Pool Controller PCB

PCB design files for an Connect 10 compatible pool controller interface board.

Overview

This project contains a custom PCB designed to interface with Connect 10 pool systems. The board features RS-232 like communication on a single wire (TX/RX) and a regulated power supply to enable reliable communication and control.

The code for the ESP32-C6 is available and documented here: (https://github.com/marklynch/pool-controller-code).

Features

• Communication Interface

  • Dedicated RX (receive) circuit - tested and verified
  • Dedicated TX (transmit) circuit - tested and verified

• Regulated Power Supply

  • Based on TI LM2678S-5.0 buck converter
  • 5V output voltage
  • Designed using TI WEBENCH tools for optimal performance

• Optimized Layout

  • All connectors positioned on one side for easy installation
  • Clean signal routing with minimal crosstalk
  • DRC/ERC compliant design

Project Status

• RX circuit designed and tested
• TX circuit designed and tested
• Power circuit designed and specified
• PCB layout optimized (Rev 8)
• DRC/ERC violations resolved
• Manufacturing files generated (Gerbers, BOM)
• Power circuit testing pending

Project Structure

pool-controller-pcb/
├── PoolController.kicad_pro     # KiCad project file
├── PoolController.kicad_sch     # Schematic design
├── PoolController.kicad_pcb     # PCB layout
├── components/              # Custom component libraries
│   └── ul_LM2678T-5-0-NOPB/ # LM2678 voltage regulator footprint/symbol
├── docs/                    # Datasheets and design documentation
│   ├── ZV1636_datasheetMain_96004.pdf
│   └── WBDesign1_Bode Plot-1.pdf
├── output/                  # Manufacturing files
│   ├── gerbers_v8.zip      # Latest Gerber files for PCB fabrication
│   ├── BOM_v8.csv          # Bill of Materials
│   └── ...
├── CHANGELOG.md            # Version history
└── README.md              # This file

Manufacturing Files

Ready-to-manufacture files are available in the output/ directory:

• Gerber Files: gerbers_v8.zip - Contains all layers for PCB fabrication
• Bill of Materials: BOM_v8.csv - Complete component list with part numbers
• Drill Files: Included in gerber package (PTH and NPTH)

Requirements

• KiCad 6.0 or later - Required to open and edit the design files
• All custom components and footprints are included in the components/ directory

Getting Started

1. Clone this repository
2. Open PoolController.kicad_pro in KiCad
3. Custom component libraries should load automatically via relative paths

Documentation

• See CHANGELOG.md for detailed version history and changes
• Component datasheets are available in the docs/ directory
• Power supply design based on TI WEBENCH simulations (see Bode plot in docs)

Notes

• Component library paths are configured as relative paths for portability
• Automatic backup files are saved to PoolController-backups/
• Output files are excluded from git tracking (see .gitignore)

License

The designs for this hardware are licenced under the CERN Open Hardware Licence Version 2 - Permissive.