DWC Electronics

Tag: PCB Design

  • Balboa WiFi Interface Module

    What Is the Balboa WiFi Interface Module?

    This is a WiFi interface board for Balboa hot tub control systems designed to fit directly between the topside panel and the main control board. It gives external (e.g. WiFi/IoT) control and monitoring, with direct passthrough to the OEM display, while protecting the main electronics and allowing advanced features unsupported by existing solutions.

    Unique Features

    • Proper Logic Separation: All button and display signals are opto-isolated, protecting the main control system from any damage or interference caused by the add-on board. Many other DIY designs omit this, risking system damage.
    • Optional Standalone Topside Transmission: If the main control board is disconnected or not powered, this board can generate and transmit clock and data signals to the topside panel so you can still send display messages or button events.
    • Direct Plug-In: Sits transparently between main board and panel via standard RJ45 connectors for seamless installation and reversion.

    Schematic and PCB Reference

    Below are the latest schematic and board design images for easy debugging and DIY assembly. For full resolution, see:
    Schematic (full PNG)
    PCB (full PNG)

    Balboa WiFi Interface Module Schematic
    Balboa WiFi Interface Module PCB

    Pinout Overview

    • Display, Clock, and Button signals – All passed through via opto-isolators, with control from both the main board and WiFi module (Wemos D1 Mini shown)
    • Optional Standalone Mode Jumper – Lets the module generate display and clock signals independently
    • RJ45 Connectors – Direct connection for panel/control board passthrough
    • Regulated 5V Supply – On-board LDO for stable logic voltage

    Digital Protocol and Button Control

    Button presses are emulated by pulling control lines via opto-isolators, safely injecting signals from the microcontroller (ESP8266/ESP32-based), while display and clock lines are conditionally transmitted with proper timing if enabled. The design guarantees safe coexistence with the original electronics—bring-up and transmission control code is published on GitHub for full integration into automation/remote platforms.

    See the project repository for:

    • Firmware for signal emulation and display protocol
    • Full schematic and PCB production files
    • Assembly instructions and troubleshooting notes