Requesting to review my PCB Design - Page 1
Forum section: electronics / general

author: rajugudala
author_rank: Newbie
timestamp: June 27, 2025, 05:02:46 am
content: Hello All,I'm new to PCB design and have recently created a PCB for an AC-DC converter that converts single-phase AC input into 360V DC. Given the high-voltage, high-power nature of this circuit, I'm particularly concerned about the robustness and safety of the design.I used EasyEDA to design the board and have already performed DRC checks and resolved all reported errors. However, I'd greatly appreciate feedback and suggestions from more experienced designers.Here are some of the specific concerns I have:1. Is the trace width and component placement appropriate for reliable high-voltage and high-current operation?2. I'm using 4mm trace width for high-current paths—will this be sufficient to safely handle 10A current?3. Are there any potential thermal issues or hotspots that could result in overheating or damage to the board?4. Does the board works fine after fabrication?I’ve attached the schematic and PCB layout for review. I’d be grateful for any advice, suggestions, or best practices that can help improve the reliability and safety of my design.Thank you for your time and support!

author: thm_w
author_rank: Super Contributor
timestamp: June 27, 2025, 09:17:01 pm
content: https://www.eevblog.com/forum/beginners/pcb-design-and-mains-voltage-advice/https://www.eevblog.com/forum/projects/pcb-isolation-for-240v/https://www.eevblog.com/forum/beginners/getting-started-with-a-240vac-pcb/Are C7 to C11 properly rated caps? They don't seem to be.Don't put vias in the component pads if you can avoid it.

author: rajugudala
author_rank: Newbie
timestamp: June 28, 2025, 05:01:17 am
content: Thank you for your feedback!I’ve now removed all vias from the SMD pads to avoid potential soldering issues, as you suggested. Regarding capacitors C7 to C11 — I double-checked their placement and ratings. They are connected on the AC input side and are rated at 250V AC, so they should be suitable for that part of the circuit.Really appreciate your input — it’s helping me improve the reliability of the design. Let me know if there’s anything else I should keep an eye on!

author: Arsh ahmad
author_rank: Regular Contributor
timestamp: June 28, 2025, 10:34:49 am
content: Few Points on the layout,1. Try using copper pours instead of traces and try to increase the width wherever possible.2. Try to avoid sharp bends in the high current paths, this will increase current density and also will result in trace getting heated.

author: Bud
author_rank: Super Contributor
timestamp: June 28, 2025, 01:28:51 pm
content: Route high current tracks on a same layer as much as possible, vias are going to be your weak points in high current path. Use multiple vias if still have to change layers.

author: Doctorandus_P
author_rank: Super Contributor
timestamp: June 28, 2025, 09:04:23 pm
content: This does not look very good to me. Apparently there is mains AC going into the PF1500B modules, but I don't know what they are. A search suggests TDK / Lambda PF correction modules, but those are bigger. I see some weird squares Connectors? Inductors? in the schematic, and there is a net called "GND" all over the PCB, which is mostly floating, does not connect anything, except destroy the (presumed) isolation between the primary and secondary side of the mysterious PF1500B modules. I have not looked at datasheets but I guess these power modules need more / better input filtering. Although in some modules, filtering is built in and they do not need any additional filtering. The schematic presented is also barely readable, so I'm not really sure what's going on here.I'm making a bit of a guess here, and that guess is that OP is not ready yet to play around with mains voltages. in a safe way.

author: rajugudala
author_rank: Newbie
timestamp: June 30, 2025, 06:26:52 am
content: Okay. Thank you for the valuable Suggestion

author: tooki
author_rank: Super Contributor
timestamp: June 30, 2025, 10:04:09 am
content: Quote from: Doctorandus_P on June 28, 2025, 09:04:23 pmHere’s the product page for the modules:https://product.tdk.com/en/search/power/switching-power/ac-dc-converter/info?part_no=PF1500B-360I skimmed the datasheet and instruction manual.rajugudala, you should review these again. You should do the recommended input filtering.Quote from: rajugudala on June 27, 2025, 05:02:46 amThe layout around the current sensing chip is terrible. You completely ruin the isolation by running the output trace underneath the chip — and both input and output current is only barely connected to one pin of each. (It has two pins each for a reason.) The input current runs through a thin little track. And the placement of the two capacitors (one from GND to filter, one from GND to the low-voltage DC supply) is far too far from the pins; these caps should be placed as close as possible to the IC, with short, direct tracks.The thick tracks connecting all the capacitors in the bottom right corner hop from layer to layer for no apparent reason. (You do this elsewhere, too.) The main reason for using a 4-layer board is so you can have layers dedicated to continuous ground pours. You’re not doing that, and would probably be better off just doing 2 layers, but with thicker copper (2oz/70um).You have various components that aren’t ICs using the U designator. Don’t do that. Use U only for ICs, but decide whether you want to call ICs U or IC, and then use that consistently. Always use R for resistors, C for caps, L for inductors, Q for transistors, etc.The 150Mohm/1.5Mohm resistor divider is presumably for some kind of voltage monitoring. But with that high resistance, it’ll be very noisy, and liable to have significant measurement error if the input impedance of whatever it’s going to is not significantly higher. (E.g. if it goes to an op amp or multimeter with 1Mohm input impedance, you’ll have a huge measurement error.) Is there a concrete reason for not using a smaller value, like 150kOhm/1.5kOhm? That’s still only 2.4mA current.