Commissioning Checklist

🏊 Smart Swimming Pool: Step-by-step checklist for first-time setup and commissioning.

Use this checklist before connecting pumps to mains voltage. Tick off each item to ensure a safe and successful first run.

1. Hardware Assembly

1.1 Controller Electronics

• ESP32 firmly seated on breadboard or perfboard
• Relay module connected: VCC → 5V (not 3.3V!), GND → GND
• Relay IN1 (GPIO26) prepared for heating circuit pump
• Relay IN2 (GPIO25) prepared for filter/circulation pump
• DS18B20 solar sensor: DATA → GPIO32, VDD → 3.3V, GND → GND
• DS18B20 pool sensor: DATA → GPIO33, VDD → 3.3V, GND → GND
• 4.7kΩ pull-up resistor between each DATA pin and 3.3V (2 resistors total)
• No shorts between adjacent pins on the breadboard

1.2 Power Supply

• USB power supply: 5V / 1A minimum (quality brand, not a phone charger from a discount store)
• USB cable is a data cable (not charge-only)
• Power supply is in a dry location or IP-rated enclosure

1.3 Enclosure (if used)

• Enclosure is IP54 or better for outdoor / pool house installation
• Cable glands (PG fittings) installed for all cable entries
• Ventilation openings if enclosure traps heat
• Strain relief on all cables entering the enclosure

2. 230V / Mains Side

⚠️ Danger to life! Work on 230V circuits must only be performed by qualified personnel. Observe all applicable electrical codes.

• RCD / FI circuit breaker installed in the supply line (mandatory!)
• Circuit breaker (MCB) with appropriate rating for each pump
• Cable cross-section adequate for pump current draw
• All connections in a junction box or distribution board
• Pumps are NOT connected to the relay outputs yet — test without 230V first
• If available: use a mains tester to verify the 230V wiring before connecting pumps

3. Firmware & First Boot

• PlatformIO project opened, environment set to esp32dev
• Firmware uploaded successfully: pio run -e esp32dev -t upload
• Filesystem image uploaded: pio run -e esp32dev -t uploadfs
• Serial monitor shows boot log at 115200 baud
• ESP32 starts in AP mode:

  [INFO] Pool Controller v3.x.x starting...
  [INFO] WiFi: Starting in AP mode
  [INFO] AP: 'Pool-Controller-Setup'. IP: 192.168.4.1

3.1 If Boot Fails

4. Temperature Sensors

• After boot, serial monitor shows detected DS18B20 sensors:

  [INFO] OneWire: Found 2 DS18B20 sensor(s)
  [INFO] DS18B20[0]: 28-xxxxxxxxxxxx (Solar sensor on GPIO32)
  [INFO] DS18B20[1]: 28-yyyyyyyyyyyy (Pool sensor on GPIO33)
• Both sensors read plausible temperatures (not -127°C or 85°C)
• Warm one sensor by holding it — reading rises within seconds
• If only 1 sensor found: check wiring, pull-up resistor, or try the sensor alone

4.1 Temperature Sensor Quick Check

5. WiFi & Network

• Connected to Pool-Controller-Setup WiFi network
• Web interface reachable at http://192.168.4.1
• Home WiFi configured in web interface → Connection section
• ESP32 rebooted and connected to home network
• New IP address noted (from router DHCP or serial monitor)
• Web interface reachable at http:///
• ESP32 pingable from your computer: ping <new-ip>

6. MQTT Connection

Prerequisites

• MQTT broker (Mosquitto) is installed and running
• Broker is reachable from the ESP32’s network (same subnet or firewall rule for port 1883)
• If using authentication: username/password noted

Configuration

• Web interface → Configuration → MQTT:
  • Broker address entered
  • Port correct (default: 1883)
  • Credentials entered (if required)
• Click Test Connection — result shows “Connected”
• Click Save — controller restarts MQTT connection

Verification

• Subscribe to all topics on the broker:

  mosquitto_sub -h <broker-ip> -t "#" -v
• Pool controller topics appear (prefixed with homeassistant/ or homie/)
• Sensor values update periodically
• If topics are missing: check homeassistant prefix in HA configuration

7. Functional Test (Without 230V)

Before connecting any pump, test that the controller can switch the relays.

• Multimeter ready, set to DC voltage mode
• Measure between relay IN1 pin and GND:
  • Web interface shows relay OFF → IN1 reads ~3.3V (HIGH)
  • Web interface shows relay ON → IN1 reads ~0V (LOW)
• Repeat for relay IN2 — same behavior
• If voltages are reversed: your relay module is active-high — check for a HIGH/LOW jumper or replace the module

Relay Test by GPIO

8. Home Assistant Integration (Optional)

• MQTT integration configured in Home Assistant (Settings → Devices & Services → MQTT)
• Discovery enabled: discovery: true in HA configuration.yaml
• Pool Controller appears as a device in Settings → Devices & Services → Devices
• All entities visible and reporting values:
  • sensor.pool_controller_pool_temp — pool temperature
  • sensor.pool_controller_solar_temp — solar temperature
  • select.pool_controller_mode — operation mode
  • switch.pool_controller_pool_pump — pump control
  • switch.pool_controller_solar_pump — solar pump control
• Operation Mode can be changed via HA (try switching to manu and back to auto)

9. First Real Test (With Pumps)

Only proceed when all previous steps pass.

• Disconnect ESP32 from USB power
• Wire relay outputs to pump contactors or directly to pumps (230V side)
• Double-check: relay common (COM) and normally open (NO) wired correctly
• Reconnect ESP32 to USB power
• Set operation mode to Manual (manu) via web interface
• Toggle Heating Pump ON via web interface — pump starts
• Toggle Heating Pump OFF — pump stops
• Toggle Filter Pump ON — pump starts
• Toggle Filter Pump OFF — pump stops
• If pump does not start: check 230V wiring, circuit breaker, RCD
• If pump starts but does not stop: relay contacts may be welded — disconnect 230V immediately

10. Automation Test

• Set operation mode to Auto
• Verify the controller switches pumps according to its heating logic
• Solar temperature > Pool temperature + hysteresis → heating pump should turn ON
• Pool temperature reaches max. set temperature → heating pump should turn OFF
• Filter/circulation pump runs according to its schedule (timer or temperature-based)

11. Final Verification

• Temperature difference between solar and pool sensor is plausible
• Controller remains stable for 24+ hours without unexpected reboots
• WiFi connection stays stable (check RSSI in diagnostics)
• MQTT connection persists (check availability topic: should read online)
• Home Assistant (if used) shows correct and current values

Quick Reference Card

Print this abbreviated checklist for quick on-site reference:

☐ ESP32: 5V USB power, data cable
☐ Relay VCC → 5V, GND → GND
☐ Relay IN1 → GPIO26 (heating)
☐ Relay IN2 → GPIO25 (filter)
☐ DS18B20 #1: GPIO32 + 4.7kΩ pull-up
☐ DS18B20 #2: GPIO33 + 4.7kΩ pull-up
☐ RCD / FI installed on 230V side
☐ Firmware + Filesystem uploaded
☐ WiFi configured, web UI reachable
☐ MQTT test connection successful
☐ Relay voltages correct (3.3V OFF / 0V ON)
☐ Manual pump test (without 230V automa