Getting Started With Flux

flux

I couldn’t produce a faithful schematic PDF: the available PDF export covers PCB layers only, and the schematic-rendering fallback loses symbol detail. No PDF was created, and your design is unchanged.
This export limitation needs Flux support: Contact Support.

flux

I’ll make a cosmetic-only readability pass using the ten requested blocks, left-to-right signal flow and inter-block net labels. I’ll compare the complete netlist, parts and values before and after, and won’t touch PCB layout.
Thought for 1 min 53 sec
Thought for 7 sec
1/3 Capture baseline component/value inventory and complete netlist invariants

Capture baseline component/value inventory and complete netlist invariants

Arrange ten schematic blocks and clean cosmetic wiring/labels without electrical changes

Compare before/after netlist and visually check readability; stop without PCB layout

Thought for 42 sec
Awaiting 1 task
"Schematic Readability Pass" completed.

flux

The readability pass is blocked: my available controls do not support schematic canvas placement, frames, or graphical wire/net-label editing, so I made no changes.
  • Before: 328 components / 188 nets.
  • After inspection: 328 components / 188 nets.
  • Parts, values and connectivity remain untouched; no PCB layout started.
I cannot claim the rearrangement or a full before/after netlist comparison was completed. This limitation needs Contact Support.
Sign up to send

Files

Schematic

Layout

3D View

Shutdown Design Notes
Latest correction — partial-power PWM isolation, 2026-10-10
This addendum controls over the earlier 50-component/24-net inventory and direct-PWM interface descriptions below. Independent revision review conditionally accepted simplified pump sizing, default pulls, test access, isolation and user bench acceptance, but identified TC4427A input absolute maximum VDD+0.3V: direct3V3 PWM with5V=0 violates it; R2 shunt pulldown does not protect that interface.
Completed hardware correction uses U6 SN74LVC1T45DBVT, LCSC C116653, a verified dual-supply translator rather than an AHCT buffer with unproven powered-off outputs. U6 pins1VCCA=3V3,2GND=localGND,3A=SHUTDOWN_RELAY_PULSE,4B=SHUTDOWN_PUMP_INPUT_5V,5DIR=3V3,6VCCB=5V; DIR HIGH selects A-to-B. Manufacturer supports Ioff partial-power-down protection and both ports high impedance when either supply is atGND. A input VIH>=2V/VIL=0.7VDD. Datasheet extraction reports no pullup maximum/no separateMR leakage bound; absence assertions were not machine-verified, so no invented leakage guarantee is used. Worst upward internalpullup isminimum resistance: Rparallel35kohm. R5max2222ohm yieldsMR/VDD=4.5mA, contactclosed voltage with nominal3.28V/4.1kohm/0.8mA load, pulsefrequency/duty and stablewarmup. Include assumed5V±5% railcorners and actual integrationrails.
  • Capture directTRIP and RELEASE_Ninhibit to electricalcontactopen: <=1ms. Separately capture ENABLE/Q3cutoff and LEDcurrent; Q3storage/logic andPhotoMOSrelease remain measured contributions, not guaranteed allocations. C8decay neednotprecede commandopening.
  • Freeze eachpulse input HIGH andLOW with theotherhealthy, thenstopboth. Record finaledge, LEDcurrentdecay andcontactopen; noinvented numerical stuck-pindecayrequirement. Independentlyverify ACKtimeout (~10msnominal), includingPWMcontinuing andbypass.
  • Brownout/ramp/remove eachrail; particularly3V3absent/5Vpresent and reverse. Validate boot,Teensyreset/upload/unpowered, adapterloss, externalGPIOhigh-Z/backfeed andMRthreshold/sourcecurrent. Fullreset/all-IEPE/analograilintegration isfutureBlock2/carrierscope.
  • Measure R9,IC1,D2/D3,C1/C8,R1/Q3temperature andpumpaverage/RMScurrent aftersteadywarming; includecontinuousPWMwhileinhibited andrepeatedstartup/rearm. Accept no datasheetrating exceedance and record temperatures/ambient/current; requested steady currenttarget is tensofmA, not an assumedbenchresult. EffectiveC/bias/aging/rippledata remaincandidate uncertainty.
  • At roomtemperature, measurecompleteoutputrelay+TVS+PCB leakage<=10uA atactualcontrolleropenvoltage; relayalone specification remains<=1uA. Useraccepts existingSMAJ24CA-Q; no furtheralternate/high-temperatureleakagesearch. Surgecoordination/overshoot andarbitrarywrong-cableprotection are not universallycertified.
  • Verifyoff-boardinsulatedrearBNC/panelhardware/cablemechanics and assembledshellisolation. X1isinternalwireinterconnect, notselectedrearBNC. SinglePhotoMOS/TVS/cableshortcan defeatshutdown; no single-faulttolerance/outputreadbackclaim.
Fresh checks, artifacts and limits
Read-only PCB milestone check at2026-10-10T20:38:55.575Z reports 86 airwire Errors because the PCB is unrouted; missing-footprint check at20:39:11.262Z reports no findings. No routing/placement/board edits were attempted, no clean DRC or manufacturing release is claimed.
FreshERC at2026-10-10T20:33:54.004Z 4Errors/1Warning: IC1IN_AfutureMCUsource; IC1VDDfuture5Vsource; IC1GNDconnectedbutnopower-outputsource; IC1IN_BnowgroundedbutsharesundrivenGNDsourcefinding (oldQ2semanticdriverexplanationobsolete). D1unspecifiedpintypesWarningremainsbidirectionalTVSlibrarysemantics. Requested floating-pin,powerconnection,driverconflict,NC,single-net andwireendpointchecksreportednofindings. Errors=wrong/unsatisfiedboundary untilfutureblocksprovideactualsources, Warning=possiblywrong/librarysemantics, notsuppressed. No fakepowerflags. Read-only fullnets confirmfloatingpaironlyU1output,D1,X1,TP11/12; noshortedoutput/localGND orremovedcomponentmemberships.
Fullschematicwire-read:238vertices;110logicalnetstubpairs220vertices,1unloadedOUTBstub2vertices,16isolatedcosmeticorphanverticesfromremovedparts withnoedge/net. Noexposedwire-nodedeletiontool; cosmeticcleanupdeferred, noelectricalendpointfinding. Remainingpositions/packagesunchanged. NopCBedittoolcalled; removingschematicpartsnecessarilyremovesobsoletefootprints. Existingdefault/provisional160x100mm4layerboardobject persists; old57footprints/132pads/onefill/noroutes snapshotishistorical, notnewinventory. Nochosenoutline,approvedplacement,routingorisolationcertification.
Commits8888a611rewire;9f784a58remove7;ea952e22/58b2f26d/277ec1e3/d6f82953deleteemptydumpnets;95e88fbdvalues/procurement/probelabels. ExactcurrentinventoryandERCindependentreviewfindingsarealsoin shutdown-focused-review.
**Completed:**schematicpump/dump simplification,releasepulldown,currentmarginresearch/keypassiveprocurementannotations,testaccess/isolationwarnings,structuralfailurestates,freshERCandconnectivity. **Unattempted:**physicalbenchacceptance/temperature/timing/leakage/isolation; Block2/layout/readback/simulation(thisrevision). **Blockedqualification:**noassembledboards; unspecifiedeffectiveC/5Vdriverbound preventsanalyticalLEDguarantee; actualreset/uploadintegrationfuture; stuck-pindecaylimitnotprovided. Overallproject/manufacturing/protectioncertificationnotcomplete. Power-losstriplogging remainsaseparatesystemdecision,notresolvedhere.
Historical design notes — old active-dump topology and simulation evidence, not current acceptance
Focused Review Fixes — Current Checkpoint
Current controlling final values supersede the earlier calculations below: R1=180Ω1%/0.5W0805 CRCW0805180RFKEAHP; R9=4.7Ω and R10=10Ω1%/1.5W2512 CRCW25124R70FKEGHP/CRCW251210R0FKEGHP; C1=4.7µF16V1206 C1206C475K4RACTU; C8=2.2µF25V0805 C0805C225K3RACTU. Procurement candidates are annotated on retained generic footprints; pulse/bias/ripple/temperature qualification is not complete. Commits b001a334/9104f0e0 changed properties only, not layout or connectivity. Final values were now simulated: driver≤20Ω assumed corners pass5mA,30Ω/4.75V reduced-cap corner gives4.721mA and blocks a guaranteed minimum. Zero-drop LED bound29.46mA at5.25V/-1%R, conditional on reservoir≤rail, fixes the earlier44.2mA concern.
The companion project file shutdown-focused-review is the current detailed record of the independent findings/requirements table, final simulation/netlists, procurement evidence, exact four ERC Errors/one Warning, and explicit blockers. Earlier paragraphs called final120Ω/1W values are historical superseded checkpoint evidence, not current design conclusions. Timing≤1ms and output leakage/protection remain unqualified. R5release source≈3.3mA/defaultLOW on reset/upload and future all-rail integration are required; no hardware trip latch exists here. IC2health timeout9.91232ms nominal is separate from command release.
Existing layout data corrected: provisional/default160×100mm4-layer rectangular board object,57footprints132pads/onefill/no routes; component bounds extend to y=-155.44mm. Not finished placement or a selected/released outline. No layout edits in this batch; do not describe the project as having no layout data.
Status, Authorization and Review Gate
The latest attachment's planning-only pause was honored. The user's subsequent explicit “Start the schematic when done” superseded that pause for the shutdown block ONLY. Shutdown connectivity is now built; stop for review before other subsystems or layout. This is not a certified safety controller, production release, measured timing result or claim that all shutdown requirements are proved.
Fresh inspection: 57 components,14 unique part types,28 named nets,127 connected pins,254 wire vertices forming127 named-net stub segments,5 intentional no-connect markers and12 connected testpoints. Every component has one Functional Group: IO U1 Shutdown Contact54 objects; IO X1 Floating Output3 objects. Modern canonical net labels provide actual logical connectivity; no routed PCB copper/outline/placement was created. No readback circuit or CONTACT_SENSE exists.
Confirmed Requirements
  • Normally-open permission contact; closure permits running, any open circuit including cable unplugging causes shutdown.
  • Nominal user measurements: terminal8 at3.28V open,approximately4.1kΩ pullup,approximately0.8mA closed. Manufacturer tolerances/logic thresholds/powered-off behavior remain unverified.
  • RearBNC center=terminal8; shell=FLOATING controllerdigitalground. User reports only1nF/2kV couplingtochassis. No localGND,sensorreturn,chassis,USB,RJ45 or mounting-hardware connection is permitted.
  • PhotoMOS Ron≤5Ω,relay-aloneleakage≤1µA,rating≥40V/≥100mA,isolation≥1.5kV. Completeoutputrelay+TVS+PCB leakage≤10µA over10–40°C.
  • Worst-case hardware-command-to-electrical-contact-open≤1ms over10–40°C; processor-hang detection,controllerfiltering andmechanicalstop excluded.
  • No revision1readback,secondoptocoupler orstuck-contactproof test. Bypass only suspendslimit/sensorfaulttrips,neverheartbeat/power/reset supervision; unlimitedduration withamberLED/app indication.
Actual Inventory and Values

Table

DesignatorsPart/value and function
U1AQY212SX normally-open PhotoMOS; pins1anode/2cathode localLED,pins3/4floatingcontact
IC1TC4427AEOA713; channelA5Vpumpbuffer,channelB5Vdefaultdumpbuffer
IC2LTC6993IS6-2#TRPBF rising-edge retriggerablehealthtimer
U2/U3SN74LVC1G11DCKRG4 three-inputAND / SN74LVC1G04DCKR TRIPinverter
U4/U5TPS3808G01QDBVRQ1;5V/3V3sense,3V3supply,sharedMR/RESET
D1SMAJ24CA-Q bidirectional across-floating-contact TVS,conditional/notqualified
D2/D3SS14 clamp/positivepump rectifiers
Q1Infineon2N7002H6327XTSA2,verifiedG1/S2/D3,active reservoir dump
Q2/Q3MMBT3904WT1G,B1/E2/C3;defaultdumptranslator/directseriesLEDcutoff
X1WAGO236-102 two-wireinternalfloatingpanelinterconnect;NOT panelBNC
R1180Ω,1%,0805,0.5W,CRCW0805180RFKEAHP; focused-review LEDcurrentlimit
R2/R3/R410kΩ,1%;pulse/ACKpulldowns andTRIPpullup
R51kΩ,1%,hardrelease/MRdefaultlow
R6/R7/R810kΩ,1%;supervisorRESETpullup/default5Vdumppullup/Q2basecurrentlimit
R9/R104.7Ω/10Ω,1%,2512,1.5W,CRCW25124R70FKEGHP/CRCW251210R0FKEGHP; pulse/thermal acceptance pending
R111kΩ,1%,reservoirbleed
R12/R13/R14121kΩ/1MΩ/392kΩ,1%,timerSET/DIVupper/DIVlower
R15/R1610kΩ,0.1%,supervisorlowerdividers
R17/R18107kΩ/66.5kΩ,0.1%,5V/3V3upperdividers
R19/R20/R21100kΩ,1%,Q2base/Q1gate/Q3basepulldowns
R221kΩ,1%,Q3basecurrentlimit
C14.7µF,10%,16V,1206,C1206C475K4RACTU nominal candidate;effective≥2.35µF/bias/ripple/10–40°C notqualified
C2–C7100nF,10%,25V,0603;IC1/IC2/U2/U3/U4/U5localdecouplers respectively
C82.2µF,10%,25V,0805 C0805C225K3RACTU nominal candidate;effective1.1–2.42µF assumed,notqualified
C94.7µF,10%,25V,0805IC1localbulk
TP1–TP1212 connected1.5mmtestpointpads;seeinterface table
Count:6ICs,1PhotoMOS,3diodes,3transistors,1connector,22resistors,9capacitors,12testpoints=57. Genericpassivevalues/packages/ratingrequirements are not exactqualifiedprocurementMPNs. ResistorsotherthanR1/R9/R10 retain0603/0.1W. Numeric tolerance properties normalized;0.1% may display as100m% in tool formatting.
Actual Named Nets and Interfaces

Table

Net / interfaceMembership or contract
5VIC1VDD,C2/C9upper,R7/R17upper,TP1;futurepower source absent
3V3IC2/U2/U3/U4/U5supplies,C3–C7upper,R4/R6/R13/R18upper,TP2;futurepower source absent
GNDLocalICgrounds,decoupler/bleed/divider/pulldownreturns,Q1S,Q2/Q3E,D2anode,TP3;NEVER floatingpair
SHUTDOWN_RELAY_PULSEIC1INA,R2pulldown,TP4;provisional3.3V50kHz50%duty. StaticHIGH/LOW supplies no continuousDCenergy
SHUTDOWN_HEALTH_ACKIC2TRIG,R3pulldown,TP5;proposed1kHzfresh-software-qualified risingpulses,not autonomousPWM
SHUTDOWN_TRIPU3A,R4pullupto3V3;HIGH=directinhibit,LOW=notrippending. High-Z/reset defaultsTRIP
SHUTDOWN_RELEASE_NU4/U5MR,R5pulldown;LOW=hardinhibit,HIGH=release request. Despite name,not anactive-lowpermission! Futurehardware must reflect reset/upload/ALLrequiredrails and supplyapproximately3.3mA intoR5. Never anunsupervisedstaticMCUpermission
SHUTDOWN_POWER_OKU4/U5open-drainRESET,R6pullup,U2B,TP6
SHUTDOWN_HEALTH_OKIC2OUT,U2A,TP7
SHUTDOWN_NO_TRIPU3Y,U2C
SHUTDOWN_QUALIFIED_ENABLEU2Y,R8/R22inputs,TP8;HEALTH_OK AND POWER_OK AND NOTTRIP
SHUTDOWN_DUMP_NPN_BASER8output,R19pulldown,Q2B
SHUTDOWN_DUMP_COMMANDQ2C,R7pullupto5V,IC1INB;defaultHIGH=dump
SHUTDOWN_DUMP_GATEIC1OUTB,Q1G,R20pulldown,TP10;5Vinternal,NOTTeensyGPIO
SHUTDOWN_LED_SWITCH_BASER22output,R21pulldown,Q3B
SHUTDOWN_LED_RETURNU1LEDcathodepin2,Q3collector
SHUTDOWN_PUMP_BUFFERIC1OUTA,R9input
SHUTDOWN_PUMP_AC_DRIVER9output,C1input
SHUTDOWN_PUMP_RECTIFIERC1output,D2cathode,D3anode
SHUTDOWN_RESERVOIRD3cathode,C8upper,R11upper,R1input,R10input,TP9
SHUTDOWN_DUMP_DRAINR10output,Q1drainpin3
SHUTDOWN_LED_ANODER1output,U1LEDanodepin1
SHUTDOWN_TIMER_SETIC2SET,R12upper
SHUTDOWN_TIMER_DIVIC2DIV,R13lower,R14upper
SHUTDOWN_5V_SENSEU4SENSE,R17lower,R15upper
SHUTDOWN_3V3_SENSEU5SENSE,R18lower,R16upper
FLOAT_VIBRUNNER_TERMINAL8U1pin3,D1pin1,X1pin1,TP11;rearinsulatedBNCcenter
FLOAT_VIBRUNNER_DIGITAL_GROUNDU1pin4,D1pin2,X1pin2,TP12;rearinsulatedBNCshell
FutureTeensy/power sources have NOT beenadded. Until releasehardwaredrivesHIGH andTRIPisdrivenLOW,theblockis intentionallyinhibited evenwithpulse/ACKactivity. Analog/IEPErailvalidity must laterfeed hardrelease;local5V/3V3monitoring alone is not all-systemsupervision. Power/resetrecoverydoesnot create a hardwaretrip latch; laterfirmware must retain deliberate rearm/latchedtrip behavior. No bypass net enters thishardware.
No-connects:IC1NC_1/NC_2,U3NC,U4CT/U5CT. CT intentionallyopen selectsdocumentedrecoverydelay. TP11/TP12 requireisolated/differentialprobes;never attachgroundedscopecliptoeitherfloatingoutputconductor.
Verified Part Evidence and Source Defect
AQY212S family60V/0.5Aabsolute maximum,recommendedload≤48V,2.5ΩmaxRon,1µAmaxleakage,0.2msmaxreleaseatIF5mA/ILmax testconditions. RecommendedLED5–30mA,operatecurrent3mAmax,turnoffcurrent0.4mAmin,LEDVF1.5Vmaxat50mAtestpoint;characteristics25°C. 1500Vrmsrelayrating is notassembledisolationcertification. ManufacturerPDFdrawingidentified1anode/2cathode;indexedquerydidnotindependentlyresolvethatdrawing. Outputpins3/4arefloating.
LTC6993-2S6pins1TRIG/2GND/3SET/4DIV/5V+/6OUT verified. POL0OUTlowduringstartupanduntiltrigger;POL1canassertafterstartup,notused. Timingformula andDIVCODE4/NDIV4096/1MΩ-392kΩDIVsetting verified.
TPS3808G01threshold0.405V,MRinternal90kΩpullup,open-drainRESETassertsonlowSENSE/MR. Negative-goingaccuracy±2%;CTopengives12–28msrecovery. Pins1RESET/2GND/3MR/4CT/5SENSE/6VDDverified. Senseassertion20µs isNOMINAL,noMAX.
TC4427A4.5–18Voperation,VIH2.4Vmin/VIL0.8Vmax;pins1NC/2INA/3GND/4INB/5OUTB/6VDD/7OUTA/8NC. RetrievedRoutlimitsused18Vconditions,notguaranteed5Vloadedpumpenvelope. SS14statedVF0.55Vat1A/25°C/pulsedtest,1Aaverageforwardcurrent. ExtractedVFentrynotexplicitlyMAX;10–40°CVF/dynamics remainunqualified.
ResolvedQ1librarydefect: removed2N7002,215librarymodel mappedG1/D2/S3,contradictingmanufacturerG1/S2/D3;part-qualityreportfiled. ReplacedwithInfineon2N7002H6327XTSA2,libraryUID7322ba8a-7592-47e2-939b-c65133647798/versionc93a160d-34c0-427e-a2d5-3c63c6f81538. Manufacturerandread-onlylibraryinspectionagreeG1/S2/D3. Pulsecurrent1.2Aat25°Cverified;extracted4ΩRDSonclaimwasNOTvalidated,sohotRDSon/SOA areopen. Infineondatasheet.
Q2/Q3MMBT3904WT1Gmanufacturer/libraryagreeB1/E2/C3. VCEsat0.2VmaxatIC10mA/IB1mA,pulsedtest. Saturationstorage atactualbaseoverdrive/10–40°C isnotboundedbyourretrievedevidence. Q3directseriescutoffavoidsrelyingsolelyonreservoirvoltagefallwithcontinuedpumping.
Calculations, Power Assumptions and Timing Budget
Health and Rail Supervision
  • tOUT=4096×121kΩ/50kΩ×1µs=9.91232msnominal. ICaccuracy±3%forNDIV≥512 plus1%RSET gives9.5188–10.3118ms,beforeTC/aging/interfaceeffects. ACKproposed1kHz,jitter<2ms requiresfirmwareapproval. This isNOTcommandlatency.
  • 5Vtripnominal0.405×(1+107k/10k)=4.7385V;3V3trip3.09825V. Combining±2%thresholdandopposite0.1%dividererrors givesapproximately4.635–4.842V and3.031–3.166V,beforeinputcurrent/TC/hysteresis. Railtolerancesmustavoidnuisanceinhibit;4.635Vlow5Vtripstillonly0.135Vabovedriver4.5Voperatingminimum. Fastdrops/supervisordelayneedtest.
  • Withtwo90kΩMRinternalpullupsinparallel andR5=1kΩ,nominalundrivenrelease=3.3×1/(45+1)=71.7mV. Thisusesnominalpullupresistance,notguaranteedworstcase. Poweredreleasebuffer3.3Vmustsupplyabout3.3mAplusinputcurrent;Teensy/resetpinimplementationnotyetbuilt.
Historical Pre-Focused-Review Passive Revision — Superseded
Anintermediate180ΩLED/10Ωpump-seriesversionfailed5mAinstantaneousminimumin5of24assumedsimulationcorners. FinalreviewvaluesareR1=120Ω,R9=4.7Ω,C1=4.7µF,C8=2.2µF,R10=10Ω;finalvaluesnotresimulated.
For5mAwithVF1.5V,VCEsat0.2V,R1+1%,reservoirminimum=1.5+0.2+0.005×121.2=2.306V. TheseVF/VCE valuesaretest-conditionevidence,notfull-temperaturejointguarantees. Underprovisionalsupply≤5.25V,evenignoringLEDdrop,R1−1%limitsDCcurrentto5.25/118.8=44.2mA,below50mAabsoluteLEDlimit butNOTproofrecommended≤30mA. MaximumR1idealDCpower0.232W approaches0.25Wrating;actualLEDdropreducesit,butfinalderating/pulsechoice mustbereviewed.
A50%dutyaveragedfixed-dropmodelusesRseries-effective≈4×(Rdriver+R9),withadditionalcouplinglossandreservoirripple. Forassumed4.64Vpump,0.55Veachdiode,1.7VLED+Q3,Rdriver30Ω,R9+1%,R1+1%,R11−1%,averageLEDestimate≈5.78mA;withC8effective1.1µF,rippleestimated≈76mVpp,givingapproximately5.46mAminimum. This isonlya handestimatebasedonunverifieddriver/diode/capacitanceassumptions,NOTaguaranteedmargin. Candidatef50kHz50%duty,jitter/edgequalityandwholetemperatureenvelope requiretesting;noacceptanceclaim.
R9aloneboundsideal5.25Vstartupcurrentat5.25/(4.7×0.99)=1.13A. InhibitedautonomousPWMmaycontinueindefinitelyafterACKtimeout,sopump/dumpthermalbudgetmustnotassumeGPIOstops. Inno-lossaveraged50%dutymodel,Idump≈5.25/(4×4.7+10)=0.182A,PR9≈4×Idump²×4.7=0.625W,PR10≈Idump²×10=0.332W. Hence1W2512requirementsratherthaninitial0.125/0.25Wparts. Theseareaveragedestimates,notRMSpulse/thermalproof. Driver/Q1hotresistancechangesdissipation;actualMPNs,SOA,pulsecurvesandtemperaturederatingremainopen.
Reservoirpassivebleedτ=1kΩ×2.2µF=2.2msnominal. Itensureseventualenergylosswhenactivedumppoweralsodies,not≤1mscommandrelease. Stuck-HIGHcantransferC1storedchargeandtake longerthanC8-onlybleed.
Separate Command-to-Open Budget — Allocation, Not Demonstrated Bound
CommanddefinedatSHUTDOWN_TRIPLOW→HIGH(orhardwareinhibitassertion),notevent-detectionsoftwaredelay. DirectTRIPpathisU3→U2→Q3LEDinterrupt→PhotoMOSoptical/contactrelease. DumpbranchU2→Q2→IC1B→Q1dischargesisparallel,NOTrequiredtodrainC1/C8beforeQ3opens.

Table

PortionProvisional allocationEvidence / gap
U3+U2logic/interface≤25µsFullvoltage/temperature/edge/loadmaxnotassembledverified
Q3drivefall+saturationstorage≤150µsAllocationonly;noactual10–40°Cstoragebound
LED/inputparasiticcharge/opticaltail≤25µsNoaddedLEDshuntstorage;device/parasiticdecayunverified
PhotoMOScontactrelease≤300µsRetrieved0.2msmaxat25°C/IF5mA/ILmax;actual0.8mA/fulltemperatureboundunresolved
Nominalallocationtotal≤500µsLeaves500µsrequirementmarginONLYIFeachallocationvalidated
≤1msworst-caseover10–40°C isNOTproved. Power/resetMRpathsalsocontainsupervisorassertiondelaywithonlynominalevidence;doNOTsubstitute9.91mshealthtimeoutforcommandrelease. NooutputthresholdtimingmeasurementorfullrelaySPICEmodelwasperformed.
Historical Behavioral Simulation Evidence — Intermediate Values Only
NativeNgspicesensitivitycompletedusingR1=180Ω,R9=10Ω,C1=4.7µF,C8=2.2µF,R11=1kΩ,f50kHz50%duty. DriverrepresentedbyassumedRout5/10/20/30Ω;source4.64/5.00/5.25V;fixedSS14drops0.55Veach;fixedLED1.5V/Q3sat0.2V. Nominal/reducedpairedcaps4.7/2.2µFand2.35/1.1µF;nofull-temperaturedevicephysics.
-24corners:worstinstantaneousLEDminimum4.034mA;average4.209–9.294mA. 5cornersmiss5mAminimum;Rdriver≤10Ωallpassinthismodel,worstminimum5.900mA. Thismotivatedfinalpassiverevision;donotmislabeloldresultasfinalvalidation. -StuckHIGH/LOWat5mswithQ3ON/Q1OFF:modelmaxdelaytoLED<0.4mA2.042msHIGH/0.587msLOW. Thesearenotcontacttimes,arbitraryfaultphaseboundsorfinalvaluepredictions. -IdealseriesQ3opensat5mswhilepumpcontinues;20µsidealizeddumpdelay/RQ1=10Ω. OldversionprecommandLEDaverage7.468mA,reservoir3.046V;C8energy10.04µJ. IdealseriescutoffreducesLEDtonAwhileC8stayscharged;continuouspump/dumpresidual0.668–0.843V,average0.759V. OldR10peak0.238W,steadystateaverage14.46mW. Dump-onlynominalcomparisonDIDextinguishLED,eventually;cannotclaimpersistentLEDcurrentforthatparticularrun. Fullvariation/physicaltimingnotproved. -Powerstopped/Q3OFF/Q1OFFshows2.2msreservoirbleed;seriescutoffkeepsreservoirdecayoutofcommandcriticalpathintheidealmodel.
Storedtraceability: healthycurrent/netlist,healthyvoltage,staticfaultmeasurements,longestdecaywaveform,seriescutoff/dumpwaveform,powerstoppedwaveform,dump-onlywaveform,completeanalysistrace. Resultshaveexactbehavioralnetlists/assumptions;retentionisnotguaranteedindefinitely. Final120Ω/4.7ΩvalueswereNOTresimulated;noactualPhotoMOScontactmodel/temperaturequalification.
Failure-State Analysis — Structural, Not Bench Validation

Table

State/faultIntended actual path and remaining limitation
Allboundarysourcesabsent/startupTRIPpullupasserts;RELEASEpulldownholdsMRlow;ACK/pulsepulldowns;IC2POL0startupOUTlow. Q3off,defaultdump. Low-voltageunpoweredICbehavior/ramp mustbe tested
Commandtrip/disarm,evenifPWMcontinuesU3/U2disableQ3directlyandQ2releasesdefaultdump. ReservoirdecaynotserialwithLEDcutoff;≤1msphysicalboundunproved
HEALTH_ACKstuckHIGHorLOW,pulsecontinuesAfterlastvalidrisingedgeapproximately9.91msIC2OUTfalls;Q3off/dumpasserts. FreshsoftwareACKcontractessential;noautonomousACKgeneration
RELAY_PULSEstuckHIGHorLOW,ACKcontinuesC1preventssteadyDCenergysource;storedC1/C8energydissipatesLED/R11. OldmodeldemonstrateseventualLEDoff;finalworsthang/openboundnotmeasured
3V3losswhile5VpresentQ3basepulldownremovesLEDenable,Q2basepulldownreleasescollector,R7/IC1Bassert5Vdump. Partialbrownout/backpowerbehaviorrequiresfulltest
5Vlosswith3V3presentU4SENSEinhibitsviaRESET;no5Vpumpenergy,Q3off/dumpifdriverstilloperational;complete5VlossusesR11bleed. Fastfalls/below4.5Vdriverbehaviorunqualified
Reset/uploadFuturehardwaremustpullRELEASE_NlowindependentGPIOsoftware;TRIP/PULSE/ACKdefaultsalsoinhibit. ActualTeensyreset/programinterconnectionnotbuilt
Analog/IEPErailbadNotlocallymonitored;laterpowerblockmustfeedhardRELEASE_N. Thisintegrationisdeferred,notimplemented
BypassNobypassinputtohardware;HEALTH/power/resetgatesremainmandatory. FirmwaremustnotqualifyACKwithoutprotectionloopprocessing
TRIPstuckHIGHOpen/inhibited
TRIPstuckLOWorRELEASEstuckHIGHCannotaloneoverridedynamicpulse/ACK/localrailgates;butsinglefaultmay defeatthatparticularcommand/resetinhibit. Notasingle-fault-tolerantcertifiedcontroller
OutputcableunpluggedControllercontactopensbywiringcontract;actualcontrollerconfiguredresponseunverified
U1/TVS/outputcableshortedMaydefeatshutdown;singlecontactarchitectureisNOTsingle-faulttolerant,noreadbackrequired
Floating TVS/Connector Qualification — Still Blocked
PESD30VL1BLusableexactlibrarypartnotfound;typical34V/42Vclampsarenotguaranteedbounds. SMAJ30CA-Qrejected:62.9Vmax8/20µsclampat41.5Aexceedsrelay60Vabsolute maximum.
ActualD1SMAJ24CA-Qhas24Vstandoff,1µAmaxleakageat24V,26.7–29.5Vbreakdownat1mA,max38.9Vclampat10.3A10/1000µs,max50.6Vat51.5A8/20µs. Headroomtorelay60Vabsmaxis21.1V/9.4VrespectivelyONLYunderstatedtestpulses. The50.6V8/20µsfigureexceedsrelayrecommended48V,eventhoughbelowabsmax. Noactualfault-source/waveform/temperature/cableinductancecoordinationproof;D1remainsconditional,notacceptedcertifiedclamp. Continuous26Vwrong-sensorcablefaultisabovestandoff;actualsensorvoltage/current/energyandcontrollerdamageriskmustbequalified. FastESDovershoot and10–40°Cleakage areopen.
Relay1µA+D1stated1µA leaves8µAof10µAbudgetforPCBunderstatedconditions,NOTa10–40°Cguarantee. At10µAtotal,nominal4.1kΩpullupdrop41mV;at2.5ΩRon,nominalclosedvoltage≈2mV. ActualPCBcontamination/creepage/clearance/material/productionvariationremainunqualified.
WAGO236-1022poles/5–5.08mmpitch,IEC≥250V/24Aunderstatedcategories isinternalinterconnect,NOTisolatedpanelBNCcertification. PriorpanelBNCsearchesfoundnoexactusablepart;Amphenol31-5486/31-5540isolatedhousingfamiliesremaininvestigational. ExactrearBNCsuffix/import,insulatinghardware,panelstack/support/strainrelief andassembledshell-to-panelisolation aredeferred/unbuilt. Do notusemetal31-5640orasimilarnamedconnectorwithoutverification.
Fresh Read-Only Checks and Completion Matrix
Finalfullmetadata/netmembershipinspectionandget_netsverifyeachfloatingnetcontainsonlyU1output,D1,X1andonefloatingtestpoint;localGNDcontainsnoneofthoseoutputpins. Q1drain3isR10dumpnode,source2localGND,gate1IC1B. All127connectedpinsand5no-connectsaccountfor132physicalpins;noavoidableinternalfloatingpinremains.
FinalERC:4Errors,1Warning. Historical129floating-pinErrorsand6missing-power-connectionErrorsresolvedbyactualwiring. Nofloating-pin,missing-power-connection,driver-conflict,shorted-component,single-pin-net,no-connect orunconnected-stub findingsreported.

Table

RemainingfindingSeverity / interpretation
IC1INAundrivenError;futureTeensypulsesourceabsent,explicitunfinishedboundary
IC1VDD/GNDundriven2Errors;futurepowersourcesabsent,nofakepowerflagsadded
IC1INBundrivenError;read-onlyconnectivityshowsQ2collector+R7pullupactuallydriveit. ERCdoesnotrecognizetransistor/resistoropendrain-style driver;requiresmodel-awareEEreview,notwrongnetwiring
D1pins1/2unspecifiedtypeWarning;bidirectionaldevicepinfunctioncheckedagainstBournsdatasheet,wiredonlyacrossfloatingpair. Librarysemanticwarningretained,notmasked
ErrorsremainopenandareNOTacleanERCclaim. Warningmeanspossiblywrongpendingreview,notprovedwrong. Logicalisolationcheckisnotphysicalcertification. Layoutchecks/airwiresdonotproveboardreadinesswithnoroutedlayout.

Table

Assigned itemResult
Readupdatedspec/notesandinspectbeforeeditCompleted
Reuse57partsandrepairQ1defectCompleted;verifiedalternate,preservedcount
Actualshutdownwiring/namedboundaries/testpoints/groupsCompleted;28nets,127stubs,5no-connects,12TPs
Avoidableinternalfloating-pinerrorsCompleted;noneinfreshERC
ERC/connectivitychecksandstructuralfailureanalysisCompleted;4Errors/1Warningexplicitlyrecorded
Behavioralpump/staticfault/idealseriescutoffsimulationCompletedforintermediatevalues;notphysicaldevicevalidation
Finalpumpcurrent/pulsepower/fulltemperaturequalificationFinal180Ω/4.7Ω values simulated in focused review; guaranteed minimum/pulse/thermal/cap envelope blocked; sourced candidateMPNs annotated
Guaranteed≤1mscommandrelease10–40°CFailedtocomplete;gate/Q3/PhotoMOSfulltemperatureactual-loadboundsandbenchmeasurementabsent
Relay/TVS/PCB10–40°CleakageandactualTVScoordinationFailedtocomplete;faultdefinition/temp/parasitic/leakageevidenceabsent
ExactinsulatedrearBNCimport/qualificationUnattemptedthisresume;exactmodel/mechanicsdeferred,boundaryX1only
FullupdateddocumentsreadbackCompletedwhenfinalfullreadreturnverified
Physicalfaultinjection/bench/EEapprovalUnattempted;hardwaredoesnotyetexist
Layout/othersubsystems/power-lossloggingUnattempted;expresslyoutsidebatch
Commits and Separate System Gate
Historicalcomponentadds:e8fb9798/8c9db61f/8403adbf/18d151fc precededplanningpause. Resumecommits:f4f79d21Q1replace;634cc102actual28nets/5NCwiring;ac6087f3initialvalue/interfaceannotation;b72a0408passiverevision/tolerancenormalization;38d08298nettypeclassification;51d433881W2512pump/dumpratings;a2edb4b1finalR9=4.7Ωstartup/currentlimit. Finalhardwarecheckpointa2edb4b1,notboardrelease.
Latest-triplogging5spre+5spostaccelerationANDbias25.6kS/s,PSRAM→second-padQSPIflash,nonvolatilesettings/logs remainsseparatescope. ImmediatepowerlosscanloseuncommittedPSRAMandcannotcollect5sposttriggerwithoutpower;hold-up/continuousdurablejournal/incompleterecordpolicy isstillunresolved. No loggingpowerstorage wasbuilt. Stopforreviewhere;donotproceedtootherblocks/layoutwithoutauthorization.

  • Latest correction — partial-power PWM isolation, 2026-10-10

  • Current revision — simplified prototype, 2026-10-10

  • Actual changes and inventory

  • Hand-selected pump and LED target — not a simulation or guaranteed envelope

  • RELEASE_N default-inhibit calculation

  • Connectivity/failure-state verification and control semantics

  • Probes and first-board acceptance checklist

  • Fresh checks, artifacts and limits

  • Historical design notes — old active-dump topology and simulation evidence, not current acceptance

  • Focused Review Fixes — Current Checkpoint

  • Status, Authorization and Review Gate

  • Confirmed Requirements

  • Actual Inventory and Values

  • Actual Named Nets and Interfaces

  • Verified Part Evidence and Source Defect

  • Calculations, Power Assumptions and Timing Budget

  • Health and Rail Supervision

  • Historical Pre-Focused-Review Passive Revision — Superseded

  • Separate Command-to-Open Budget — Allocation, Not Demonstrated Bound

  • Historical Behavioral Simulation Evidence — Intermediate Values Only

  • Failure-State Analysis — Structural, Not Bench Validation

  • Floating TVS/Connector Qualification — Still Blocked

  • Fresh Read-Only Checks and Completion Matrix

  • Commits and Separate System Gate