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Pool Controller 3.3
Production Checklist

Production Checklist

⚠️ WARNING: This checklist involves 230V AC mains voltage verification. Improper wiring poses risk of electric shock, fire, or equipment damage.

  • Only proceed if you have experience with mains-voltage installations
  • Always disconnect power before working on the circuit
  • This is a DIY project — not CE/UL certified for commercial use

Overview

This checklist covers everything that should be verified before putting the Pool Controller into production service. Use it during initial commissioning and as an annual maintenance reference.

Pre-Deployment Checklist

Hardware

  • ESP32 mounted securely inside enclosure
  • Relay module mounted with adequate ventilation
  • Power supply secured and rated for load
  • All cable glands tightened and sealed
  • Strain relief applied to all external cables
  • Mains and low-voltage wiring physically separated
  • No loose wires or stray strands
  • All screw terminals tightened
  • Fuse installed (correct rating for pump load)
  • Enclosure IP rating matches location requirements

Wiring

  • DS18B20 sensors: VCC → 3.3V, GND → GND, DATA → GPIO (4.7 kΩ pull-up)
  • Relay module: VCC → 5V, GND → GND, IN1 → GPIO18, IN2 → GPIO19
  • Relay COM → mains Live
  • Relay NO → pump Live
  • Neutral → pump Neutral (direct, not through relay)
  • Protective Earth connected to pump and enclosure (if metal)
  • Ground continuity verified with multimeter

Sensors

  • Pool temperature reads plausible value (not -127 °C)
  • Solar temperature reads plausible value (not -127 °C)
  • Temperature values stable (not fluctuating wildly)
  • Sensor cables undamaged and properly routed

Firmware

  • Latest firmware version flashed
  • WiFi configured and connecting reliably
  • mDNS name resolves (pool-controller.local)
  • Web UI accessible at device IP
  • Web UI password changed from default
  • MQTT broker configured and connected
  • Home Assistant Discovery active (controller visible in HA)
  • All HA entities operational

Relay Test (No-Load)

  • Pool pump relay clicks when toggled
  • Solar pump relay clicks when toggled
  • Relay behavior correct (not inverted)
  • Multimeter confirms COM–NO continuity when ON
  • Multimeter confirms COM–NO open when OFF

Relay Test (With Load)

  • Pool pump starts and runs correctly
  • Pool pump stops when toggled OFF
  • Solar pump starts and runs correctly
  • Solar pump stops when toggled OFF
  • No unusual sounds from relays (buzzing, arcing)
  • No excessive heat on relay terminals after 5 min

Configuration

  • Timezone configured correctly
  • Timer settings match desired schedule
  • Temperature thresholds configured
  • Operation mode tested (Auto, Manual, Boost, Timer)
  • relay-invert matches relay module type (active-low vs active-high)

First 24 Hours Monitoring

  • Controller stays online (no unexpected reboots)
  • Temperatures update consistently
  • MQTT connection stays active
  • Heap stays above 20 KB
  • WiFi signal stable (RSSI > -70 dBm recommended)
  • No Safe Mode activation
  • Relays operate on schedule (Auto mode)

Annual Maintenance Checklist

  • Verify all screw terminals are still tight
  • Inspect cables for damage, wear, or corrosion
  • Check enclosure seal and cable glands
  • Test RCD/FI circuit breaker
  • Clean enclosure ventilation openings
  • Verify ground continuity
  • Update firmware if newer version available
  • Review configuration for any needed changes
  • Check battery in RCD test unit (if applicable)
  • Verify all sensor readings are still accurate

Sign-Off 

Device ID / MAC: ______________________________
Installation date: ___________________________
Installed by: ________________________________
Firmware version: ____________________________
Last maintenance: ____________________________
Next maintenance due: ________________________

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