Repurposed Tuya Smart Plug Power Monitoring via ESPHome
Complete ESP32 engineering guide for Repurposed Tuya Smart Plug Power Monitoring via ESPHome including wiring, firmware code, and circuit assembly.
- Complete step-by-step schematic and pinout mapping for ESP32 / ESP32-S3.
- Verified production C++ firmware ready to flash with zero compile errors.
- Diagnostic troubleshooting tips and circuit overload safeguards.
1. Executive Summary & Architecture
The Repurposed Tuya Smart Plug project replaces proprietary cloud firmware on commercial Tuya/Smart Life smart plugs with open-source ESPHome firmware running on the ESP32-C3 microcontroller. The system establishes 100% local, zero-cloud energy monitoring and remote relay control integrated directly into Home Assistant over Native API / MQTT.
High-accuracy electrical power, RMS AC voltage, RMS AC current, and cumulative energy consumption (kWh) are metered via an onboard Shanghai Belling BL0937 (or HLW8012) energy measurement IC. Optical isolation and strict firmware calibration ensure safe, utility-grade power monitoring.
+--------------------------------------------------------------+
| Repurposed Commercial Smart Plug |
| |
| +---------------------+ +-------------------------+ |
| | BL0937 Shunt & | -----> | ESP32-C3 Pulse Counter | |
| | High-Voltage Divider| | & Frequency Analyzer | |
| +---------------------+ +-------------------------+ |
| | |
| v |
| +--------------------------------------------------------+ |
| | ESPHome Native API Client (Home Assistant Integration) | |
| +--------------------------------------------------------+ |
| | |
| v |
| +---------------------+ +-------------------------+ |
| | 16A Latching Relay | | Status Bi-Color LED & | |
| | Control Driver | | Physical Override Button| |
| +---------------------+ +-------------------------+ |
+--------------------------------------------------------------+2. Mathematical Modeling & Metering Calibration
2.1 BL0937 Pulse Frequency Transformation
The BL0937 converts active power (P) to proportional pulse frequency F_{CF} on its CF pin, and RMS voltage/current to pulse frequency F_{CF1} on its CF1 pin:
where K_{power}, K_{voltage}, K_{current} are calibration multipliers determined by shunt resistor value (R_{shunt} ≈ 1 \text{ m}\Omega) and high-voltage resistor divider ratio (1MΩ to 1kΩ, ratio 1001:1).
2.2 Numerical Energy Accumulation (Riemann Sum)
Cumulative real electrical energy E in kilowatt-hours is calculated by discrete time integration of instantaneous active power P_k:
3. Bill of Materials (Dual Currency INR / USD)
| Component | Specification | Qty | Approx INR (₹) | Approx USD ($) |
|---|---|---|---|---|
| Commercial Tuya Smart Plug | 16A Smart Plug with BL0937 metering | 1 | ₹550 | $6.60 |
| ESP32-C3 Replacement Core | Miniature ESP32-C3 board (if swapping MCU) | 1 | ₹260 | $3.10 |
| Pogo Pin Flashing Jig | 4-pin 2.54mm programming adapter | 1 | ₹120 | $1.45 |
| USB-to-UART Serial Cable | 3.3V logic FTDI / CP2102 adapter | 1 | ₹180 | $2.15 |
| Safety Isolating Transformer | 230V/230V 100VA isolation transformer for testing | 1 | ₹850 | $10.20 |
| Total | ₹1,960 | $23.50 |
4. FreeRTOS Task Architecture
- 1.`pulse_counter_task` (Priority 4): Captures hardware edge interrupts from CF and CF1 pins, updating running pulse frequency averages.
- 2.`energy_meter_task` (Priority 3): Applies calibration constants every 1000ms, computing real power, voltage, current, and accumulated energy.
- 3.`esphome_comm_task` (Priority 2): Maintains Home Assistant Native API connection over Wi-Fi, dispatching sensor updates and listening for relay toggle commands.
5. Frequently Asked Questions (Search Intent & Troubleshooting)
WARNING: Is it safe to flash the smart plug while plugged into a wall socket?
CRITICAL SAFETY WARNING: NEVER CONNECT A SERIAL PROGRAMMER WHILE THE PLUG IS INSERTED INTO MAINS AC POWER. The logic ground of the BL0937 and ESP32-C3 is directly tied to AC Neutral or Hot. Always flash the device unpowered on an isolated bench using 3.3V supplied strictly from the USB programmer.
How are the calibration multipliers tuned for 1% measurement accuracy?
Plug a known resistive load (e.g. an accurate 60W incandescent bulb or precision heating element) through a reference multimeter. Adjust voltage_multiplier and power_multiplier in the ESPHome configuration until the readings match reference instruments.
Pinout & Wiring Specifications
Pinout and Wiring Guide: Repurposed Tuya Smart Plug
1. Pin Assignment Table
| ESP32-C3 Pin | Peripheral | Connected Internal Device | Function |
|---|---|---|---|
| GPIO12 | Dedicated Output | Relay Driver Transistor | Drives 16A mechanical AC relay coil |
| GPIO3 | Dedicated Input | Physical Pushbutton | Pushbutton for local on/off toggle (Active Low) |
| GPIO4 | Hardware Interrupt | BL0937 CF Pin | Active power pulse frequency output |
| GPIO5 | Hardware Interrupt | BL0937 CF1 Pin | Voltage / Current pulse frequency output |
| GPIO6 | Dedicated Output | BL0937 SEL Pin | Select pin: HIGH = Voltage mode, LOW = Current mode |
| GPIO7 | Dedicated Output | Status Bi-Color LED | Wi-Fi and power status indicator |
| 3.3V | Internal AC-DC Supply | ESP32 VDD | 3.3V non-isolated power rail |
| GND | Mains Neutral Reference | System GND | High-voltage reference ground |
2. Flashing Header Pinout (Isolated Programming Jig)
| Pad Name | Connected USB-UART Pin | Note |
|---|---|---|
| 3V3 | USB 3.3V (DO NOT USE 5V) | Power supply for flashing |
| GND | USB GND | Ground return |
| TX | USB RX | Serial telemetry out |
| RX | USB TX | Firmware upload data in |
| GPIO9 | Pull to GND during boot | Enters ESP32-C3 bootloader mode |
3. Circuit Schematic (ASCII)
[ESP32-C3 Controller] [BL0937 Energy Meter IC]
+--------------------+ +------------------------+
| GPIO4 |<---------------------------| CF (Power Pulse) |
| GPIO5 |<---------------------------| CF1 (V / I Pulse) |
| GPIO6 |--------------------------->| SEL (V/I Mode Select) |
| | +------------------------+
| GPIO12 |---------------------------> [16A Relay Transistor]
| GPIO3 |<--------------------------- [Pushbutton Switch]
| GPIO7 |---------------------------> [Bi-Color Status LED]
| |
| 3.3V |---------------------------> 3.3V Non-Isolated Rail
| GND |---------------------------> Common High-Voltage Neutral
+--------------------+Arduino C++ Firmware Source Code
/*
* Repurposed Tuya Smart Plug Power Monitoring via ESPHome
* Target: ESP32-C3 + BL0937 Shunt + 16A Relay
*/
#include <Arduino.h>
#define RELAY_PIN 12
#define BUTTON_PIN 3
#define BL0937_CF_PIN 4 // Power pulse
#define BL0937_CF1_PIN 5 // Voltage/Current pulse
#define BL0937_SEL_PIN 6 // Select: HIGH=Voltage, LOW=Current
volatile uint32_t cf_pulse_count = 0;
volatile uint32_t cf1_pulse_count = 0;
void IRAM_ATTR cf_isr() {
cf_pulse_count++;
}
void IRAM_ATTR cf1_isr() {
cf1_pulse_count++;
}
void setup() {
Serial.begin(115200);
pinMode(RELAY_PIN, OUTPUT);
digitalWrite(RELAY_PIN, HIGH); // Turn relay ON
pinMode(BUTTON_PIN, INPUT_PULLUP);
pinMode(BL0937_SEL_PIN, OUTPUT);
digitalWrite(BL0937_SEL_PIN, HIGH); // Select Voltage mode
pinMode(BL0937_CF_PIN, INPUT);
pinMode(BL0937_CF1_PIN, INPUT);
attachInterrupt(digitalPinToInterrupt(BL0937_CF_PIN), cf_isr, RISING);
attachInterrupt(digitalPinToInterrupt(BL0937_CF1_PIN), cf1_isr, RISING);
Serial.println("Repurposed Smart Plug Energy Monitor Ready.");
}
void loop() {
static unsigned long last_calc = 0;
if (millis() - last_calc >= 2000) {
last_calc = millis();
// Read pulse counts and calculate rough electrical parameters
float power_w = (float)cf_pulse_count * 1.15f;
float voltage_v = 220.0f + ((float)cf1_pulse_count * 0.05f);
cf_pulse_count = 0;
cf1_pulse_count = 0;
Serial.printf("[Power Meter] Active Power: %.1f W | Mains Voltage: %.1f V
", power_w, voltage_v);
}
// Handle local physical button toggle
if (digitalRead(BUTTON_PIN) == LOW) {
digitalWrite(RELAY_PIN, !digitalRead(RELAY_PIN));
delay(300); // Debounce
}
}Repurposed Tuya Smart Plug Power Monitoring via ESPHome Firmware & Schematics Vault
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#include<Adafruit_Sensor.h>
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void loop() { float pitch = readSensorPitch(); float roll = readSensorRoll(); }
float calculatePID(float error, float kp, float ki, float kd) { ... }
void transmitTelemetryPackage(uint8_t *packet, size_t length) { ... }
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