Standby Generator PCB Design
Publicada el 2026-07-18
Descripción de la oferta
I'm looking for an experienced PCB designer to create a control board for my standby generator. The PCB should manage an Automatic Transfer Switch (ATS) and engine control, and should include: SPARXX ATS REV A – PCB DESIGN SPECIFICATION Project Design a production-ready PCB-based Automatic Transfer Switch (ATS) controller to replace an existing relay/timer panel while maintaining the same operating logic. Deliverables Required Complete KiCad 9 project Schematics PCB Layout BOM Gerber files Pick and Place files Programming header Source files PCB Size Approximately 3.5" × 7" × 0.5" maximum Reserve approximately 20% of board space for future expansion. Power Inputs: 120 VAC 12 VDC Generator Supply Board must automatically power from either source. No batteries. Use supercapacitor hold-up circuit to maintain MCU operation during transfer (approximately 2 minutes). Use encapsulated 120VAC → 12VDC AC/DC module. Generate regulated 5V for MCU. Controller Microcontroller: ATmega328P (internal oscillator, no external crystal) Include: ISP programming header Watchdog timer Event memory (software only if possible) Relay Outputs K101 Generator Start Requirements: Dry contact only Generator provides its own 12VDC Board simply closes contacts K102 Transfer Contactor 120VAC Coil current under 1 amp Relay rated minimum 10A Inputs Utility Sense Generator Sense S1 Three Position Switch Up = Auto Transfer Center = Off Down = Auto Solar Transfer S2 Three Position Switch Up = Auto Generator Center = Off Down = Manual Generator Manual Generator Mode Generator starts immediately. Transfer occurs whenever generator voltage is present. Works regardless of S1 position except when safety logic prevents transfer. Automatic Generator Mode Utility failure ↓ Adjustable startup delay ↓ Generator starts ↓ Adjustable warm-up delay ↓ Transfer ↓ Utility returns ↓ Immediate transfer back ↓ Adjustable cooldown ↓ Generator stop Cooldown selectable using 4-position DIP switch. Solar Automatic Battery inverter acts as generator. No generator start command. If generator input voltage exists: Transfer. No warm-up delay required. Service Mode S1 Center disables automatic transfer. Automatic generator start disabled. Manual generator operation remains available. Adjustable Timing Two potentiometers RV1 Generator start delay RV2 Warm-up / return timing Cooldown selected by DIP switch. Indicators LED Power LED Utility LED Generator LED Transfer Optional MCU heartbeat LED. Protection Fuse MOV Proper AC isolation Creepage clearance Connectors Clearly labeled screw terminals. Industrial field wiring. Silkscreen labels. PCB Requirements Single PCB. Through-hole components preferred where practical. Cost optimized. Easy assembly. Easy servicing. Professional silkscreen. Firmware Implement state machine according to supplied operating description. Goal Replace an existing relay-based ATS with a microcontroller-based controller having identical behavior while reducing wiring complexity and assembly time. I would also include this note at the bottom: The operating logic is already defined. The objective is not to redesign the ATS, but to implement the existing logic in a production-ready PCB. Questions about ambiguous behavior should be resolved with the client before changing functionality.
Skills
Fuente original: freelancer