Outdoor-Lighting-Controller

Description

This is the hardware (PCB) and the software (ESPHome configuration) for a Home Assistant-based motion-lights controller. ESPHome is used to interface with Home Assistant, which is responsible for controlling the lights and motion alerts, etc.

Instructions

1. Download the board files from GitHub Release.
2. Order the needed parts (parts list below).
   1. I used JLCPCB for the PCB; it cost me $2 (+ shipping) for 5 boards.
3. Assemble all parts on the PCB.
4. Install ESPHome.
5. Create the secrets file from the template.
6. Connect the ESP-01 to the programming adapter.
7. Run esphome lights.yaml compile to compile the firmware.
8. Run esphome lights.yaml upload to upload the newly-compiled firmware.
9. Place the ESP-01 in the PCB, paying attention to the direction of where it points

Parts List

• 1x Custom designed Circuit Board
• 1x 8 channel Relay Board (any generic one will work as long as it supports the needed power for your lights)
• 1x MCP23017 I2C IO Expander (IC1)
• 1x ESP-01 module with programmer (U1)
• 1x D24V10F3 Voltage Regulator (powers ESP-01) (VR1)
• 1x D24V10F5 Voltage Regulator (powers the motion sensors and MCP23017) (VR2)
• up to 8x PIR motion sensor
• up to 8x lights and a way to power them
  • I used 12 Volt DC LED lights and a 120VAC --> 12VDC power supply
• jumper wires to connect the Relay Board to the PCB (either individual wires or a 1x10 cable works)
• 2x 1x10 male header (RELAYS and J1)
• 1x 2x4 female header (alternatively, 2 rows of 1x4 would work too) (socket for ESP-01)
• 1x 2-pin 3.5mm screw terminal blocks (J2)
• 1x 10-pin 2.54mm (0.1 in) screw terminal blocks (PIRS)
• 1x SPDT on/off switch (S1)
• 1x 10K ohm resistor (R1)
• optional: 1x LED (D1) and 1x 330 ohm resistor (R2)
• 1x 5K ohm resistor (I used a 5.2K ohm resistor I had lying around) (R3)
• 1x safe casing that prevents access to 120VAC power
• 1x server running Home Assistant for automating the lights in reaction to the motion sensors

Notes

• If ESPHome is not working properly (either not installing or not compiling), you can upload the binary in the GitHub Release using another uploading tool, such as esptool.
• I tested this with ESPHome v1.15.3.

Schematics

Credits

• ESPHome
• Home Assistant
• Sparkfun's EAGLE libraries