A smart pump/induction motor controller with advanced features and protection systems
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Project Status: Active Development & Testing
Safety Notice: |
💪 Core Features
⚡ Dual Core ESP32- One core for UI, one for sensor monitoring🔄 OTA Updates- Over-the-air firmware updates via local network📱 WiFi Manager- Easy device setup using smartphone💾 Preferences- Persistent settings storage
🛡️ Protection Systems
🚱 Dry Run Protection- Prevents pump damage from running dry⚠️ Overload Detection- Monitors current draw and shuts off if exceeded🔌 Short Circuit- Advanced electrical protection features📊 Load Monitoring- Real-time current and power monitoring
🎮 Smart Controls
🔘 One-Button System- Short press to navigate, long press to select📟 OLED Display- 128x64 clear visual interface🚥 RGB Indicators- Status and warning indicators⏲️ Timer Controls- Scheduled operations
📊 Monitoring & Logging
💧 Water Level- Real-time tank level monitoring📈 Google Sheets- Data logging and analysis🔍 Diagnostics- Comprehensive system monitoring⚡ Power Stats- Current and power consumption tracking
Note: Settings and parameters can be customized through an intuitive menu system.
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| Item | Description | Notes |
|---|---|---|
| 1. | Tested on: DOIT ESP32 DEVKIT V1 (30 pin) | |
| 2. | 128x64 OLED Display | |
| 3. | Removed | |
| 4. | DS1307 RTC | |
| 5. | SCT013 30A/1V Current sensor | Check for Wiring |
| 6. | AJ-SR04 Ultrasonic Sensor(Water Proof) | Check Mode 2 for connection |
| 7. | WS2812B LED (Single LED Module) | |
| 8. | Any Push Button | I used metal one, feels sturdy |
| 9. | Any desired float sensor | |
| 10. | Wires, connectors, etc | According to your need |
| 11. | Fotek 100Amps SSR |
Check Issues
Circuit Schematic |
Front View |
Front View 2 |
Front View 3 |
Full View |
Ultra Sonic |
Ultra Sonic USB |
Complete Setup |
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🧮 Dual Core Processing
- 🖥️ Core 1: User Interface & Display
- 🎨 UI Rendering
- 📱 Menu System
- 🔄 Display Updates
- 🤖 Core 2: Sensor & Safety
- 📊 Real-time Monitoring
- ⚡ Power Management
- 🛡️ Protection Systems
- 🖥️ Core 1: User Interface & Display
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💾 Memory System
- 🎚️ Dynamic Sensor Configuration
- 📦 Persistent Settings Storage
- 🔧 Resource Optimization
- 💧 Pump Safety
- 🚱 Dry Run Prevention
- 🔍 Continuous Monitoring
- 🛑 Auto Shutdown
- ⚡ Overload Protection
- 📈 Current Monitoring
- 🚨 Threshold Alerts
- 🔌 Short Circuit Guard
⚠️ Fault Detection- 🚫 Emergency Cutoff
- 🚱 Dry Run Prevention
- 🔘 One-Button Interface
- 👆 Short Press Navigation
- 👇 Long Press Selection
- 🌈 RGB Status Feedback
- 📟 Display System
- 📱 1.3" OLED Screen
- 📊 Real-time Stats
- 🚦 Status Indicators
- 🔊 Audio Alerts
- 📏 Level Monitoring
- 🎚️ Float Sensor (Primary)
- ✅ Reliable Detection
- 🛑 Overflow Prevention
- 📡 Ultrasonic Sensor
- 📊 Real-time Monitoring
- 📈 Level Tracking
- 🎚️ Float Sensor (Primary)
- 📡 WiFi Features
- 📱 Smart Device Setup
- 🔄 OTA Updates
- ⏰ Auto Time Sync
- 📊 Remote Monitoring
- 🕒 RTC Features
- 📅 Scheduling
- ⚡ Power Monitoring
- 🔄 Auto Recovery
- 📊 Time Tracking
- ☁️ Cloud Integration
- 📈 Google Sheets Logging
- 📊 Performance Analytics
- 📉 Usage Statistics
- 🔍 System Diagnostics
💡 Pro Tips:
- 🔧 Configure sensors based on your setup
- ⚙️ Adjust thresholds for optimal performance
- 📱 Use WiFi features for remote monitoring
- 🔄 Keep firmware updated for best results
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This project offers two methods for logging pump data to Google Sheets:
- 🌟 Using PythonAnywhere as middleware (Recommended, Advanced)
- 🔗 Direct Google Sheets integration (Comparatively Simpler, Not Recommended)
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🌐 Google Cloud Setup
- Follow this guide up to step 2
- 🔑 Obtain necessary Google Cloud credentials
- 📊 Set up your Google Sheet for data reception
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⚙️ PythonAnywhere Configuration
- 🔄 Deploy provided Flask code to PythonAnywhere
- 📂 Code available in
/resourcesfolder - 📡 Handles JSON data from ESP32
- 📝 Manages Google Sheets communication
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📊 Data Collection
- ⏱️ Records fill time duration
- 📈 Logs sensor parameters
- 📊 Tracks system performance
- 💾 Stores historical data
- 📂 Located in
/resourcesfolder - 💻 Requires different partition scheme
- 🔧 Higher memory usage
- 📋 Check header comments for configuration
| ⏱️ Duration | 💧 Water Level | ⚡ Power Usage | 🔄 System Status |
💡 Tip: Choose Method 1 for better memory management and system stability. Use Method 2 only if you need direct integration and have configured the appropriate partition scheme.
- Track system efficiency
- Monitor fill patterns
- Identify potential issues
- Analyze performance trends
Known Issues 1.2.0
1. Same as 1.1.1-beta 2. Ultrasonic works as of now (when it is connected), because the water is falling from height and waves are forming, hence accuracy is affected.Known Issues 1.1.1-beta
1. When ultrasonic is not connected, but turned on in settings, the ESP32 restarts in loop. The primary issue is that the Serial Monitor for ultrasonic returns garbage values even when nothing is connected and ESP32 tries to make sense of it and fails. The secondary issue is that it is running on CORE 0 and hence there is some kind of issue that is not faced by CORE 1 a.k.a. loop(). I'll check it in detail later. 2. Removed voltage sensor completely for now.Known Issues 1.1.0-beta
1. Same as 1.0.2-alphaKnown Issues 1.0.3-alpha
1. Same as 1.0.2-alphaKnown Issues 1.0.2-alpha
1. Voltage Monitoring is not working (Giving higher values than individual test results, will look into it later). 2. Wattage is dependent on voltage, so it is also not working.
| SCT013 | Water Level | Ultrasonic |
📊 Default Value: 27
🔧 Adjustable via program
📈 Reference: Home electricity meter
🎯 Goal: Match readings
| ⚡ Voltage | 📊 Current |
| 220-240V AC | 2.6A - 3.3A |
1. 🏃 Run pump normally
2. 📊 Compare readings
3. 🔧 Adjust values
4. ✅ Verify results
- 🔌 Voltage Protection: External voltage protection is recommended
- 📊 Current-Voltage Relationship:
- 📈 Current increases when voltage drops
- 📉 Current decreases when voltage rises
- 🔍 This relationship helps detect power quality issues
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- 🛡️ Always have external circuit protection
- 📊 Monitor initial readings carefully
- 📝 Document your calibration values
- 🔄 Perform periodic calibration checks
💡 Pro Tip: The relationship between current and voltage provides indirect power quality monitoring even without dedicated voltage sensors.
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- External Protection - Regular Checks - Documentation |
- Track Readings - Record Changes - Verify Values |
- Regular Calibration - Keep Records - Update Settings |
🔧 Made with ❤️ for the IoT Community 🌐
This project is licensed under the GNU General Public License v3.0 - see below for details.
GNU GENERAL PUBLIC LICENSE
Version 3, 29 June 2007
Copyright (C) 2007 Free Software Foundation, Inc. <https://fsf.org/>
Everyone is permitted to copy and distribute verbatim copies
of this license document, but changing it is not allowed.
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