Smart IoT Water Level Controller Design

irshadchenakkal

irshadchenakkal

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flux

I’ll use these reference images to refine the documented architecture and PCB feature list, especially the single-board labels, touch/network edition, relay/protection zones, and user-control layout. I’ll update the project files rather than duplicating the long details in chat.

flux

I updated the project requirements using the uploaded reference images and added a new Reference Image Assessment.
I also updated the Project Specification with the image-derived features: touch/network edition labeling, front-panel LEDs, five-key backup UI, relay/protection zones, and clear PCB service markings.
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Reference Image Assessment
Purpose
This file records design cues extracted from the uploaded concept images for the IRAA / UVARION Smart IoT Water Controller. These images are treated as product and layout references, not as safety-verified schematics.
Concepts Shown
  1. IRAA IoT Water Controller - International Premium Touch and Network Edition
    • 230 VAC input with power, surge, and lightning protection.
    • ZMPT101B voltage sensor concept.
    • ACS712 30 A current sensor concept.
    • ESP32 MCU with Wi-Fi and Bluetooth.
    • Tank level sensors plus dry-run input.
    • Motor relay or contactor output.
    • 4.2 inch TFT touch display interface and remote access labeling.
    • Programming and direct system access USB port.
    • Front-panel status LEDs.
    • Auto/Manual, Emergency Fill, and Bypass controls.
    • Relay power section and 30 A motor output label.
  2. UVARION Smart Water Level Controller Layout
    • Five proximity or level-sensor inputs.
    • Level LED indication: 20%, 40%, 60%, 80%, 100%.
    • Lightning protection near AC input.
    • Non-contact dry-run sensor area.
    • Alert sensor complaint / fault input concept.
    • Buzzer for alarms.
    • Auto/Manual relay and dry-run protection relay.
    • Emergency Fill, System Mode, and Reset buttons.
    • Motor output terminal block on board edge.
  3. UVARION Smart Water Level Controller - IoT Edition PCB Layout and Marking
    • Similar architecture to the premium edition, with strong emphasis on connector marking.
    • Tank sensor connector labeled for five levels.
    • Dry-run sensor non-contact input.
    • Front panel LEDs for power, motor, fault, and tank level.
    • Manual bypass/service switch location.
Features to Preserve
  • Large, readable PCB silkscreen labels.
  • Clear separation between AC/motor section and ESP32 logic section.
  • AC input and motor output terminals on board edges.
  • Relay/contactors grouped near motor output.
  • Protection components near AC input.
  • Sensor connectors grouped and labeled by function.
  • Local manual controls accessible from front panel.
  • Dedicated display connector area.
  • Dedicated programming/service access.
  • Bilingual/local-language product markings may be useful for the target market.
Engineering Concerns to Correct Before Production
  • A single-board concept mixing 230 VAC, 30 A motor output, ESP32, sensors, and touch/display signals is risky unless creepage, clearance, slots, isolation, enclosure barriers, and thermal design are handled professionally.
  • ACS712 board-level sensing for a 30 A motor may create high-current PCB routing and heat issues. A split-core current transformer such as SCT013 or another isolated current sensor is safer for a commercial product.
  • ZMPT101B-style sensing must be isolated and calibrated; ESP32 ADC inputs must never connect directly to mains-referenced circuitry.
  • Motor switching should preferably use an external contactor or certified relay module rather than routing full motor current through the logic PCB.
  • Wi-Fi performance requires ESP32 antenna keepout and placement away from relay coils, AC terminals, and metal enclosure walls.
  • TFT touch display and front-panel buttons need ESD protection if user-accessible.
  • All external sensor wiring needs surge/ESD protection because tank and borewell cables can be long and exposed.
Use the uploaded images as the visual and feature target, but implement the electrical design as:
  1. High-voltage power board
    • AC input, fuse, MOV, GDT, EMI filter, NTC, isolated power supply, voltage sensing, current sensing, and contactor interface.
  2. Low-voltage controller/UI board
    • ESP32-S3 module, 3.3 V power, TFT connector, buttons, LEDs, buzzer, RTC, settings storage, protected sensor inputs, protected analog monitor inputs, USB/programming, and isolated relay command.
Impact on Schematic Plan
The first schematic should prioritize the low-voltage board and connectorized isolated interfaces. The high-voltage board can then be designed separately once mains-rated component choices, spacing requirements, enclosure dimensions, and contactor/relay strategy are finalized.

  • Purpose

  • Concepts Shown

  • Features to Preserve

  • Engineering Concerns to Correct Before Production

  • Recommended Product Direction

  • Impact on Schematic Plan

IRAA ESP32 IoT Water Controller

IRAA ESP32 IoT Water Controller thumbnail
Premium dual-PCB ESP32 smart water level controller with isolated high-voltage power/motor board, low-voltage IoT logic board, level sensing, dry-run/voltage/current protection, TFT UI, MQTT connectivity, RTC logging, and industrial surge protection.

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