Just and FYI I really got more questions then answersm
For pcb manufacturing I use pcbcart.com make sure to choose prototype when getting a quote from their online calculator. prototypes are way cheaper. I believe it's a max of 4 layers the board price - mine is like $35 for 5 boards (5 days to print) you will have like $35 in shipping which is fast in my mind usually about 3 - 4 days from when they indicate they shipped. So for around $70 for a small board you have a prototype in 10 days. I felt that was fair and cheap.
Tom here is a snippet of one of the switches on the board ....
You can't see it here but after much thought and advice from some very smart folks on this forum I am running one snubber between black and white (hot and neutral). The data sheet for the triacs say it's not necessary but due to the type of motor we decided one snubber would be sufficient
Not much to see I am using MOC3162M with zero crossing trigger as the opto
I am using KTR10EZPF3600 360ohm resistors
also a T850-6G snubberless logic level triac
All rated for at least 250VAC of course all are the smd version.
You can't see the net names but this one is switching +115V with the common on the caps pack of the fan and will give me high.
The prototype circuit I built served the same puprpose high on the fan. I used through hole parts and not the smd parts I have designed the board with but the prototype was the same otherwise.
I switched it on and off and let the fan run and I never noticed any heat at all.
My board has an rf-mcu, power supply, 3 speed switches, one light switch and 4 switches set up as an H-Bridge to reverse the fan.
The 115V portion of the board has 15 mill traces and 15mill clearance upgraded from the 12 I believe eagle defaults to
Tom if you are interested in looking at the eagle files I am going to be doing some work this morning adding a hole to mount the board and of course finishing up the air wires that still need routing before creating the gerbers and ordering if you want shoot me a PM and I will give you a link to the files.