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
Created a thread
ESP32 Pump Controller Verification
Completed
View Thread
Thought for 9 sec — Creating documentation while reviewing
Referenced guidance.
Thought for 47 sec — Creating firmware documentation
Updating 3 project docs.
Created 3 project docs

Firmware Getting Started

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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

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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

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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...
Thought for 8 sec
Awaiting 1 background task
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

3D View

U2
R5
Resistance
100kΩ
R4
Resistance
680Ω
J7
J2
J6
D1
J3
SW1
R2
Resistance
10kΩ
R1
Resistance
10kΩ
R3
Resistance
100kΩ
SW2
J4
J8
Q1
C3
Capacitance
100nF
K1
U1
J1
C1
Capacitance
1uF
PS1
C4
Capacitance
47uF
J5
C7
Capacitance
100nF
C6
Capacitance
100uF
J9
C2
Capacitance
4.7uF
C5
Capacitance
1uF
Power Budget
Controller Rails
The controller is powered from an isolated, certified 220-240 VAC to 5 VDC module. The pump branch is electrically separate and is not included in the low-voltage supply sizing.

Table

ConsumerRailTypical currentPeak/design current
ESP32 Wi-Fi module3.3 V120-240 mA500 mA
LEDs, pull resistors, regulator quiescent current3.3 V5-20 mA30 mA
Interposing relay coil5 V70-100 mA120 mA
3.3 V rail design peak: 530 mA. Select a regulator rated for at least 600 mA, preferably 1 A, and verify thermal performance from 5 V input.
5 V input design peak is approximately 650 mA. Select the isolated AC-DC module at 5 V / 1 A minimum to provide transient and temperature margin.
Pump Branch
Provisional load: 12 A at 220-240 VAC. This is not verified. Motor starting current may be several times the running current.
  • Use an external contactor with an AC-3 motor rating, provisionally at least 16 A at 230 VAC, subject to the pump nameplate and duty cycle.
  • A provisional 16 A time-delay/gG protection device may be a starting point only; final selection must follow the pump manufacturer and local wiring rules.
  • Supply cable, terminals, enclosure, disconnect, protective earth, and upstream breaker must all be sized by a qualified electrician.

  • Controller Rails

  • Pump Branch