Phase-1 board: shrink to 100 × 80 mm, with the BOM's L1 and U7 lands

HANDOVER.md

@@ -42,7 +42,7 @@ manager, CAN 2.0B @500k. Docs 01–07 are the spec; read 05 (build plan) first
 | Design docs 01–07 | complete (07 = module firmware, new) |
 | Phase-1 schematic | **complete, v1**: 7 generated sheets, 137 components, ~90 nets machine-verified; audited (kicad-happy + ngspice 38/40 pass) |
 | Footprints | all vetted; custom lib `labbench.pretty` (LM5145 RGY, LMR36015 RNX, DAC80502 no-EP WSON, PowerFET_SON5x6_GDS) |
-| PCB — Phase 1 | **Routed, 0 unconnected, 0 DRC errors** (PR #3, 2026-09-27; review fixes in a follow-up PR from `claude/project-thread-nojoms`): pass-1 + `fanout.py` + Freerouting 1.9 + `finish_routes.py`, then `eco_move.py` for the review moves; 1166 tracks / 357 vias. DRC = 9 silk *warnings* (6 are J1/J4 terminal-block silk over the edge, by design). Fab zip generated. `gen_board.py` PLACEMENT matches the board again (every footprint checked) |
+| PCB — Phase 1 | **100 × 80 mm, routed, 0 unconnected, 0 DRC errors** (2026-09-27, draft PR from `claude/phase1-100x80`; the 120 × 80 layout it replaces is kept on branch `phase1-120x80`). Re-placed from the netlist, so L1 now has the 17 mm MWSA1707S/XAL1510 superset land and U7 the SC-70-5 land the BOM orders (the 120 × 80 board still carried XAL1350 and SOT-23-5 lands: do not order it). Output bank tightened round the bigger L1; R30 Kelvin shunt, U4/U5 and their sense traces moved as one block with the same geometry; Q3/Q4, J4 and the LTC7004 stack down the right edge. Pipeline: pass-1 + `fanout.py` + Freerouting 1.9 + `finish_routes.py`; 1303 tracks / 353 vias. DRC = 11 silk *warnings*. Fab zip + CPL regenerated |
 | PCB — Phase 3 backplane | **FAB-READY (2026-07-26, d9e1a7b)**: 0 DRC, 0 unconnected, silk 39/39 clean, no plane islands. Gerbers+drills in `fab/` (gitignored) via `python3 ../common/finish_board.py phase3-backplane.kicad_pcb`. Cross-checked: Edge_Cuts exactly 330.00×100.00 mm; drills 2×6.4 (M6 lugs), 16×2.8 (8 slots × 2 XT60 pins), 6×3.2 (M3), 86×1.0, 61×0.4. **Still gated on the XT60 polarity buzz-out before ordering** |
 | PCB — Phase 2 | **83 unconnected, 0 copper DRC, silk clean (2026-07-26, c1a86eb)** — see the resume section; finish by hand in KiCad. Older detail below: |
 | PCB — Phase 2 (history) | **(2026-07-25, 27fb2d1).** `gen_board.py` placement green (173 comps, all pour/courtyard/edge assertions pass, 130×90 4-layer); `route_board.py` pass-1 done (power pours, In2 heat patches, both phases' gate fan-outs, Kelvin pairs, disconnect trunk). DRC: **copper down to ~19 clearance + ~11 dangling/mask/hole in 3 known clusters** (see resume section); 243 unconnected = signal nets, autoroute not yet run. Found & fixed a real LM5143 land-pattern bug in the process (see load-bearing decisions) |
@@ -209,12 +209,14 @@ Notable route_board facts a future session needs:
    is `common/lcsc_parts.py`; `--check` fails if anything is stale. Still
    open: generic R/C/jellybean/header numbers, and the `CHECK:` rows in the
    BOMs (footprint/variant mismatches vs SOURCING.md).
-4. **Phase-1 board** — routed (0 unconnected, 0 DRC errors) and its
-   review items fixed (2026-09-27): C28 sits on U3.20, the VBUS divider
+4. **Phase-1 board** — shrunk to 100 × 80 mm and re-routed (0
+   unconnected, 0 DRC errors, 2026-09-27) with the BOM's L1 and U7 lands;
+   the 120 × 80 version (wrong L1/U7 lands) is on branch `phase1-120x80`.
+   Earlier review items still hold: C28 sits on U3.20, the VBUS divider
    (R60/R61/C62) sits by U10.14, and every part offset is in `gen_board.py`
-   PLACEMENT. VOUT_INT's 39.5 mm FB sense run was left as routed: it keeps
-   5.5 mm or more from SW copper on every layer and its long end is the
-   low-impedance output side. Next: owner picks the BOM `CHECK:` parts,
+   PLACEMENT. The VOUT_INT FB sense run (52 mm, tapped at L1.2) keeps
+   5.5 mm or more from SW copper on every layer, enforced by
+   `tools/fb_reroute.py` after routing. Next: owner picks the BOM `CHECK:` parts,
    then order.
 
 **Gates before ordering ANY board — including the fab-ready backplane:**
@@ -316,9 +318,9 @@ by hand. If a DRC report ever shows this class again, suspect the env.
 - **INA228 ALERT has no external pull-up** in schematic v1 — firmware enables
   PB7's internal one; add a discrete pull-up in the next schematic rev.
 - **Grounding**: PGND/AGND split planes joined ONLY at NT1 (net-tie beside the
-  sense amps); In1 has an AGND pocket under the LTC7004 cluster. Never add a
-  via that shorts the domains — the seam geometry lives in gen_board.py
-  (`SEAM`, `AUXW`, `POCKET`).
+  sense amps). Phase-1 (100 × 80) has no AGND pocket: the LTC7004 cluster
+  sits below the seam. Never add a via that shorts the domains — the seam
+  geometry lives in gen_board.py (`SEAM`, `AUXW`).
 - **Kelvin shunt**: pours grab only the outer halves of R30's pads; sense
   traces leave the inner edges. Preserve this in any re-layout.
 - Package truths (all datasheet-verified): LM5145 pin 15 = isolated "EP"

hardware/MECHANICAL.md

@@ -25,7 +25,7 @@ component + airflow:
 | Board | Size | Layers/copper | Notes |
 |---|---|---|---|
 | phase2-module | **130 × 90 mm** | 4-layer (stackup below) | grows from P1's 120×80 for hot-swap + 4 FETs; XT60PW-M + signal row on the bottom edge (power connector proud by ~2 mm for power-first mating) |
-| phase1-module | 120 × 80 mm | 4-layer | unchanged; gets the same bottom-edge connector pair so it can plug the backplane too |
+| phase1-module | **100 × 80 mm** (was 120 × 80; that layout is kept on branch `phase1-120x80`) | 4-layer | shrunk to fit JLCPCB's ≤100 × 100 mm tier; gets the same bottom-edge connector pair so it can plug the backplane too |
 | phase3-backplane | **~330 × 100 mm** | 2-layer 2 oz | 8 × 30 mm slots + end margins + manager header zone; M6 lug bolts at entry; bus rails solder-reinforced |
 | phase3-manager | **100 × 80 mm** | 2-layer 1 oz | display module on standoffs above (or panel-mounted via ribbon); encoder/keys wired to panel |
 

hardware/common/lcsc_parts.py

@@ -221,8 +221,9 @@
      "through-hole, hand-solder; SOURCING lists 2EDG 5.08 plugs C3697 for "
      "P1 bench IO, but this footprint is a 5.0 mm Phoenix PT - pick the "
      "matching header"),
-    ({P1: ["F1"]}, "through-hole, hand-solder; mini blade holder, likely "
-     "C3207114 as on the manager, not confirmed for 10 A"),
+    ({P1: ["F1"]}, "through-hole, hand-solder; the land is KiCad's "
+     "direct-solder mini blade pattern, so a 10 A mini blade (ATM) fuse "
+     "solders straight in with no holder (C3207114 does not fit it)"),
     ({BP: ["C2"]}, "SOURCING's 470 uF part C106666 is THT D10; this board "
      "uses a 16x17.5 SMD footprint - choose an SMD part"),
     ({P1: ["J2", "J3", "J5", "J6"]}, "through-hole pin header: hand-solder "

hardware/phase1-module/bom/phase1-module-bom.csv

@@ -27,7 +27,7 @@ Item,Qty,References,Value,Footprint,LCSC,MPN,Manufacturer,Unit USD,Ext USD,Note
 26,1,D5,SMBJ33A,Diode_SMD:D_SMB,C224019,SMBJ33A,Littelfuse,0.122,0.122,
 27,1,D6,1N4148W,Diode_SMD:D_SOD-323,C2128,1N4148WS,"Jiangsu Changjing Electronics Technology Co., Ltd.",0.0158,0.016,1N4148WS is the SOD-323 version (1N4148W is SOD-123)
 28,1,D7,STATUS,LED_SMD:LED_0603_1608Metric,C2286,KT-0603R,Hubei KENTO Elec,0.0075,0.007,red 0603 LED (Basic)
-29,1,F1,10A blade,Fuse:Fuse_Blade_Mini_directSolder,,,,,,"through-hole, hand-solder; mini blade holder, likely C3207114 as on the manager, not confirmed for 10 A"
+29,1,F1,10A blade,Fuse:Fuse_Blade_Mini_directSolder,,,,,,"through-hole, hand-solder; the land is KiCad's direct-solder mini blade pattern, so a 10 A mini blade (ATM) fuse solders straight in with no holder (C3207114 does not fit it)"
 30,1,J1,VBUS IN,"TerminalBlock_Phoenix:TerminalBlock_Phoenix_PT-1,5-2-5.0-H_1x02_P5.00mm_Horizontal",,,,,,"through-hole, hand-solder; SOURCING lists 2EDG 5.08 plugs C3697 for P1 bench IO, but this footprint is a 5.0 mm Phoenix PT - pick the matching header"
 31,1,J2,SWD,Connector_PinHeader_2.54mm:PinHeader_1x05_P2.54mm_Vertical,,,,,,through-hole pin header: hand-solder (or pay for JLCPCB THT assembly)
 32,1,J3,UART,Connector_PinHeader_2.54mm:PinHeader_1x03_P2.54mm_Vertical,,,,,,through-hole pin header: hand-solder (or pay for JLCPCB THT assembly)

hardware/phase1-module/bom/phase1-module-cpl.csv

@@ -8,22 +8,22 @@ C18,63.4000mm,-62.0000mm,Top,0
 C19,68.2000mm,-61.0000mm,Top,0
 C20,50.0000mm,-36.9000mm,Top,270
 C21,42.3000mm,-36.9000mm,Top,270
-C22,106.2000mm,-26.9000mm,Top,90
-C23,89.6000mm,-36.9000mm,Top,270
+C22,103.1600mm,-26.9000mm,Top,90
+C23,91.5600mm,-36.9000mm,Top,270
 C24,60.2000mm,-64.0000mm,Top,0
 C25,63.2000mm,-56.0000mm,Top,0
 C26,63.4000mm,-58.5000mm,Top,0
 C27,75.3000mm,-47.2000mm,Top,90
 C28,67.7500mm,-52.2000mm,Top,90
 C29,72.0000mm,-61.5000mm,Top,0
-C31,122.2000mm,-49.0000mm,Top,0
-C32,127.5000mm,-60.0000mm,Top,270
-C33,119.6000mm,-39.5000mm,Top,0
-C34,110.5000mm,-56.0000mm,Top,270
-C41,127.7000mm,-36.6000mm,Top,90
-C42,122.0000mm,-45.5000mm,Top,270
-C43,112.8000mm,-65.5000mm,Top,270
-C44,107.0000mm,-58.0000mm,Top,270
+C31,99.6000mm,-56.7000mm,Top,270
+C32,107.8000mm,-69.2000mm,Top,270
+C33,106.8000mm,-41.0000mm,Top,90
+C34,103.6000mm,-60.0000mm,Top,270
+C41,111.5000mm,-60.1000mm,Top,90
+C42,117.6000mm,-62.6000mm,Top,0
+C43,97.0000mm,-64.0000mm,Top,270
+C44,101.6000mm,-59.9000mm,Top,270
 C50,28.2000mm,-52.2000mm,Top,0
 C51,28.2000mm,-55.6000mm,Top,0
 C52,37.0000mm,-52.5000mm,Top,270
@@ -38,19 +38,19 @@ C65,93.0000mm,-74.0000mm,Top,0
 C66,76.8000mm,-79.0000mm,Top,0
 C67,76.8000mm,-82.0000mm,Top,0
 C68,83.0000mm,-90.5000mm,Top,0
-C69,113.0000mm,-76.5000mm,Top,0
-C70,113.0000mm,-83.5000mm,Top,0
+C69,109.0000mm,-76.3000mm,Top,0
+C70,109.0000mm,-83.7000mm,Top,0
 C71,83.3000mm,-75.8000mm,Top,0
 C72,96.7000mm,-75.8000mm,Top,0
 C73,83.3000mm,-88.2000mm,Top,0
 C74,96.7000mm,-88.2000mm,Top,0
 C75,54.0000mm,-36.9000mm,Top,270
 C76,58.0000mm,-36.9000mm,Top,270
 C77,62.0000mm,-36.9000mm,Top,270
-C78,95.5000mm,-26.9000mm,Top,90
-C79,93.3000mm,-36.9000mm,Top,270
-C80,97.0000mm,-36.9000mm,Top,270
-C81,100.7000mm,-36.9000mm,Top,270
+C78,94.3400mm,-26.9000mm,Top,90
+C79,94.7800mm,-36.9000mm,Top,270
+C80,98.0000mm,-36.9000mm,Top,270
+C81,101.2200mm,-36.9000mm,Top,270
 D1,68.0000mm,-78.5000mm,Top,0
 D2,75.5000mm,-85.5000mm,Top,0
 D3,54.4000mm,-66.2000mm,Top,0
@@ -62,20 +62,20 @@ F1,34.7500mm,-26.5000mm,Top,0
 J1,25.0000mm,-35.5000mm,Top,270
 J2,65.0800mm,-96.8000mm,Top,90
 J3,48.5400mm,-96.8000mm,Top,90
-J4,136.5000mm,-44.5000mm,Top,90
-J5,136.5000mm,-78.8900mm,Top,0
+J4,116.6500mm,-51.8000mm,Top,90
+J5,116.5000mm,-81.5900mm,Top,0
 J6,30.8700mm,-94.0000mm,Top,90
-L1,81.0000mm,-35.0000mm,Top,0
+L1,80.5700mm,-35.0000mm,Top,0
 L2,33.0000mm,-61.0000mm,Top,0
 Q1,67.5000mm,-30.0000mm,Top,0
 Q2,67.5000mm,-43.0000mm,Top,180
-Q3,122.9000mm,-30.0000mm,Top,0
-Q4,131.7000mm,-30.0000mm,Top,180
+Q3,115.5000mm,-34.0000mm,Top,270
+Q4,115.5000mm,-42.5000mm,Top,90
 Q5,51.5000mm,-58.0000mm,Top,0
 Q6,55.5000mm,-58.0000mm,Top,0
-Q7,128.0000mm,-65.5000mm,Top,0
+Q7,95.5000mm,-68.0000mm,Top,0
 Q8,34.0000mm,-90.2000mm,Top,0
-Q9,109.0000mm,-67.0000mm,Top,0
+Q9,99.5000mm,-68.0000mm,Top,0
 R1,60.2000mm,-54.0000mm,Top,0
 R2,60.2000mm,-60.0000mm,Top,0
 R3,58.5000mm,-81.5000mm,Top,0
@@ -94,19 +94,19 @@ R23,51.0000mm,-65.0000mm,Top,0
 R24,60.2000mm,-62.0000mm,Top,0
 R25,63.4000mm,-60.0000mm,Top,0
 R26,63.4000mm,-64.0000mm,Top,0
-R27,104.7000mm,-37.2000mm,Top,270
+R27,109.5200mm,-24.4000mm,Top,90
 R28,77.6000mm,-47.2000mm,Top,90
 R29,66.2000mm,-36.6000mm,Top,270
-R30,114.5000mm,-30.0000mm,Top,0
-R31,118.5000mm,-49.0000mm,Top,0
-R32,130.5000mm,-54.0000mm,Top,270
-R33,130.5000mm,-60.0000mm,Top,270
-R43,122.0000mm,-66.0000mm,Top,270
-R44,131.5000mm,-65.5000mm,Top,270
-R45,104.0000mm,-53.0000mm,Top,270
-R46,104.0000mm,-58.0000mm,Top,270
-R47,124.5000mm,-62.5000mm,Top,270
-R48,124.5000mm,-68.5000mm,Top,270
+R30,106.7000mm,-34.8000mm,Top,0
+R31,99.6000mm,-53.5000mm,Top,270
+R32,106.0000mm,-66.0000mm,Top,270
+R33,106.0000mm,-69.2000mm,Top,270
+R43,92.0000mm,-68.0000mm,Top,270
+R44,114.5000mm,-62.6000mm,Top,0
+R45,101.6000mm,-53.5000mm,Top,270
+R46,101.6000mm,-56.7000mm,Top,270
+R47,102.8000mm,-64.5000mm,Top,270
+R48,102.8000mm,-67.7000mm,Top,270
 R50,34.0000mm,-65.5000mm,Top,0
 R51,34.0000mm,-68.0000mm,Top,0
 R52,103.5000mm,-81.5000mm,Top,0
@@ -124,12 +124,12 @@ RT2,81.0000mm,-48.7000mm,Top,0
 U1,54.0000mm,-82.0000mm,Top,0
 U2,64.0000mm,-82.0000mm,Top,0
 U3,67.0000mm,-56.0000mm,Top,0
-U4,114.5000mm,-44.0000mm,Top,90
-U5,114.5000mm,-56.0000mm,Top,90
-U6,127.0000mm,-42.0000mm,Top,0
-U7,114.0000mm,-62.0000mm,Top,0
+U4,106.7000mm,-48.8000mm,Top,90
+U5,106.7000mm,-60.8000mm,Top,90
+U6,115.8000mm,-59.6000mm,Top,180
+U7,99.5000mm,-64.0000mm,Top,0
 U8,33.0000mm,-54.9997mm,Top,0
 U9,31.5000mm,-73.0000mm,Top,0
 U10,90.0000mm,-82.0000mm,Top,0
-U11,118.0000mm,-80.0000mm,Top,0
+U11,109.0000mm,-80.0000mm,Top,0
 Y1,81.5000mm,-80.5000mm,Top,0