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46 parts14kMIT
2 layers81 × 95 mm
WaterLevelController
charlesgeorge85/waterLevelControllerwater level controller using ESP32
- Size
- 81 × 95 mm
- Copper layers
- 2
- Thickness
- 1.6 mm
- Parts
- 46
- Nets
- 47
- Pads
- 136
- Tracks, vias
- 262, 4
- Routed
- Yes
- KiCad
- KiCad 9.0 (file 20241229)
- Created
- 2 Jun 2025
- Updated
- 4 Jul 2026
Overview
WaterLevelController is an open-source printed circuit board by charlesgeorge85, from the charlesgeorge85/waterLevelController repository on GitHub. It is a 2-layer board of 81 × 95 mm with 46 parts on 47 nets, routed with 262 tracks and 4 vias.
It is built around the BC547. Its parts include 19 resistors, 11 capacitors, 7 connectors, 4 diodes and 2 ICs. It belongs with the ESP32 boards of this library.
Main components
1README
README.mdWater Level Controller for Home
This project implements a smart water tank pump controller using an ESP32 microcontroller. It manages the transfer of water between an Underground Tank (UGT) and an Overhead Tank (OHT), ensuring safe, efficient operation with dry-run protection and a web interface for monitoring and manual control.
1. Problem Statement
The system is designed to automatically control a water pump to transfer water from a UGT to an OHT. Key challenges addressed include:
- Preventing pump operation when UGT is empty (dry run).
- Automating pump ON/OFF based on OHT and UGT water levels.
- Providing manual mode, switch is set to manual, in manual mode, pump will be 'on', so thts pump can be controlled via main power switch
1.1 Tank Level Thresholds
-
Overhead Tank (OHT):
OHT_FULL: Tank is full.OHT_EMPTY: Tank is empty.
-
Underground Tank (UGT):
UGT_EMPTY: Tank is empty.UGT_NOT_EMPTY: Tank has sufficient water.
2. Use Cases
2.1 Pump Activation
The pump is activated when:
- OHT level is below
OHT_EMPTY. - UGT level is above
UGT_EMPTY.
2.2 Pump Deactivation
The pump is turned off when:
- OHT reaches
OHT_FULL, or - UGT falls below
UGT_EMPTY, or - A dry-run condition is detected.
If deactivation is due to UGT low level, the pump will only reactivate once UGT is above UGT_NOT_EMPTY.
2.3 Dry Run Detection & Handling
- Dry-run is detected via motor current using a Current Transformer (CT).
- For a 0.25 HP motor, current < 0.8 A indicates a dry run, during normal run, the measured current is 1.27A
- On dry run:
- A buzzer alerts.
- Alarm can be cleared with a Alarm reset switch
3. Hardware Implementation
- Controller: ESP32
- Features:
- Water level monitoring (UGT & OHT)
- Motor control (auto/manual)
- Current sensing
- Configurable dry-run threshold
- Web UI for (future Plan):
- Displaying water levels
- Manual motor control
- Viewing current consumption
- Threshold configuration
4. Web UI(future Plan)
A web-based interface hosted on ESP32 allows real-time visualization and control of the pump system.
5. ESP32 Devkit V1 details
ESP32 DOIT DevKit V1 Board Details
Author
Joseph George
License
This project is open-source and available under the MIT License.
Parts
46| Qty | Value | Footprint | References |
|---|---|---|---|
| 19 | 22k | Resistor_THT:R_Axial_DIN0309_L9.0mm_D3.2mm_P5.08mm_Vertical | R1, R2, R3, R4, R5, R6, R10, R11, R12, R13, R14, R15, R16, R17, R18, R19 +3 |
| 9 | .1uF | Capacitor_THT:C_Disc_D3.8mm_W2.6mm_P2.50mm | C2, C4, C5, C6, C7, C8, C9, C10, C11 |
| 3 | 1N4001 | Diode_THT:D_DO-41_SOD81_P10.16mm_Horizontal | D1, D2, D4 |
| 2 | Conn_01x02_Pin | Connector_PinHeader_2.54mm:PinHeader_1x02_P2.54mm_Vertical | J2, J7 |
| 1 | 1000uf | Capacitor_THT:C_Radial_D12.5mm_H20.0mm_P5.00mm | C1 |
| 1 | 10uF | Capacitor_THT:CP_Radial_D8.0mm_P2.50mm | C3 |
| 1 | BC547 | Package_TO_SOT_THT:TO-92_Wide | Q1 |
| 1 | Buzzer | myLib:BUZ_12X7P6 | BZ1 |
| 1 | Conn_01x03_Pin | Connector_PinHeader_2.54mm:PinHeader_1x03_P2.54mm_Vertical | J4 |
| 1 | Conn_01x05_Pin | Connector_Phoenix_MC:PhoenixContact_MCV_1,5_5-G-3.81_1x05_P3.81mm_Vertical | J6 |
| 1 | Conn_01x08_Pin | Connector_PinHeader_2.54mm:PinHeader_1x08_P2.54mm_Vertical | J5 |
| 1 | ESP32-DevKit-V1 | myLib:ESP32-DevKit-V1 | U1 |
| 1 | LED | LED_THT:LED_D3.0mm | D3 |
| 1 | LM7805_TO220 | Package_TO_SOT_THT:TO-220-3_Vertical | U2 |
| 1 | SANYOU_SRD_Form_C | Relay_THT:Relay_SPDT_SANYOU_SRD_Series_Form_C | K1 |
| 1 | TerminalBlock | Connector_Phoenix_MC:PhoenixContact_MCV_1,5_3-G-3.81_1x03_P3.81mm_Vertical | J1 |
| 1 | TerminalBlock | Connector_Phoenix_MC:PhoenixContact_MCV_1,5_2-G-3.81_1x02_P3.81mm_Vertical | J3 |
Questions
How big is the WaterLevelController PCB?
It measures 81 × 95 mm and has 2 copper layers, 1.6 mm thick.
What parts does the WaterLevelController use?
46 parts, built around the BC547. The full list of its parts is on this page, with links to each part's symbol and footprint where PCBKit's library has them.
Where can I download the WaterLevelController KiCad files?
From the charlesgeorge85/waterLevelController repository on GitHub, at the commit this page was made from: the board is hardware/waterLevelController.kicad_pcb and its schematic hardware/waterLevelController.kicad_sch. PCBKit opens the board in the browser, with nothing to install.
Can I use the WaterLevelController design in my own project?
Its repository states no licence, so its author keeps all rights: ask charlesgeorge85 before reusing the design.
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