Custom Zigbee Controller – ESP32-H2

A family of Zigbee-based controllers built around the ESP32-H2, designed for lighting automation, shutter/blind control, switch retrofitting, and LED dimming applications. Multiple PCB variants are available to fit different installation scenarios. All devices operate as Zigbee routers and support Zigbee OTA firmware updates.

Source code and flashing tools: https://github.com/scavenrage/ESP32-H2-Custom-Zigbee

Assemblying and testing video: https://www.youtube.com/watch?v=BoSZvjjPbms

1. Overview

All three hardware variants share a single unified firmware, configured per-device at first programming via configure.py — no recompilation needed. Configuration is stored in the NVS partition and survives OTA firmware updates.

2. PCB Variants

✅ A) 4-Relay Modular PCB

A compact, modular relay board for multi-channel automation.

Features:

• Up to 4 relay outputs (10 A rated)
• Up to 4 digital inputs (3.3 V pull-up)
• Cuttable PCB: supports 2, 3, or 4 relays depending on physical trimming
• Integrated 230 VAC → 5 VDC AC/DC supply
• Suitable for lighting and shutter motor control

For inductive loads (e.g. shutter motors), install a suitable snubber/filter near the motor.

✅ B) Single-Relay PCB (Universal Input/Output Variant)

Designed for single-load automation and wall-switch retrofits.

Features:

• 1 relay output (10 A rated)
• Output selectable by hardware: dry-contact or switched 230 V
• Input selectable by hardware: dry-contact or 230 V optoisolated sensing
• Integrated 230 VAC → 5 VDC AC/DC supply

For inductive loads, installation of a snubber/filter is required.

✅ C) MOSFET / LED Control PCB

A solid-state board for LED lamps and drivers with external low-voltage supply.

Features:

• AO3400 MOSFET output stage
• Powered via 5 VDC external (internal LDO to 3.3 V)
• Input compatible with capacitive touch modules or any 3.3 V digital signal
• Ideal for lamps/drivers that already include their own AC supply

3. Power Supply Summary

4. Firmware Architecture

4.1 Per-device configuration via NVS

Device behaviour is configured at first programming using configure.py (Python 3, no ESP-IDF required), which generates an NVS partition (nvs_config.bin) containing all parameters. The firmware reads this partition at boot — no recompilation needed to change a device's function.

Configurable parameters include:

• Number of active channels (1–4)
• Channel type: stable relay, impulse relay, roller shutter, or PWM dimmer
• Input type per channel: momentary pushbutton or bistable switch
• Timing parameters: debounce, impulse duration, shutter travel times, etc.

NVS configuration survives OTA firmware updates.

4.2 Channel Types

4.3 Zigbee

• Always operates as a Zigbee router
• Exposes one endpoint per active channel
• On/Off cluster (0x0006) for relay and dimmer channels
• Window Covering cluster (0x0102) for roller shutter channels
• OTA Upgrade cluster (0x0019) for wireless firmware updates

5. Target Applications

• Lighting automation (relay or MOSFET)
• Motorized shutters and blinds
• Wall-switch retrofits
• LED dimming with external drivers
• General-purpose load control