Pd1180-epr r0.3

NEMA34 48 V EPR controller — RP2040 redesign

System block diagrams and operating sequence.

Design revision 0.5.0-RP2040-DRAFT — implementation and commissioning handoff. The source now uses RP2040, DRV8262DDVR with integrated power bridges, TPS26750 for the retained 48 V / 5 A EPR input, and an optional AS5600. The stocked-driver ECO follows merged PR #27 (5035034) and retains that 48 V architecture. Use the assembly and commissioning guides below to prepare the order and collect physical results after assembly.

Start with the nine-sheet power/component review, current reference-board decisions, the redesign and evidence, reviewer checklist and firmware instructions. index.circuit.tsx is the current schematic/placement source. The DATA-only source, firmware and native route are synchronized. The paired native review archive contains fresh DRC/ERC reports: 8 retained USB hole-clearance errors, 488 cosmetic warnings, and zero other errors, unconnected items or schematic-parity/ERC findings. The older GUI screenshot is explicitly historical.

The new commissioning firmware is an ARM RP2040 image with verified ELF/BIN/UF2 format and matching source hashes. The default image remains diagnostics-only. Separate stationary-power and bounded motor-test profiles provide the post-assembly workflow: <=0.8 A RMS request, 10 rpm, 10 seconds, local START and automatic stop. Use programming, readback and commissioning. Physical measurements are performed by the assembly/test team; the software results do not claim them.

The hosted preview opens release/circuit.json; its routed payload has been regenerated from the verified native board and checked against this DATA-only source. index.circuit.tsx remains editable; bun run dev opens that source. The PCB carries the matching 0.5 DRAFT revision marking.

For order preparation, use fabrication and assembly instructions, the exact-part sourcing snapshot and manufacturer acceptance checklist. They separate the supplied files/software from supplier allocation, installation and post-assembly measurements.

Source/firmware development checks:

bun install --frozen-lockfile
bunx tsci build index.circuit.tsx --routing-disabled --disable-parts-engine
bun run typecheck
bun run check:firmware-pins
bun run check:firmware
bun test scripts/rp2040-contract.test.mjs scripts/encoder-bypass-policy.test.mjs
bun run check:schematic-style

Run bun run review for all engineering and artifact checks; consult its generated report. The machine-readable release record separately retains manufacturer acceptance, sourcing and physical-test evidence.

The completed reviewer scope and remaining physical acceptance steps are in the handoff. The ordered-motor manufacturer STEP archive establishes the rear hole axes; it does not approve replacement screws or engagement depth.

Previous-board context: historical README. It is retained for review, not as evidence for the redesign.

DATA-only MCU: J10 supplies RP2040 even when J1 PD is connected. PD alone cannot run local controls. Board-side I²C and status signals are isolated through U39/U40; the brake retains independent motor-bus power. See power domains.