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Attached below are images of a 2-layer PCB layout I am currently designing. I have always had the habit of removing the ground plane underneath AC signals, but a more experienced PCB designer advised me that the removal of the ground plane should only be done near the connectors and high-power AC traces.

In this PCB, there are three isolated secondary windings from the same transformer providing the following voltages:

  • 24VAC: Rectified using a full-bridge rectifier to power a DC motor that consumes approximately 90W.

  • 14VAC: Used directly to power an AC lamp.

  • 12VAC: Rectified and regulated to supply the digital circuits with 3.3V.

From an EMI perspective, would the return paths for the currents be negatively affected if I remove the ground plane under all AC traces and connectors across the board?

Alternatively, should I only cut the ground plane in the region where the AC connectors and traces are located? Or would it be better to leave a continuous ground plane underneath the entire system?

PCB with continuos ground plane. PS: I added some silkscreens to make it easier for you to identify what is what

2- PCB after cutting the ground plane. PS: this is a preliminary cut for purposes of demonstration

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  • \$\begingroup\$ I would add a keepout around each of your mounting holes. Bigger than any standoffs or screwheads you are planning to use. There is no benefit for copper there. \$\endgroup\$
    – spuck
    Commented 2 hours ago

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Given that this is low-frequency AC (50 or 60 Hertz), you can consider it to be DC for the purposes of impedance calculations on the PCB. The wavelength of these AC signals is much longer than the size of your entire PCB - about 5000 kilometers in fact. Removing the ground plane will have no effect on the propagation of these signals.

What it will have an influence on, though, is the path that return currents will take, as you already identified yourself. Given that these are power traces, this is actually quite important both to prevent unwanted resistive voltage drops and for EMI reasons. An unbroken ground plane will provide a better (shorter and lower resistance) return path, so it's always a good idea to keep the ground plane intact underneath power traces.

In your case, you should fill the entire bottom layer of the board with ground plane wherever possible.

What you might want to do, though, is to increase the clearance between the ground plane and adjacent signals on the same layer in order to prevent accidental bridges during soldering. This can be done in the design rule settings of the CAD software you're using (KiCAD?). 0.5mm to 1mm is probably a good idea. Another thing to consider is to increase the default thickness of your signal traces - they look awfully thin and there doesn't seem to be any reason to keep them that way (lots of empty space around them). 0.5mm is likely a good starting point as well there.

You could also consider flooding the top layer with ground plane too and stitching it to the bottom plane with vias in a regular-ish grid to lower the plane resistance further.

And lastly, it looks like you've placed some (ground) vias within the pads of components. This will cause you trouble with manufacturing unless you very specifically know what you're doing there. Don't do it with this board, there's enough space to run a short trace to a via slightly away from the pad. It'll save you a lot of headaches during soldering (via-in-pad can suck solder away if not done properly).

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    \$\begingroup\$ What about clearance/creepage? \$\endgroup\$
    – Lundin
    Commented 11 hours ago
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    \$\begingroup\$ @Lundin OP mentioned that the board operates at 24V AC, which is absolutely not a problem for any standard two-layer board whether there's ground on the other side (or adjacent to the trace) or not. \$\endgroup\$ Commented 11 hours ago
  • \$\begingroup\$ Oh right, I just assumed it was 230 VAC mains. \$\endgroup\$
    – Lundin
    Commented 11 hours ago
  • \$\begingroup\$ Got it, makes sense, especially about keeping the ground plane intact to ensure efficient current return and reduce resistance and EMI. I do have a specific question, though: for high-current traces, like 3 to 5A (24V AC, before rectification), is it still a good idea to keep the ground plane directly underneath them? Or would it be better to increase the distance a bit to avoid any potential interference or other issues? \$\endgroup\$
    – ever_pi
    Commented 11 hours ago
  • \$\begingroup\$ I’m asking because I’ve noticed there’s often a recommendation to keep the ground plane slightly away from AC power signals even when the voltage is relatively low, like in this case with 24V AC. \$\endgroup\$
    – ever_pi
    Commented 11 hours ago

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