FINAL COMPONENTS AND SPECIFICATIONS

1. ESP32 Microcontroller
 Purpose: Acts as the central control unit to process sensor data,
manage fault conditions, and control relays.
 Connections:
 Power Supply: Connect to a 5V DC power supply.
 GPIO Pins: Used for input from sensors, buttons, and controlling
outputs like relays and indicators.
 Ground (GND): Common ground connection shared with all
components.

2. Sensors
 Voltage Sensor (ZMPT101):
 Purpose: Measures motor line voltage.
 Connection:
 Input: Connected across one phase of the 220V AC line.
 Output: Signal pin to an ESP32 analog input (ADC).
 Ground: Shared with ESP32 ground.

 Current Sensor (SCT013):

 Purpose: Monitors the motor's current to detect overloads or
underloads.
 Connection:
 Input: Clamps around one phase wire to measure current.
 Output: Signal pin to an ESP32 analog input (ADC).
 Ground: Shared with ESP32 ground.

 Temperature Sensor (DS18B20):

 Purpose: Monitors the motor's surface temperature.
 Connection:
 Signal wire to a digital GPIO pin on ESP32.
 Power (VCC) to 3.3V pin of ESP32.
 Ground to ESP32 ground.

3. Indicator Lights
 Each sensor has three indicator lights to show its status:
 Green (Normal): Lights up when sensor readings are within safe
limits
 Yellow (Warning): Lights up if readings are approaching unsafe
limits
 Red (Fault): Lights up if readings exceed safe thresholds.
 Connection:
 LEDs are connected to GPIO pins on the ESP32 with
currentlimiting resistors (typically 330Ω).
 Cathodes (negative terminals) of all LEDs are connected to the
ground.

4. Buttons
 Start Button:
 Purpose: Activates the protection system.
 Connection:
 One terminal to a digital GPIO input pin.
 The other terminal to a pulldown resistor and ground.
 Stop Button:
 Purpose: Deactivates the protection system or stops the motor
manually
 Connection:
 One terminal to a digital GPIO input pin.
 The other terminal to a pulldown resistor and ground.

5. Buzzer
 Purpose: Emits an audible alert during a fault conditioN
 Connection:
 Positive terminal to a GPIO output pin via a currentlimiting
resistor.
 Negative terminal to the ground.

6. Timer
 Purpose: Ensures proper timing for wyetodelta transition during
motor start.
 Connection:
 Input signal from ESP32 to control the timer.
 Timer output connected to the wye and delta contactor control
circuits.

7. Contactors
WyeDelta Switching Contactors (3 contactors):
 Purpose: Enable proper motor starting with reduced
current.
 Connection:
 Coil terminals connected to 220V AC through the
timer and forward/reverse relays.
 ESP32 controls the relays to manage these
contactors.
Forward/Reverse Contactors (2 contactors):
 Purpose: Control the motor's rotation direction.
 Connection:
 Coil terminals connected to 220V AC via control
signals from ESP32.
 Proper interlocking ensures only one contactor is
active at a time.

8. Overload Relay
 Purpose: Protects the motor from excessive current draw.
 Connection:
 Placed in series with the motor’s power line.
 Fault signal output connected to an ESP32 GPIO input pin for
monitoring.

9. LCD Display
 Purpose: Displays realtime data (voltage, current, temperature, and
system status).
 Connection:
 SDA and SCL pins to corresponding ESP32 GPIO pins for I2C
communication.
 Power (VCC) to 5V pin of ESP32.
 Ground to ESP32 ground.

10. Power Supply Unit

 Purpose: Provides 5V for the ESP32 and sensors, and 12V for relays
and contactors.
 Connection:
 Input: 220V AC connected to the power supply.
 Outputs:
 5V output to ESP32 and sensors.
 12V output to contactor coils and indicator lights.

11. Circuit Protection

 Snubber Circuits: Across each contactor coil to suppress voltage
spikes.
 Fuses or Circuit Breakers: On the motor’s power line for safety.
 Flow Summary
1. System Activation: Pressing the start button powers the ESP32 and
activates the sensors.
2. Normal Monitoring: Sensor data is continuously read by the ESP32.
3. Fault Detection:
 If any sensor exceeds safe thresholds, the red indicator for that
sensor lights up, the buzzer activates, and the motor shuts off
via contactor control.
4. Manual Stop: Pressing the stop button deactivates the motor and
system.

SPECIFICATIONS
1. ESP32 Microcontroller
 Specification:
 Operating Voltage: 3.3V (logic level)
 Input Voltage: 5V (via USB or VIN pin)
 Number of GPIO Pins: At least 30
 Communication Protocols: I2C, SPI, UART, WiFi, PWM support
2. Sensors
 Voltage Sensor (ZMPT101B):
 Operating Voltage: 5V
 Measurement Range: 0–250V AC
 Output: Analog signal (scaled voltage value)
 Accuracy: High sensitivity for lowvoltage measurements
 Current Sensor (SCT013000):
 Measurement Range: 0–30A AC
 Output: 0–1V analog signal (through a burden resistor)
 Accuracy: ±1%
 Type: Noninvasive clamp
 Temperature Sensor (DS18B20):
 Measurement Range: 55°C to +125°C
 Accuracy: ±0.5°C (between 10°C and +85°C)
 Output: Digital (1Wire communication protocol)
 Operating Voltage: 3.3–5V
3. Indicator Lights
 Specification:
 Voltage: 12V DC (to match power supply)
 Current: ~20mA per LED
 Colors:
 Green: Normal
 Yellow: Warning
 Red: Fault
 Resistors: 330Ω (currentlimiting)
4. Buttons
 Start Button:
 Type: Normally open (NO) momentary push button
 Voltage Rating: 12V DC
 Current Rating: ~1A
 Stop Button:
 Type: Normally closed (NC) momentary push button
 Voltage Rating: 12V DC
 Current Rating: ~1A
5. Buzzer
 Specification:
 Operating Voltage: 12V DC
 Current Draw: ~30mA
 Sound Output: ~85dB
6. Timer
  Specification:
 Type: Adjustable delay timer relay module
 Operating Voltage: 12V DC
 Time Range: 0–60 seconds (adjustable)
 Output: Relay contact (NO/NC)
7. Overload Relay
 Specification:
 Adjustable Current Range: 3A–6A (for 1 HP motor full load
current ~3.4A with margin)
 Type: Thermal or electronic

8. LCD Display
 Specification:
 Type: 12x6 or 16x2 character display (I2C interface
preferred)
 Operating Voltage: 5V
 Current Draw: ~20mA
9. Power Supply
 Specification:
 Input Voltage: 220V AC
 Outputs:
 5V DC (for ESP32 and sensors)
 12V DC (for contactors, buzzer, and LEDs)
 Power Rating: At least 2A total current output
10. Snubber Circuits (for Contactors)
 Specification:
 Resistor: 100Ω, 2W
 Capacitor: 0.1μF, 400V AC
 Type: RC snubber network
11. Wiring and Connectors
 Wires:
 For Power (220V AC): 14 AWG (sized for up to 10A)
 For Control Signals (12V DC): 18–20 AWG
 For Sensor Signals: Shielded cables (to reduce noise)
 Connectors:
 Screw terminal blocks or industrialgrade quick connectors

Additional Notes:
 All components should be enclosed in a ventilated, insulated
control panel to ensure safety and durability.
 Ensure grounding of all components and follow proper electrical
safety standards (e.g., Philippine Electrical Code 2017 for your
system).

GROUNDING
### **1. Grounding Principles**
- **Common Ground Point:** Create a single ground point (ground bus
bar or terminal block) in your control panel. All ground wires should
connect here.
- **Separation of Power and Signal Grounds:** If possible, separate the
high-current (AC power) ground from the low-current (DC signal)
ground and connect them at one point to avoid ground loops.

---

### **2. Components Grounding**

1. **ESP32 Microcontroller:**
- **Ground Pin (GND):** Connect directly to the low-voltage (DC)
common ground.
 - Ensure the ESP32's power source shares the same ground as other
DC components.

2. **Voltage Sensor (ZMPT101):**

- Connect the sensor's ground terminal to the ESP32's ground.
- Ensure the AC side of the sensor (primary side) has proper isolation
from the low-voltage DC ground.

3. **Current Sensor (SCT-013):**

- The output signal ground connects to the ESP32 ground.
- The sensor itself is non-invasive and does not require additional
grounding.

4. **Temperature Sensor (DS18B20):**

- The ground wire connects directly to the ESP32's ground.

5. **Indicator Lights (LEDs):**

- The cathode (negative terminal) of each LED connects to the
common ground.
- If LEDs are powered by a 12V supply, ensure the 12V ground is
linked to the common ground.

6. **Buttons (Start/Stop):**
- One side of each button connects to ground (when using pull-up
resistors).

7. **Buzzer:**
- The negative terminal connects directly to the DC common ground.

8. **Timer Module:**
- The ground pin connects to the DC common ground.
- If the timer relay module has a separate AC control circuit, ensure
proper isolation and grounding.

9. **Contactors:**
- Coil Ground: For DC-powered coils, the ground terminal of the coil
connects to the DC common ground.
- Chassis Ground: Attach the contactor frame or metallic casing to
the panel's AC ground.

10. **Overload Relay:**

- Frame Ground: If it has a metallic body, ground it to the AC ground.
- Signal Ground: The output fault signal ground connects to the
ESP32 ground.

11. **Power Supply Unit:**

- **Primary Side (AC):** Ground the input ground terminal to the AC
power ground.
- **Secondary Side (DC):** Ground the DC negative terminal to the
common ground.

12. **LCD Display:**

- Connect the ground pin (GND) to the ESP32 ground.

---

### **3. Enclosure Grounding**

- Use a **metallic enclosure** for your control panel, and connect it to
the AC ground.
- Ensure all metallic components inside the enclosure are bonded to
the enclosure's ground using a ground wire.
---

### **4. Grounding the Motor**

- Ground the motor's frame to the AC ground terminal.
- Use a separate ground wire connected to the motor's grounding lug
or bolt.

---

### **5. Grounding the Blynk or ESP8266MOD (if used):**

- Ground the ESP8266MOD to the ESP32 ground.
- Ensure proper isolation if the ESP8266MOD operates at a different
voltage level.

---

### **6. Ground Wire Specifications**

- **Wire Size:** Use at least 14 AWG for high-current AC grounds and
18 AWG for DC grounds.
- **Wire Color:** Use **green** or **green/yellow** for AC ground and
**black** for DC ground.

---

### **Final Checks**

- Use a **multimeter** to verify continuity between all ground
connections and the common ground.
- Ensure no ground loops by connecting all grounds at a single point.

---

If you want specific guidance or diagrams for grounding the entire

system, let me know!

Yes, a step-down transformer or a suitable power supply is necessary

to provide the ESP32 with the correct voltage and ensure electrical
isolation. Here's how you can handle it:

---

### **Why Use a Step-Down Transformer or Power Supply?**

1. **Voltage Requirement:**
- ESP32 operates at 3.3V (logic level) and typically accepts 5V input
via the VIN pin.
- Directly connecting the 220V AC supply to the ESP32 would damage
it.

2. **Safety:**
- A transformer provides electrical isolation between the high-voltage
AC and low-voltage DC circuits.

3. **Powering Additional Components:**

- Sensors, relays, and other low-voltage components also need a 5V
or 12V DC power source.

---

### **Options for Powering the ESP32**

1. **Using a Step-Down Transformer and Rectifier Circuit**
- **Step-Down Transformer:** Converts 220V AC to 9V or 12V AC.
 - **Bridge Rectifier:** Converts AC to DC.
- **Filter Capacitors:** Smoothens the DC output.
- **Voltage Regulator (e.g., LM7805):** Provides a stable 5V output
for the ESP32.

**Advantages:**
- Customizable and cost-effective.
- Suitable for DIY enthusiasts.

**Disadvantages:**
- Requires additional design and assembly effort.

2. **Using an AC-DC Power Supply Module**

- A compact AC-DC converter module can be used, which directly
steps down and converts 220V AC to 5V DC or 12V DC.

**Recommended Module Specifications:**

- Input Voltage: 100–240V AC
- Output Voltage: 5V DC or 12V DC (depending on system needs)
- Output Current: At least 2A (to power ESP32, sensors, and relays)

**Examples:**
- HLK-PM01 (5V DC, 3W mini power module)
- HLK-PM12 (12V DC, 3W mini power module)

**Advantages:**
- Compact, plug-and-play, and reliable.
- Provides electrical isolation.

3. **Using a USB Wall Adapter**

- Use a standard USB adapter to provide 5V to the ESP32 via the USB
port.

**Advantages:**
- Easiest and safest option.
- Readily available.

**Disadvantages:**
- May not be practical for systems requiring 12V for relays or
indicators.

---

### **How to Integrate**

- **Powering the ESP32:**
- Use a 5V DC supply from the step-down circuit or AC-DC module.
Connect to the ESP32's **VIN** and **GND** pins.

- **Powering Other Components:**

- If using relays, indicators, or sensors that need 12V DC, select a
power supply with dual outputs (e.g., 5V and 12V).

- **Grounding:**
- Ensure the DC ground is connected to the ESP32 ground and all
other low-voltage components.

---

### **Recommendation**
- **If you're looking for simplicity and reliability:** Use an **AC-DC
power supply module** like the HLK-PM01 or similar.
- **If you're experienced with circuit design:** Build a custom step-
down transformer circuit.

Let me know if you need further guidance or a schematic for either

option!

The specifications or model of the AC-to-DC converter for your ESP32

depend on the power requirements of your system and components
connected to the ESP32. Below are the recommended specifications
and models:

---

### **AC-to-DC Converter Specifications**

1. **Input Voltage:**
- 220V AC (standard supply in your region).

2. **Output Voltage:**
- 5V DC (ideal for ESP32 and most sensors).

3. **Output Current:**
- Minimum: 1A (to power the ESP32 alone).
- Recommended: 2A or more (to account for sensors, indicators,
relays, and other components).

4. **Power Rating:**
- At least 5W (higher for systems with many relays or indicators).

5. **Type:**
- Isolated AC-DC converter for safety.

---

### **Recommended Models**

1. **HLK-PM01:**
- **Input Voltage:** 90–264V AC
- **Output Voltage:** 5V DC
- **Output Current:** 600mA
- **Power Rating:** 3W
- **Size:** Compact (ideal for small enclosures).
- **Usage:** Suitable for lightweight applications (ESP32 and a few
sensors).

2. **HLK-PM03:**
- **Input Voltage:** 90–264V AC
- **Output Voltage:** 5V DC
- **Output Current:** 3A
- **Power Rating:** 15W
- **Usage:** Better for systems with multiple relays, indicators, and
higher power needs.

3. **MYRRA 47174:**
- **Input Voltage:** 85–265V AC
- **Output Voltage:** 5V DC
- **Output Current:** 1A
- **Power Rating:** 5W
- **Usage:** Reliable for medium power needs.

4. **Mean Well IRM-05-5:**

- **Input Voltage:** 85–264V AC
- **Output Voltage:** 5V DC
 - **Output Current:** 1A
- **Power Rating:** 5W
- **Usage:** High-quality industrial-grade option.

---

### **Considerations for Selection**

1. **System Load:**
- Add the current consumption of all components:
- ESP32: ~250mA
- Sensors: ~100mA
- Relays (if 5V): ~70mA per relay
- LEDs, buzzer, etc.

Ensure the power supply provides at least **30% margin** over the
total calculated load.

2. **Safety Features:**
- Short-circuit protection, over-voltage protection, and over-
temperature protection.

3. **Size:**
- Choose a compact model if you have space constraints in your
control panel.

4. **Mounting Options:**
- PCB mount (e.g., HLK series) or chassis mount (e.g., Mean Well).

---

### **Wiring and Usage**

- Connect the **AC input** to the 220V AC supply through a fuse for
safety.
- Connect the **DC output (5V and GND)** to the ESP32's VIN and GND
pins, respectively.

---

### **Recommendation**
If your system requires higher current (e.g., relays or multiple sensors),
choose **HLK-PM03** or **Mean Well IRM-05-5** for reliable operation.
For minimal setups, **HLK-PM01** is sufficient.

Let me know if you'd like further guidance!