Project Start
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Created 5 project docs
Firmware Starter — WeLift Gate Controller
Arduino/PlatformIO starter for U3 ESP32-S3-WROOM-1U-N16R8. The mapping below is grounded in the live U3 netlist; TXD0/RXD0 GPIO identities a...
Board Bring-Up Plan — WeLift Gate Controller
Use an isolated, current-limited bench source, DMM, oscilloscope with appropriate differential probing, electronic load, USB data isolator w...
FCC/CE TCF Draft and RF Integration Notes — WeLift Gate Controller
Host controller using U3 ESP32-S3-WROOM-1U-N16R8, a Wi-Fi/Bluetooth module with U.FL external-antenna interface, plus an optional plug-in LT...
Preliminary Safety Analysis and FMEA — WeLift Gate Controller
The product presents only isolated, normally-open dry contacts to command inputs of an independently certified gate operator. It does not sw...
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The schematic is complete and ERC-clean, with firmware, bring-up, compliance, safety, and manufacturing files created.
Open blockers
- PCB stackup repeatedly reverts to two layers due to a platform persistence fault, so routing cannot safely proceed.
- Cellular-area placement remains unroutable.
- Production also requires the TVS, cellular connector, fuse-inrush, mounting-hole, and relay-surge items listed in the Manufacturing Readiness Checklist.
Completed files
The stackup fault has been reported internally; routing and manufacturing export remain intentionally unfinished rather than producing an unsafe board.
Fix blockers and review
Fix PCB blockers
Replace input TVS
Verify cellular connector
Review BOM cost
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FCC/CE TCF Draft and RF Integration Notes — WeLift Gate Controller
Product and radio configuration
Host controller using U3 ESP32-S3-WROOM-1U-N16R8, a Wi-Fi/Bluetooth module with U.FL external-antenna interface, plus an optional plug-in LTE-M/NB-IoT modem/carrier on J7. Final cellular compliance is explicitly dependent on the selected modem, carrier, antenna, cable, enclosure and host integration.
Technical Construction File index (draft)
- Product description, intended use and safety boundary.
- Project Specification, schematic, BOM, PCB fabrication data and assembly drawings.
- Radio module grants/DoC, datasheets, approved antenna lists and integration instructions.
- Risk assessment and standards matrix.
- EMC/RF test plan and accredited-lab reports.
- User/installer instructions, labels, FCC/CE statements, antenna separation and professional-installation limits.
- Supplier declarations/RoHS/REACH evidence and production change control.
- Firmware version, radio configuration, maximum transmit settings, secure-update controls and test firmware hashes.
- Declaration of Conformity and authorized representative/importer records as applicable.
US/FCC plan
- Verify the exact ESP32-S3-WROOM-1U variant FCC ID and grant conditions from Espressif at release; do not infer certification from family name alone.
- Integrate only antennas/cable assemblies permitted by the module grant, within gain and connector restrictions. If an unlisted antenna, different RF path, co-location, simultaneous transmission, or portable exposure condition is used, obtain a qualified TCB/lab assessment and perform additional testing as required.
- Host still requires Part 15B unintentional-radiator evaluation. Apply required exterior label wording such as “Contains FCC ID …” only after the exact grant is verified.
- User instructions must include Part 15 conditions, interference statement, installation/separation requirements, approved antennas, and prohibition on unauthorized modifications.
- Optional LTE modem: capture its FCC ID, carrier approvals/PTCRB status as applicable, approved antenna list, RF exposure conditions and host integration instructions. Final certification cannot be claimed until the modem/antenna is selected.
EU/CE plan
Assess the complete product to RED 2014/53/EU, EMC 2014/30/EU where applicable, RoHS 2011/65/EU as amended, and relevant safety/environmental requirements. Candidate harmonized standards must be confirmed against the current Official Journal and final use configuration; likely families include ETSI EN 300 328 (2.4 GHz), EN 301 489-1/-17 and modem-specific radio/EMC standards, EN IEC 62368-1 safety, and EN 62311/EN 50665 RF exposure. Do not freeze standard editions until the compliance lab review.
ESP32-S3-WROOM-1U RF integration
- U3 is the 1U external-antenna variant; no PCB antenna keepout is claimed, but preserve a clean ground/reference and short, mechanically protected U.FL-to-bulkhead cable route.
- Use the exact approved antenna type/gain and cable loss needed to remain within the module authorization. Record antenna manufacturer, MPN, gain by band, cable MPN/length/loss and bulkhead connector.
- Keep switching nodes (U1/L1, U2/L2), relay coils/contacts, long field wiring and cellular power pulses away from the Wi-Fi antenna cable and antenna.
- Bond/shield the enclosure consistently; metal enclosure operation requires an external antenna mounted with manufacturer-required spacing from people and other antennas.
- Verify conducted/radiated emissions, receiver performance and coexistence with cellular active. Pre-scan with relays switching, Wi-Fi transmit, cellular load pulses, USB attached and worst-case input cable configuration.
Optional LTE-M/NB-IoT integration
- J7 is a project-defined interface, not a standard modem pinout: 1–2 CELL_5V_SW, 3–4 GND, 5 host RX, 6 host TX, 7 CTS, 8 RTS, 9 module enable, 10 reset_n, 11–12 unused/mechanical.
- Connector identity/footprint/numbering must be resolved before modem hardware is built.
- Select a pre-certified LTE-M/NB-IoT module/carrier supporting the deployment bands and network/carrier. Preserve its mandated ground, antenna clearance, SIM/eSIM rules, power profile and firmware version.
- Host supply is designed for 0.4 A continuous and 2.0 A bursts. A module exceeding this invalidates the current power assumption.
- Obtain module FCC/ISED/RED reports, grant notes, PTCRB/carrier evidence where needed, permitted antennas and RF exposure guidance. Co-location with Wi-Fi may require simultaneous-transmission analysis or testing.
EMC and immunity test configuration
Test at 12/24 V AC and DC, both DC polarities, representative maximum field-cable lengths, USB attached/detached, Wi-Fi active, cellular active, relay cycling, optocoupler contacts switching and maximum load pulses. Include ESD, EFT/burst and surge levels selected for outdoor low-voltage wiring; conducted/radiated emissions and immunity; RF exposure; and enclosure ingress/environmental tests outside RED as required by market claims.
Open items blocking final TCF
- Exact LTE modem/carrier, firmware, antenna and certifications not selected.
- Exact ESP32 antenna/cable and verified grant conditions not frozen.
- D1 must be replaced by a qualified 40–43 V bidirectional ≥600 W TVS.
- Enclosure/IP rating, cable glands, installation separation and grounding/bonding are undefined.
- PCB is unrouted on a live 2-layer stackup with a reported stackup persistence fault; no manufacturing exports or compliance prototypes exist.
- Final standards/editions and test severities require compliance-lab agreement.
This is a planning draft, not a Declaration of Conformity or certification claim.
Product and radio configuration
Technical Construction File index (draft)
US/FCC plan
EU/CE plan
ESP32-S3-WROOM-1U RF integration
Optional LTE-M/NB-IoT integration
EMC and immunity test configuration
Open items blocking final TCF
