2 layers105 × 58 mm
ViRa V1.0
VikramR3/ViRa_Ai_plug
ESP32-S3 mains smart plug: HLK-5M05 isolated supply, SRD-05VDC relay, DS3231M RTC. 2-layer KiCad design.
80 partsMIT
2 layers105 × 58 mm
ZAP-010A
lalithk06/Esp32_Smart_PlugHardware reference design for an ESP32-S3 smart plug with mains power conversion, relay switching, RTC support, USB connectivity, and protection components. Built to explore real-world embedded hardware and power electronics design. The design is recreated for educational purposes to understand mains-powered embedded hardware.
- Size
- 105 × 58 mm
- Copper layers
- 2
- Thickness
- 1.6 mm
- Parts
- 80
- Nets
- 69
- Pads
- 275
- Tracks, vias
- 400, 24
- Pours
- 4
- Routed
- Yes
- KiCad
- KiCad 10.0 (file 20260206)
- Created
- 2 Feb 2026
- Updated
- 15 Apr 2026
Overview
ZAP-010A is an open-source printed circuit board by lalithk06, from the lalithk06/Esp32_Smart_Plug repository on GitHub. It is a 2-layer board of 105 × 58 mm with 80 parts on 69 nets, routed with 400 tracks and 24 vias.
It is built around the ESP32-S3-WROOM-1-N8, HLK-5M05 and AMS1117-3.3, with the DS3231MZ+, USBLC6-2P6 and 1N4148W among its other parts. Its parts include 26 resistors, 16 capacitors, 7 diodes, 7 switches and 4 ICs. It belongs with the home automation and IoT boards and the ESP32 boards of this library.
Main components
10
ESP32-S3-WROOM-1-N8
SMD,25.5x18mm-40℃~+85℃ -98.2dBm 2.4GHz 20.5dBm 355mA 3V~3.6V 95mA Bluetooth5.0 ESP32-S3 Chip On-board PCB Antenna UART、SPI、I2C、I2S、USB SMD,25.5x18mm WiFi Modules ROHSEspressif SystemsWiFi Modules
HLK-5M05
DIP,38x23mm0.1W 18mm 1A 23mm 38mm 3kV 50mVp-p 5V 5W 70% 70V~350V 85VAC~264VAC AC/DC-DC Short Circuit Protection、Over Current Protection ±0.2% DIP,38x23mm AC-DC Power Modules ROHSHI-LINKAC-DC Power Modules
AMS1117-3.3
SOT-223-40℃~+125℃ 0.003%Vout 1 1.1V@(800mA) 15V 1A 3.3V 5mA 72dB@(120Hz) Fixed Over Current Protection、Short Circuit Protection、Thermal shutdown Positive SOT-223 Voltage Regulators - Linear, Low Drop Out (LDO) Regulators ROHSAdvanced Monolithic SystemsVoltage Regulators - Linear, Low Drop Out (LDO) Regulators
DS3231MZ+
SOIC-8-40℃~+85℃ 2.3V~5.5V I2C Temperature compensation、Backup power management and battery charging、Alarm function、Periodic interrupt output SOIC-8 Real Time Clocks ROHSMaxim Integrated (Analog Devices)Real Time Clocks
USBLC6-2P6
SOT-666-6-40℃~+125℃ 150nA 17V 2 3.5pF 5.25V 5A@8/20us 6V ESD IEC 61000-4-2 Unidirectional SOT-666-6 ESD and Surge Protection (TVS/ESD) ROHSSTMicroelectronicsESD And Surge Protection (TVS/ESD)
1N4148W
SOD-123150mA 1A 1V@50mA 1uA@75V 400mW 4ns 75V Independent SOD-123 Switching Diodes ROHSSTMicroelectronicsSwitching Diodes
AO3400A
SOT-23-55℃~+150℃ 1 N-channel 1.45V 1.4W 30V 48mΩ@2.5V 5.7A 50pF 630pF 75pF 7nC@10V N-Channel SOT-23 MOSFETs ROHSAlpha & Omega SemiconductorMOSFETsCH291-1220LF
SMDSMD New Arrivals ROHSMulticompUncategorisedMBR0520
SOD-123-55℃~+150℃ 20V 450mV@500mA 5.5A 500mA Independent SOD-123 Schottky Diodes ROHSJiangsu Changjing Electronics Technology (CJ)Schottky Diodes
MLT-8530
SMD,8.5x8.5mm-20℃~+70℃ 2.5V~4.5V 2.7kHz 3.3mm 3.6V 8.5mm 8.5mm 80dB 95mA Electromagnetic Passive (Externally Driven) SMD SMD,8.5x8.5mm Buzzers ROHSJiangsu Huaneng ElecBuzzers
README
README.md⚡ ESP32 Smart Plug — Hardware Reference Design
A compact and efficient smart plug built around the ESP32-S3 for intelligent power control, protection, and connectivity.
This project presents the schematic and PCB design of a smart plug capable of switching AC loads while supporting modern embedded features such as USB connectivity, RTC support, and protection circuitry. Designed to explore real-world embedded hardware development and PCB design practices.
📺 This project was developed by following a YouTube playlist by Ampnics, with additional learning and implementation.
⚙ Working Principle
- The system uses an ESP32-S3 microcontroller as the core processing unit.
- AC mains input is stepped down and regulated to provide safe DC power for the controller.
- A relay switching circuit enables the ESP32 to control connected appliances.
- Protection components safeguard the device against voltage spikes and electrical faults.
- USB connectivity allows programming and debugging.
- RTC support enables future time-based automation features.
📌 Objective
To design and develop a reliable hardware platform for a smart plug that demonstrates safe mains power handling, embedded control, and scalable architecture for future IoT-based automation.
⚙ Components Used
| No. | Components | Specifications / Role |
|---|---|---|
| 1. | ESP32-S3 Module | Main microcontroller with Wi-Fi & BLE |
| 2. | Relay | AC load switching |
| 3. | AC-DC Power Module | Converts mains to regulated DC |
| 4. | Voltage Regulators | Stable voltage supply |
| 5. | Protection Circuitry | Fuse, MOV, flyback diode, etc. |
| 6. | USB Interface | Programming & debugging |
| 7. | Capacitors & Resistors | Filtering and biasing |
| 8. | RTC (Optional) | Time-based control support |
📷 Preview
🖼 Schematic Diagram
📐 PCB Layout
🧊 3D View
🧠 Design Highlights
- Proper isolation between AC mains and low-voltage sections
- Dedicated power zoning for noise reduction
- Flyback protection for relay reliability
- USB interface for easy firmware flashing
⚠ Safety Considerations
- Isolation maintained between high-voltage and low-voltage domains
- Proper creepage and clearance followed
- Fuse and MOV used for protection
- Designed for educational and prototyping purposes only
📊 Specifications
| Parameter | Value |
|---|---|
| Input Voltage | 230V AC |
| Output Control | Relay-based switching |
| MCU | ESP32-S3 |
| Communication | Wi-Fi, BLE |
🚀 Key Highlights
✅ Designed with real-world electrical safety considerations
✅ Suitable for home automation applications
✅ Expandable for IoT integration
✅ Compact PCB layout
✅ Industry-relevant hardware design workflow
🔄 Future Improvements
- Energy monitoring (current & voltage sensing)
- Mobile app / cloud integration
- Overload and thermal protection
- Smart scheduling and automation
- Voice assistant compatibility
- Custom enclosure design
- Power consumption optimization
⭐ This project is part of my learning journey in hardware design and PCB development.
Parts
80| Qty | Value | Footprint | References |
|---|---|---|---|
| 10 | 0.1uF | Capacitor_SMD:C_0603_1608Metric | C4, C6, C8, C9, C10, C11, C12, C13, C14, C15 |
| 10 | 10K | Resistor_SMD:R_0603_1608Metric | R9, R13, R14, R15, R16, R17, R18, R21, R22, R25 |
| 6 | 0R | Resistor_SMD:R_0603_1608Metric | R6, R7, R19, R20, R23, R24 |
| 5 | 1K | Resistor_SMD:R_0603_1608Metric | R8, R10, R11, R12, R26 |
| 5 | SW_Push | Button_Switch_THT:SW_PUSH_6mm | SW1, SW3, SW4, SW5, SW6 |
| 3 | 10uF | Capacitor_SMD:C_0805_2012Metric | C3, C5, C7 |
| 3 | Fiducial | Fiducial:Fiducial_0.75mm_Mask1.5mm | FID1, FID2, FID3 |
| 3 | RED_LED | LED_THT:LED_D3.0mm | D1, D5, D6 |
| 2 | 1N4148W | Diode_SMD:D_SOD-123 | D3, D7 |
| 2 | 5k | Resistor_SMD:R_0603_1608Metric | R4, R5 |
| 2 | AO3400A | Package_TO_SOT_SMD:SOT-23 | Q1, Q2 |
| 1 | 0.1uF | Capacitor_THT:C_Rect_L13.0mm_W6.0mm_P10.00mm_FKS3_FKP3_MKS4 | C1 |
| 1 | 10D56K | Varistor:RV_Disc_D12mm_W5.8mm_P7.5mm | RV1 |
| 1 | 10k | Resistor_SMD:R_0603_1608Metric | R3 |
| 1 | 1M | Resistor_THT:R_Axial_DIN0204_L3.6mm_D1.6mm_P5.08mm_Horizontal | R1 |
| 1 | 2.2uF | Capacitor_SMD:C_0805_2012Metric | C16 |
| 1 | 220uF | Capacitor_SMD:CP_Elec_8x10 | C2 |
| 1 | 3V3 | Test Point:TestPoint_Pad_D2.5mm | TP3 |
| 1 | 4k | Resistor_SMD:R_0603_1608Metric | R2 |
| 1 | 500mA 250V | Fuse:Fuse_Littelfuse_395Series | F1 |
| 1 | 5V | Test Point:TestPoint_Pad_D2.5mm | TP4 |
| 1 | AMS1117-3.3 | Package_TO_SOT_SMD:SOT-223-3_TabPin2 | U1 |
| 1 | BOOT | Test Point:TestPoint_Pad_D2.5mm | TP6 |
| 1 | CH291-1220LF | CH291-1220LF:BAT_CH291-1220LF | BT1 |
| 1 | Conn_01x04_Pin | Connector_PinHeader_2.54mm:PinHeader_1x04_P2.54mm_Vertical | J3 |
| 1 | DS3231M | Package_SO:SOIC-16W_7.5x10.3mm_P1.27mm | U4 |
| 1 | EN | Test Point:TestPoint_Pad_D2.5mm | TP5 |
| 1 | ESP32-S3-WROOM-1 | RF_Module:ESP32-S3-WROOM-1 | U2 |
| 1 | GND | Test Point:TestPoint_Pad_D2.5mm | TP7 |
| 1 | HLK-5M05 | Converter_ACDC:Converter_ACDC_Hi-Link_HLK-5Mxx | PS1 |
| 1 | MBR0520 | Diode_SMD:D_SOD-123 | D2 |
| 1 | MLT-8530 | footprints:MLT-8530_JHE | LS1 |
| 1 | RED_LED | LED_SMD:LED_0603_1608Metric_Pad1.05x0.95mm_HandSolder | D4 |
| 1 | RXD0 | Test Point:TestPoint_Pad_D2.5mm | TP2 |
| 1 | Relay_SPDT | Relay_THT:Relay_SPDT_Hongfa_HF3F-L-xx-1ZL1T | K1 |
| 1 | SW_Push | Button_Switch_SMD:SW_Push_SPST_NO_Alps_SKRK | SW2 |
| 1 | Screw_Terminal_01x04 | TerminalBlock:TerminalBlock_MaiXu_MX126-5.0-04P_1x04_P5.00mm | J1 |
| 1 | TXD0 | Test Point:TestPoint_Pad_D2.5mm | TP1 |
| 1 | USBLC6-2P6 | Package_TO_SOT_SMD:SOT-666 | U3 |
| 1 | USB_C_Receptacle_USB2.0_16P | Connector_USB:USB_C_Receptacle_HCTL_HC-TYPE-C-16P-01A | J2 |
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Questions
How big is the ZAP-010A PCB?
It measures 105 × 58 mm and has 2 copper layers, 1.6 mm thick.
What parts does the ZAP-010A use?
80 parts, built around the ESP32-S3-WROOM-1-N8, HLK-5M05, AMS1117-3.3 and DS3231MZ+. 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 ZAP-010A KiCad files?
From the lalithk06/Esp32_Smart_Plug repository on GitHub, at the commit this page was made from: the board is Hardware/Hardware Design/ZAP-010A.kicad_pcb and its schematic Hardware/Hardware Design/ZAP-010A.kicad_sch. PCBKit opens the board in the browser, with nothing to install.
Can I use the ZAP-010A design in my own project?
Its repository states no licence, so its author keeps all rights: ask lalithk06 before reusing the design.