, I’ll proceed directly into USB breakout, neckdowns, and auto-routing.
Zero component-body overlaps, out-of-board parts, keepout violations, or edge-placement violations
U1 antenna placement and edge connectors remain correctly constrained
Routing is blocked by pre-existing footprint defects: JP1 and U2 contain overlapping pads assigned to different nets. Auto-routing would remove those pins from their nets, so I stopped rather than corrupt connectivity. 90 airwires remain; correcting the authoritative footprints for JP1 and U2 is required before routing can continue.
Current-limited 5 V USB source or USB power meter.
Protected 1S LiPo with known state of charge.
DMM and oscilloscope with a short ground spring.
USB-C data cable and PlatformIO host.
Pre-Power Inspection
Confirm no short from VBUS, SYS, BAT, or 3V3 to GND. Pass: each rail measures >10 kΩ after capacitors settle; investigate any steady reading <1 kΩ.
Verify JST-PH polarity: pin 1 BAT+, pin 2 GND.
Inspect U2/U3 exposed-pad soldering, L3, USB-C pins, and diode orientation.
Verify JP1 is normally closed/bridged and can be opened by cutting or solder wick.
USB-Only, No Battery
Apply 5.0 V with a 500 mA current limit and leave J2 empty.
Table
Measurement
Expected
Pass range
VBUS to GND
5.0 V
4.75–5.25 V
SYS to GND
BQ24074 regulated OUT
4.30–4.50 V
3V3 to GND
Regulated rail
3.20–3.40 V
BAT at J2 pin 1
No battery attached
No sustained source capable of powering a load; record observed voltage only
Pass: board boots, 3V3 remains inside range, and USB input current remains below 500 mA. Confirm LED2 is visibly on at low brightness with JP1 bridged.
JP1 Power-LED Disable Test
Measure LED2/R22 path current indirectly from R22 voltage: expected approximately 1.2 V across 3 kΩ, or 0.3–0.5 mA.
Open JP1 by cutting/wicking. Pass: LED2 is off, current through R22 is <10 µA, and 3V3 remains 3.20–3.40 V.
Re-bridge JP1 if the indicator is required for the prototype.
Native USB Flashing and Interfaces
Hold BOOT, tap RESET, release RESET, then release BOOT.
Verify the ESP32-S3 ROM USB download device appears.
Run pio run -t upload, then reset normally.
Pass: firmware enumerates both USB CDC serial and HID keyboard interfaces and produces no repeated disconnects during a 10-minute test.
Battery-Only Operation
Connect a protected LiPo with USB removed.
Table
Measurement
Expected
Pass range
BAT
Cell voltage
3.0–4.2 V
SYS
Battery through power path
BAT−0.25 V to BAT+0.10 V
3V3
Regulated rail
3.20–3.40 V
Pass: board boots throughout the intended protected-cell range, 3V3 stays in range during encoder/RGB activity, and no component overheats.
Charging and Power-Path Tests
Connect a partially discharged battery, then apply USB.
Confirm PGOOD_N is low and CHG_N is low.
At light system load, measure battery charge current. Pass: approximately 250–330 mA around the 300 mA programmed target, subject to battery voltage and thermal regulation.
Run Wi-Fi/BLE and RGB simultaneously. Pass: 3V3 remains ≥3.20 V; charge current may reduce as DPPM prioritizes SYS.
Remove and reconnect the battery while USB is present. Pass: USB-only operation continues without 3V3 collapse.
Remove USB while battery is present. Pass: transfer to battery operation causes no reset and SYS follows BAT within the range above.
Near charge completion, verify current trends toward the ~30 mA termination threshold and CHG_N deasserts when complete.
Encoder, Buttons, and RGB
Rotate the PEC11R-4220F-S0024 through all 24 detents in each direction. Pass: count direction is correct, no persistent skipped/reversed transitions, and one stable application step is generated per chosen firmware detent policy.
Press encoder. Pass: GPIO4 reads low and wakes the board from deep sleep.
BOOT/RESET. Pass: RESET restarts normally; BOOT+RESET enters ROM download mode.
RGB PWM. Test GPIO7 red, GPIO8 green, GPIO15 blue individually and mixed. Pass: channels are active high, off at 0% duty, visually distinct, and total LED current is approximately 9 mA typical at full duty.
Deep sleep. Pass: RGB channels turn off before sleep; wake occurs only from the intended encoder press test.
Radio Transient Test
Run continuous Wi-Fi or BLE transmit activity while monitoring 3V3 at U1.
Pass: 3V3 remains 3.20–3.40 V with no resets.
Investigate excursions below 3.10 V or sustained ripple above 100 mV peak-to-peak.
Final Pass Criteria
USB-only and battery-only operation both pass.
VBUS, SYS, BAT, and 3V3 meet the stated thresholds.
Native USB flashing, CDC, and HID enumeration are reliable.
Charging, DPPM/load sharing, battery removal, and source switchover behave correctly.
Encoder, RGB PWM, power LED, and JP1 all pass.
No abnormal heating, odor, oscillation, or unstable rail behavior.