Project Kickoff

Worked for 3 mins 37 sec
3/4 Run connectivity and ERC review; remediate issues

Inspect current schematic, project documents, and executor report

Wire the power, ESP32, relay driver, and external contactor/manual override interfaces

Run connectivity and ERC review; remediate issues

Create ESPHome configuration and record remaining safety assumptions

Thought for 7 sec
Reading schematic details.
Thought for 10 sec — Assessing connectivity issues
Completed 13 design checks — found 86 issues.
Thought for 13 sec — Considering executor review
Thought for 9 sec — Creating documentation while reviewing
Referenced guidance.
Thought for 47 sec — Creating firmware documentation
Updating 3 project docs.
Thought for 8 sec
Awaiting 1 background task
Created 3 project docs

Firmware Getting Started

View Document
Firmware Getting Started Platform
  • MCU: ESP32-C3-WROOM-02-N4 (U2)
  • Framework: ESPHome
  • Home Assistant integration: native ESPHome API
  • Relay output: GPIO4, active high
  • Hardware default: OFF via R3 100 kΩ pull-down and Q1 low-side driver
Pin Mapping ESPHome Configuration
Save as esp32-pump-controller.yaml. Substitute secrets and encryption/API keys using the ESPHome dashboard.
Control Behavior
  • After power-up or reset, the automatic relay output is OFF.
  • Wi-Fi or Home Assistant loss does not energize the relay and does not reboot the controller.
  • The external BTicino switch at J3 is not read by firmware. It directly bypasses K1's NO contact and can force the external contactor coil ON.
  • Home Assistant cannot force the pump OFF while the manual switch is ON.

Board Bring-Up Plan

View Document
Board Bring-Up Plan Prerequisites and Safety
  • Equipment: multimeter, current-limited isolated 5 V bench supply, 3.3 V USB-UART adapter, oscilloscope if available.
  • First tests must be performed with all mains wiring disconnected.
  • Do not apply 230 VAC until the PCB enclosure, clearances, terminals, contactor, fuse/breaker, PE bonding, and wiring have been inspected by a qualified person.
  • Never connect the pump directly to the PCB relay.
1. Visual Inspection
  • Verify PS1, U1, U2, Q1 and D1 orientation.
  • Verify K1 is the 5 V coil variant.
  • Check separation between CTRL_MAINS_L/CTRL_MAINS_N/contact nets and 5V_SELV/3V3_SELV/GND_SELV.
  • Confirm J5-J9 external representations are not populated on the PCB.
2. Unpowered Continuity 3. SELV Power Test

FCC CE Technical Construction File

View Document
FCC CE Technical Construction File Status
Draft — schematic stage.
Product
Home Assistant/ESPHome water-pump controller using an ESP32-C3-WROOM-02-N4 Wi-Fi module. The controller energizes an external motor-rated contactor; it does not switch pump current directly.
Applicable Regulatory Areas
  • FCC Part 15 intentional radiator requirements for US marketing.
  • CE Radio Equipment Directive (RED) for EU marketing.
  • EMC and electrical safety requirements for a mains-powered controller.
  • Local installation codes for fixed 230 VAC pump equipment.
Wireless Module RF Integration Requirements
  • Preserve the module antenna keepout specified by Espressif on every copper and mechanical layer.
  • Place the antenna at a board edge with no enclosure metal, mains wiring, contacto...
Received notification from "ESP32 Pump Controller Verification" that it finished — picking the work back up.

flux

The schematic is fully wired with 20 nets and independently verified: power, ESP32 support, relay driver, manual override, isolation, and external pump path all pass ERC with no warnings or errors.
Start PCB constraints
Choose enclosure size
Review contactor options
Prepare manufacturing BOM
Sign up to send

Files

Schematic

Layout

Preview

U2
FCC CE Technical Construction File
Status
Draft — schematic stage.
Product
Home Assistant/ESPHome water-pump controller using an ESP32-C3-WROOM-02-N4 Wi-Fi module. The controller energizes an external motor-rated contactor; it does not switch pump current directly.
Applicable Regulatory Areas
  • FCC Part 15 intentional radiator requirements for US marketing.
  • CE Radio Equipment Directive (RED) for EU marketing.
  • EMC and electrical safety requirements for a mains-powered controller.
  • Local installation codes for fixed 230 VAC pump equipment.
Wireless Module

Table

DesignatorModuleRadioBandIntegration status
U2ESP32-C3-WROOM-02-N4Wi-Fi/BLE2.4 GHzModule; certification IDs and exact integration conditions must be confirmed from Espressif documentation for the chosen regional SKU
RF Integration Requirements
  • Preserve the module antenna keepout specified by Espressif on every copper and mechanical layer.
  • Place the antenna at a board edge with no enclosure metal, mains wiring, contactor, or large copper directly in front of it.
  • Do not add an external antenna or RF matching modifications without reassessing certification.
  • Record the final enclosure material, antenna clearance, and installation orientation.
Safety/EMC Design Evidence
  • Certified encapsulated isolated AC/DC module PS1 (IRM-05-5).
  • SELV rails are separate from mains and relay-contact domains.
  • K1 switches only the external contactor coil.
  • Pump motor current and protection are external to the PCB.
  • Manual override is a dry contact in parallel with K1's NO contact.
Documentation Checklist
  • Project specification
  • Power budget
  • Safety analysis
  • Preliminary FMEA
  • Firmware configuration
  • Board bring-up plan
  • Final schematic PDF
  • PCB layout and Gerbers with RF keepout and creepage annotations
  • Final BOM with safety approvals and certification identifiers
  • Accredited EMC/RF test reports
  • Final user/installer manual
  • Signed Declaration of Conformity
Open Items
  • Confirm Espressif module FCC/CE identifiers and all grant/integration conditions.
  • Complete PCB layout review for antenna keepout, mains creepage/clearance, and conducted/radiated emissions risk.
  • Select the final motor contactor and fuse/breaker from the pump nameplate and local regulations.
  • Define enclosure ingress protection and installation category.
  • Obtain accredited testing before sale or distribution.

  • Status

  • Product

  • Applicable Regulatory Areas

  • Wireless Module

  • RF Integration Requirements

  • Safety/EMC Design Evidence

  • Documentation Checklist

  • Open Items