Initialize piNail project with modern piNail2 web controller

2026-03-11 20:11:59 +00:00
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+# piNail Hardware (Prototype v2)
+
+This file captures confirmed hardware details for the cigar-box prototype.
+Unknowns are marked `TBD` instead of guessed.
+
+## Prototype Summary
+- Enclosure: cigar box with integrated monitor in lid.
+- Input power: IEC C14-style AC inlet ("computer PSU" style).
+- Runtime controller: Raspberry Pi.
+- Heating channels: 2 coil channels (channel 2 wired but not yet validated in operation).
+
+## High-Level Power Architecture
+
+### AC input path
+1. AC inlet -> WiFi power switch.
+2. From WiFi switch output -> master mains switch for system.
+3. Master switch output branches:
+   - Branch A: to main DC switching PSU (powers Pi/control electronics).
+   - Branch B: to per-channel heater paths.
+
+### Control electronics power (DC)
+- Main DC PSU output provides control-side power for:
+  - Raspberry Pi
+  - Two thermocouple interface chips
+  - Two SSR control sides
+- Nominal rail appears to be `5V` (TBD: confirm exact PSU output voltage/current).
+
+### Heater power path (per channel)
+- After master switch, AC route per channel is:
+  - fuse -> manual front-panel cutoff switch -> SSR load side -> coil connector power line
+- The opposite AC pole is routed from WiFi switch output directly to coil connector corresponding pole.
+- Ground/earth conductor is routed to coil connector grounds.
+
+## Channel/Signal Topology
+- Each channel has:
+  - Thermocouple input (via MAX6675-type board)
+  - SSR-driven AC heater output
+  - Manual front panel power switch in series with heater path
+- Raspberry Pi drives each relay channel independently.
+- Thermocouple boards are connected to Pi GPIO.
+
+## Monitor Subsystem
+- Separate 12V power supply for the built-in monitor.
+- Short HDMI from Pi -> monitor.
+- Monitor considered optional for future versions.
+
+## Grounding Notes
+- Enclosure is non-metal (cigar box), so chassis bonding is not the main factor here.
+- Coil grounds are connected.
+- DC PSU ground is connected on the input-side ground scheme.
+- `TBD`: provide explicit earth/neutral/hot naming by region and verify continuity paths.
+
+## Protection and Switching (Current Understanding)
+- SSRs used for heater switching (`TBD`: exact model/rating).
+- Fuses appear to be 1A glass tube, one per channel (`TBD`: verify rating + slow/fast blow type).
+- Per-channel front switches are manual toggles.
+- WiFi switch has onboard button and can keep networked power state independent of channel switches.
+
+## Operational Behavior (as built)
+- You can power down Pi + nail supply via master mains switch while keeping WiFi switch infrastructure behavior available.
+- You can cut each coil independently with front-panel switches without shutting down software.
+- Channel 2 is wired but not yet fully tested under load.
+
+## Legacy/Prototype Context
+- Prototype v1: external Pi setup (pinout/relay/thermocouple cable to Pi), no built-in monitor.
+- Prototype v2: integrated Pi + wiring + optional integrated monitor.
+
+## Required TBDs Before Final Electrical Spec
+1. Coil connector pinout (both channels, exact pin numbering/function).
+2. Main DC PSU make/model and output spec (V/A).
+3. SSR model and AC load ratings.
+4. Fuse exact spec (amp, voltage, blow type, holder type).
+5. Exact line/neutral/earth routing confirmation diagram.
+6. Channel 2 validation checklist/results.