Project Wire Routing Help
Yes, reconnect those missing ends to the correct nets.
Thought for 14 sec
I’ll reconnect those missing passive ends to 3V3 and the buck output now, then verify the same parts again.
Worked for 1 min 15 sec
Done — I reconnected the missing ends.
Fixed connections:
- L1 P2 → 3V3
- C7/C8/C11 P1 → 3V3
- R3/R4/R6/R7/R12/R13 P1 → 3V3
Verified:
- C7, C8, C11 now go between 3V3 and GND
- L1 now goes between BUCK_SW and 3V3
- The listed pull-up resistors now go between 3V3 and their signal nets
There are still other schematic warnings unrelated to that exact list, including U1:3V3, OLED1:3V3, U2:FB, and R5:P1, so the schematic still needs another cleanup pass before routing/manufacturing.
Fix remaining warnings
Explain warnings
Run full review
Fix schematic first
Check buck circuit
Refine this doc
Ask about this doc
Preliminary 24 VDC Power Budget
Purpose
Record the current 24 VDC power assumptions for the Dual Well Pump Controller before selecting power-path components.
Design Decision
The controller and contactor/control outputs will use a 24 VDC control rail. With the new distributed architecture, each remote well node may have its own local listed 240 VAC to 24 VDC supply, and each electronics node will locally derive 3.3 V for the WiFi microcontroller/radio.
Updated decision: each well node and the tank/controller node will be powered from local listed isolated 240 VAC to 24 VDC supplies/transformers, because 240 VAC is already available at the well locations and the tank will be near at least one well.
Loads to Include
The final 24 VDC supply must include:
Table
| Load | Quantity | Status |
|---|---|---|
| Controller electronics | 3 WiFi nodes | Pending MCU/controller selection; ESP32-class WiFi modules are likely candidates |
| 24 VDC contactor coils | 2 | Pending exact contactor selection and coil current |
| Pulse-output water meters | 2 | Pending exact meter selection; many dry-contact/reed meters require little or no sensor power, powered pulse meters may draw current |
| Tank float-switch sensing | 1 | Normally-open dry-contact float selected; expected low current; final input circuit pending |
| Status indicators / UI | TBD | Local screen/buttons selected, plus web/phone interface |
| Input/output protection overhead | TBD | Pending schematic |
Additional Distributed Node Loads
If WiFi-enabled nodes are used, budget each node separately:
Table
| Node | 24 VDC Loads | Local Low-Voltage Loads | Status |
|---|---|---|---|
| Well 1 node | Contactor coil, field I/O protection, optional indicators | WiFi MCU/radio, flow pulse input electronics | Pending contactor and MCU selection |
| Well 2 node | Contactor coil, field I/O protection, optional indicators | WiFi MCU/radio, flow pulse input electronics | Pump 2/contactors pending |
| Tank/controller node | Float input sensing, optional outlet meter sensing, UI/display if local | WiFi MCU/radio, display/control electronics | Pending UI and enclosure plan |
Confirmed node count is three: Well 1 node, Well 2 node, and Tank/controller node. Each node should include local 24 V to 3.3 V conversion sized for WiFi transmit peaks.
Tank Float Input Update
The tank-full float switch is selected as a normally-open dry-contact input. The sensing current should be low, so this does not materially change the 24 VDC power budget. Because a normally-open field contact cannot inherently distinguish "not full" from a broken/disconnected cable, the final input circuit should include surge/ESD protection and, if practical, diagnostic biasing or a supervised input strategy.
Because WiFi transmit current is pulsed, the 3.3 V regulator on each node must be sized for MCU/radio peak current, not only average current. A buck regulator from 24 V to 3.3 V is preferred over a linear regulator for WiFi nodes because a 24 V to 3.3 V LDO would waste too much heat at radio peak currents.
Pump 2 Update
Pump 2 is now identified as Goulds 5GS07422C: 3/4 HP, 230 V, single-phase, 2-wire, approximately 5 A listed by supplier. This reduces the required motor contactor horsepower/current rating for the Pump 2 power circuit compared with Pump 1, but it does not yet define the 24 VDC control supply size because the contactor coil current depends on the selected external contactor. Keep the Well 2 24 VDC budget pending until the exact 24 VDC contactor is selected.
Pump Contactor Load Notes
- Pump 1: Hallmark MA0419X-12A, 2 HP, 230 V, catalog 10.2 A, user-observed approximately 10-15 A running current. Select contactor by motor HP rating and inrush capability.
- Pump 2: Goulds 5GS07422C, 3/4 HP, 230 V, single-phase, 2-wire PSC, supplier-listed full-load current 5 A. Select contactor by motor HP rating and inrush capability, not resistive-current rating.
- The 24 VDC power budget must include the coil current of the selected Pump 1 and Pump 2 motor-rated contactors. The pump motor current itself does not flow through the controller PCB.
Preliminary Sizing Rule
Until the contactors and controller are selected, assume both contactor coils may be energized at the same time unless the firmware and safety logic explicitly prevent simultaneous pumping.
Required supply current should be calculated as:
For a single shared controller:
I_24V_total = I_controller_peak + I_contactor1_coil + I_contactor2_coil + I_flow_meters + I_UI + marginFor distributed nodes:
I_24V_well_node = I_contactor_coil + I_24V_to_3V3_input_peak + I_local_IO + marginI_24V_tank_node = I_24V_to_3V3_input_peak + I_float_input + I_outlet_meter + I_UI + marginUse a margin after summing real component currents. Protection devices, connectors, and PCB output drivers should be sized from this same current budget.
Current Blocking Data
- Exact 24 VDC contactor model and coil current.
- Whether simultaneous pump operation is allowed.
- Exact controller/MCU architecture; ESP32-class WiFi nodes are likely but not selected yet.
- Exact pulse-output water meter type and whether it needs powered excitation; designer has permission to select with cost/quality balance.
- Status display / user-interface hardware choice; requirement is local screen/buttons plus phone/web interface.
- Number of WiFi-enabled nodes confirmed as three, each with local 240 VAC to 24 VDC supply.
- WiFi MCU/module selection and its 3.3 V peak current.
- 24 V to 3.3 V buck regulator selection and efficiency.
- Whether both pump contactors can ever be energized at the same time.
- Whether both pump contactors can ever be energized at the same time. If simultaneous pumping is allowed, each well node only powers its own coil, but the tank/controller scheduling firmware must still account for total tank inflow.
Practical Starting Recommendation
For field wiring, use listed 24 VDC supplies sized after the contactor coil current and WiFi node electronics are known. For each WiFi node, use a 24 V to 3.3 V buck regulator sized for radio peak current. Do not select the final supply, fuse, connector, regulator, or output driver until the loads above are enumerated with real datasheet values.
Purpose
Design Decision
Loads to Include
Additional Distributed Node Loads
Tank Float Input Update
Pump 2 Update
Pump Contactor Load Notes
Preliminary Sizing Rule
Current Blocking Data
Practical Starting Recommendation
