Smart IoT Water Level Controller Design

irshadchenakkal

irshadchenakkal

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flux

0:17

Thought for 10 sec

Thought for a moment

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

1:37

Thought for 3 sec

1/3 Review existing project files before updating image-derived requirements

Thought for 2 sec

Read project docs.

Thought for 2 sec

2/3 Update specification with image-derived features and labels

Thought for 3 sec

Read project docs.

Thought for 14 sec

Read project docs.

Thought for 5 sec

3/3 Create a visual reference assessment file from the uploaded images

Thought for 17 sec

Read project docs.

Thought for 2 sec

3/3 tasks completed.

Thought for a moment

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

Documents

    Project Specification:IRAA ESP32 IoT Water Controller

    Power and Architecture Notes

    Schematic Implementation Plan

    Reference Image Assessment

Assets

No assets added.

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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