PS1 PCB Review Fix

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Purpose of the PCB
This PCB is a low-current monitoring and communications controller for a nominal 24 V wind-turbine system. It collects operating data, processes it with an ESP32, and sends the information to local or cloud systems.
It is not a turbine power controller and must not carry the turbine’s approximately 24 A output current.
What it does 1. Receives low-current system power
The board accepts a separately fused 12–36 VDC branch, normally about 24 V, from the turbine or battery system.
Onboard power circuitry:
  • Protects against input transients and voltage spikes
  • Converts the incoming voltage to regulated low-voltage rails
  • Generates 5 V and 3.3 V for the electronics
  • Provides local filtering and decoupling
Only enough current to operate the monitoring electronics should enter the PCB.
2. Reads the electrical measurements
A JSY-MK-229 energy meter measures electrical values in the external turbine power path, such as:
  • Voltage
  • Current
  • Power
  • Accumulated energy
  • Other values supported by its Modbus register set
The board communicates with that meter through RS485/Modbus. The high turbine current passes through an external shunt and appropriately sized wiring, not through this PCB.
An isolated RS485 interface helps separate the ESP32’s low-voltage logic domain from the field-wiring and measurement domain.
3. Measures turbine rotational speed
The board provides a Hall-effect sensor input for RPM measurement. A magnet or magnetic target on the turbine produces pulses as the shaft rotates.
The ESP32 counts these pulses and calculates RPM:
RPM=60×pulse frequencypulses per revolutionRPM=\frac{60 \times \text{pulse frequency}}{\text{pulses per revolution}}
The exact conversion depends on the number of magnets or pulses generated per revolution.
4. Processes the data
The ESP32-WROOM-32 is the main controller. Firmware can:
  • Poll the JSY-MK-229 over Modbus
  • Count Hall-sensor pulses
  • Calculate RPM and derived performance data
  • Detect abnormal or missing measurements
  • Timestamp and organize readings
  • Control indicators
  • Package the data for transmission
It can also compare electrical output with turbine speed to help identify low production, sensor faults, overspeed conditions, or changing operating performance.
5. Sends measurements remotely
The ESP32 provides Wi-Fi and Bluetooth capability. The intended cloud function is to publish measurements using MQTT to AWS IoT Core.
Possible reported values include:
  • Turbine voltage
  • Output current
  • Instantaneous power
  • Generated energy
  • Rotor RPM
  • Communications status
  • Device health and fault states
The design also includes LoRa-related connectivity for longer-range local telemetry where Wi-Fi is not practical, subject to the connected radio and firmware configuration.
6. Supports programming and servicing
The USB-C and CP2102N circuitry provide a computer interface for:
  • ESP32 firmware programming
  • Serial diagnostics
  • Configuration
  • Debug logging
  • Maintenance and commissioning
USB-C is a service/programming interface. It is not intended to carry turbine power.
Correct system arrangement
The turbine’s high-current path should remain entirely external:
Wind turbine → external fuse or breaker → external shunt/metering path → charge controller → battery/load
This path requires wiring, protection, terminals, and equipment rated for approximately 24 A or more, with suitable engineering margin.
The monitoring PCB receives only:
  1. A separately fused, low-current nominal 24 V power branch
  2. RS485 measurement data from the JSY-MK-229
  3. Hall-effect RPM pulses
  4. Any intended low-power sensor or communications connections
What it does not do
The PCB does not:
  • Carry the turbine’s approximately 24 A output
  • Replace the external fuse or breaker
  • Replace the external shunt
  • Replace the JSY-MK-229 meter
  • Regulate turbine charging
  • Replace the charge controller
  • Switch or interrupt the main turbine current
  • Act as a dump-load controller
  • Provide battery overcharge protection
  • Make high-current wiring safe
In short, it is the system’s measurement, processing, and communications layer, while the external charge controller, protection devices, shunt, and heavy wiring handle the actual turbine energy.
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Files

Schematic

Layout

Preview

Project Specification — ESP32 Wind Turbine Monitor
Objective
Production-ready two-layer PCB for a small wind turbine monitoring system. The board collects turbine sensor data, formats JSON, and publishes to AWS IoT Core using MQTT over Wi-Fi.
Architecture
  • Controller: ESP32-WROOM-32 module.
  • Field bus: one shared half-duplex RS485 Modbus RTU bus using MAX3485ESA+.
  • Sensors on RS485: wind speed sensor, wind direction sensor, JSY-MK-229-compatible DC power meter.
  • Rotor speed: Hall-effect sensor input on ESP32 GPIO interrupt.
  • Power: 12–36 VDC field input, protected front end, 5 V DC/DC module, 3.3 V logic regulator.
  • Programming/debug: USB-C to CP2102N USB-UART plus UART header.
Power Tree
Diagram



  
    
  
  
    
  


















12-36 VDC field input
Protection: fuse, reverse polarity, TVS, filtering
PS1 CCG6-24-05SR 5 V / 1.2 A
5 V rail
U3 TLV75533 3.3 V LDO
3.3 V rail
ESP32-WROOM-32
MAX3485 RS485
Hall input, LEDs, logic
ESP32 Pin Assignment

Table

FunctionESP32 PinNet
UART0 RX programmingRXD0 / GPIO3ESP_UART0_RX
UART0 TX programmingTXD0 / GPIO1ESP_UART0_TX
RS485 UART RXGPIO16RS485_RX
RS485 UART TXGPIO17RS485_TX
RS485 driver/receiver enableGPIO4RS485_DE_RE
Hall RPM interrupt inputGPIO27HALL_RPM
Boot buttonGPIO0ESP_BOOT
Reset/enableENESP_EN
Connector Pinout

Table

ConnectorPurposePins
J212–36 VDC input1 = VIN+, 2 = VIN-/GND
J3Wind speed RS4851 = RS485_A, 2 = RS485_B
J4Wind direction RS4851 = RS485_A, 2 = RS485_B
J5JSY-MK-229 power meter RS4851 = RS485_A, 2 = RS485_B
J6Hall RPM sensorPin_1 = 3V3, Pin_2 = HALL_RPM, Pin_3 = GND
J7UART headerPin_1 = 3V3, Pin_2 = ESP_UART0_RX, Pin_3 = ESP_UART0_TX
J1USB-C programmingVBUS = 5V, D+/D- to CP2102N, CC1/CC2 5.1k to GND
RS485 Wiring Diagram
Diagram



  
    
  
  
    
  












ESP32 UART2 GPIO16/17 + GPIO4 DE/RE
MAX3485
Shared RS485 A/B bus
Wind speed Modbus
Wind direction Modbus
JSY-MK-229 power meter
Design Notes
  • ESP32-WROOM-32 requires 3.0–3.6 V and at least 500 mA available for Wi-Fi peaks.
  • EN uses a 10 kΩ pull-up and 1 µF reset-delay capacitor per Espressif guidance.
  • GPIO0 has a 10 kΩ pull-up and boot button to ground for UART download mode.
  • RS485 A/B include TVS placeholder protection and optional 120 Ω termination; populate termination only if the PCB sits at one physical end of the RS485 cable.
  • Hall RPM input uses a 10 kΩ pull-up to 3.3 V and TVS/ESD placeholder protection.
  • Remaining production items: assign exact fuse, reverse-polarity MOSFET/diode, and TVS MPNs before manufacturing; then complete PCB placement/routing and DRC.

  • Objective

  • Architecture

  • Power Tree

  • ESP32 Pin Assignment

  • Connector Pinout

  • RS485 Wiring Diagram

  • Design Notes