SOP-01: ESP32 Development Bench Safety

Document ID: SOP-01 | Version: 1.0 | Category: Hardware Safety

1. Purpose

To establish a rigorous safety and validation framework for the initial power-up and ongoing development of ESP32-based hardware to prevent catastrophic component failure and protect host computing equipment.

2. Hardware Constraints

Warning: ESP32 GPIOs operate at 3.3V. Connecting 5V or higher directly to a GPIO pin will likely result in permanent hardware failure.

Never drive inductive loads (motors, solenoids) directly from GPIO pins.

3. Mandatory Protection Stack

Host PC → Powered USB Hub → USB Isolator → ESP32 Board

Powered USB Hub: Acts as a sacrificial layer.
USB Isolator: Provides galvanic isolation, essential for industrial equipment.

4. First Power-Up Procedure

1.Disconnect all external loads/peripherals.

2.Perform visual inspection and continuity tests across power rails.

3.Verify that supply rails match target components (3.3V for ESP32).

4.Power the controller alone first. Verify USB/Serial communication.

5.Add peripherals one by one incrementally.

6.Monitor components for abnormal temperature rise.