PowderSense - User Manual

Product: PowderSense Precision Measurement System
Author: Processware
Version: 1.1.0
Last Updated: December 2025

🎯 Introduction

What is PowderSense?

PowderSense is a precision measurement system designed for ammunition reloading. It measures powder depth with high precision and converts it to grain weight for consistent ammunition loading. The device features a 1.47" color display for status monitoring and a WiFi-enabled web interface for complete control and configuration.

Key Features

• High Precision: 16-bit ADC (ADS1115) with 0.001 grain display precision
• Real-Time Monitoring: 1.47" TFT LCD display with visual feedback (blue/green/red) for low/perfect/high measurements
• WiFi & Web Console: Embedded web console for real-time configuration, data logging, CSV export, and remote monitoring via WiFi
• Configurable: Multiple measurement profiles with customizable thresholds and automatic stability detection
• Universal Fit: Designed for 9mm, but works with other calibers with a simple probe swap

Technical Specifications

🚀 Quick Start Guide

What You Need

• PowderSense device (assembled)
• USB-C cable and 5V power adapter
• Computer or smartphone with WiFi
• Web browser (Chrome, Firefox, Safari, Edge)
• Precision scale for calibration

5-Minute Setup

Step 1: Power On

1. Connect USB-C cable to PowderSense and power adapter
2. Device boots and shows splash screen
3. Display shows AP Mode screen with WiFi credentials

Step 2: Connect to WiFi

1. On your phone/computer, connect to WiFi: "PowderSense-XXXX"
2. Password: "powdersense"
3. Browser opens automatically (or navigate to http://192.168.4.1)
4. Enter your WiFi credentials and click "Save"
5. Device reboots and connects to your network

Step 3: Access Web Interface

1. Display shows your network IP address (e.g., 192.168.1.100) or access via http://powdersense.local
2. Open browser and navigate to that IP address
3. Web dashboard loads

Step 4: Create Configuration

1. Click "Add New" in Quick Settings
2. Enter: Caliber (9mm), Bullet Weight (145), Powder (N340), Target (4.7)
3. Set Low/High thresholds (e.g., 4.6 - 4.8 grains)
4. Click "Save Configuration"

Step 5: Calibrate

1. Click "Calibrate" button (orange)
2. Step 1: Extend probe fully, click "Set Zero"
3. Step 2: Insert case with precisely weighed powder (e.g., 4.7 grains)
4. Enter exact weight, click "Set Known Grains"
5. Calibration complete! Status shows "Calibrated" in green

Step 6: Start Measuring

1. Place powder measure under probe
2. Adjust powder level
3. Display shows real-time measurement
4. When stable, measurement is automatically recorded

You're ready to reload! 🎉

🖥️ Device Overview

Physical Components

Front Panel:

• 1.47" TFT Display: Shows current measurement and status (read-only, no touch)
• Visual Indicators: Color-coded background (blue/green/red) for measurement status

Top/Side:

• Measurement Probe: Spring-loaded probe that extends/retracts
• 9mm Probe Tip: Measures powder depth in cartridge case

Back Panel:

• USB-C Port: Power input (5V) and firmware updates

Internal Components:

• ESP32-C6: Main controller with WiFi
• ADS1115: 16-bit ADC for precision measurement
• Potentiometer: Linear position sensor connected to probe

Control Method

Important: The display is read-only and shows status information only. All configuration, calibration, and control is done through the web interface accessed via WiFi from your computer or smartphone.

📺 Display States

The PowderSense display shows different screens depending on the device status. The display is read-only and provides visual feedback only.

1. AP Mode (WiFi Setup)

When shown: First boot or when no WiFi is configured

Information displayed:

• "AP MODE ACTIVE"
• WiFi network name: "PowderSense-XXXX"
• Password: "powdersense"
• IP address: http://192.168.4.1

What to do: Connect to the displayed WiFi network and configure your home WiFi via the web interface.

2. No Configuration

When shown: Device is connected to WiFi but no powder configuration is loaded

Information displayed:

• Current measurement: 0.000 grain
• Status: "No Config"
• IP address for web access

What to do: Access the web interface and create a powder configuration profile.

3. Measurement - LOW (Below Target)

When shown: Measurement is below target weight

Information displayed:

• Current measurement (e.g. 4.585 grain)
• Target weight (e.g. 4.700 grain)
• Configuration name
• Blue bar: Indicates below target

Meaning: Add more powder to reach target weight.

4. Measurement - PERFECT (On Target)

When shown: Measurement is within tolerance of target weight

Information displayed:

• Current measurement (e.g. 4.700 grain)
• Target weight (e.g. 4.700 grain)
• Configuration name
• Green bar: Indicates perfect measurement

Meaning: Powder charge is correct, proceed with loading.

5. Measurement - HIGH (Above Target)

When shown: Measurement is above target weight

Information displayed:

• Current measurement (e.g. 4.802 grain)
• Target weight (e.g. 4.700 grain)
• Configuration name
• Red bar: Indicates above target (alarm)

Meaning: Remove powder to reach target weight. Red indicates out-of-spec condition.

⚙️ First Time Setup

Probe Installation

Proper installation of the PowderSense device is crucial for accurate measurements.

1. Position Your Press: Move the handle of your progressive press to bring the shell plate to its highest position.
2. Install the Die: Screw the PowderSense die into an empty station (e.g., station 4) until it makes firm contact with the shell plate.
3. Secure the Die: Lock the die in place using the lock ring. The probe should now be resting on the shell plate at its zero position.

Once installed, you can proceed to power on the device and begin the setup process.

Initial Power-On

When you first power on PowderSense:

1. Self-Test: Device performs hardware initialization
2. Display Check: Shows PowderSense splash screen
3. WiFi Check: Looks for saved WiFi credentials
4. AP Mode: If no WiFi configured, starts Access Point mode

WiFi Configuration

Connect to PowderSense AP:

1. Look at display for network name (e.g., "PowderSense-A1B2")
2. On your device, connect to that WiFi network
3. Password: powdersense
4. Captive portal should open automatically
5. If not, navigate to: http://192.168.4.1

Configure Home WiFi:

1. Select your WiFi network from dropdown (or enter manually)
2. Enter your WiFi password
3. Click "Save Configuration"
4. Device reboots and connects to your network
5. Display shows new IP address

Finding Your Device:

• IP address is shown on the display
• You can also access the device by navigating to http://powdersense.local in your browser
• Check your router's DHCP client list
• Use network scanner app (e.g., Fing, Advanced IP Scanner)

Bookmark the IP address in your browser for easy access!

📱 Web Interface

The web interface provides complete control over PowderSense. Access it by navigating to the IP address shown on the display or http://powdersense.local.

Dashboard

The main dashboard shows:

Current Measurement Panel:

• Large display of current weight in grains
• Updates in real-time

Last Measurement Panel:

• Details of the last recorded measurement
• Timestamp and weight

Quick Settings Panel:

• Powder Configuration dropdown
• Low/High grain thresholds
• Buttons: Add New, Edit, Delete, Measure, Calibrate

Session Statistics Panel:

• Average, Standard Deviation, Minimum, Maximum
• Total Count, Session Count
• Buttons: Start Session, End Session, Reset Session, Export Data

Real-time Chart:

• Visual representation of measurements over time

Session Logs Table:

• Historical session data
• Date, bullet count, total weight, duration

Advanced Settings

The advanced settings page allows for fine-tuning of the device's behavior.

Auto-Measurement:

UI & Alarm Behavior:

• Display Refresh (ms)
• Alarm Margin (± gr)
• Display Orientation
• ADC Input Source
• RGB LED
• Buzzer
• Buzzer Volume

Sensor & Network:

• ADC Sample Buffer
• Wi-Fi Retries

Date & Time Display:

• Date Format
• Timezone

Diagnostics

The diagnostics page provides a comprehensive system health check and component verification.

System Information:

• Board, Uptime, Free Heap, Heap Usage

Component Status:

• Display, RGB LED, Buzzer, I2C Bus, ADC/Sensor, Calibration, WiFi, Storage (SPIFFS)

🎯 Configuration & Calibration

Creating a Configuration Profile

A configuration profile stores settings for a specific load:

1. Click "Add New" in Quick Settings panel
2. Fill in the dialog:
   • Caliber: Cartridge type (e.g., "9mm")
   • Bullet Weight: Projectile weight in grains - numbers only (e.g., "145", "gr" is added automatically)
   • Powder Name: Powder type (e.g., "N340")
   • Target Grain: Desired powder charge (e.g., "4.7")
3. Click "Save Configuration"

The configuration is now active but shows "Not Calibrated" in orange. You must calibrate before use.

Calibration Process

Why Calibrate?

Each configuration must be calibrated because:

• Different powders have different densities
• Mechanical tolerances vary
• Temperature affects measurements
• Ensures accurate grain weight readings

When to Calibrate:

• After creating a new configuration
• When switching powder types
• If measurements seem inaccurate
• Weekly for frequent use, monthly for occasional use

Calibration Steps:

Step 1: Set Zero Point

1. Click "Calibrate" button (orange)
2. Calibration wizard appears
3. Fully extend the probe (no compression)
4. Click "Set Zero" button
5. Confirmation: "Zero point set successfully"

Step 2: Set Known Reference

1. Weigh powder precisely on a scale (e.g., 4.7 grains)
2. Place powder in case and position under probe
3. Insert probe to measure depth
4. Wait for reading to stabilize (2-3 seconds)
5. Enter exact weight in "Known Powder Weight" field
6. Click "Set Known Grains" button
7. Device calculates conversion factor
8. Confirmation: "Calibration complete"

Calibration Tips:

• Use a precision scale for reference weight
• Use mid-range weight (not too light or heavy)
• Ensure stable environment (no vibration)
• Allow device to warm up (2-3 minutes)
• Wait for readings to stabilize before clicking buttons

🔬 Using PowderSense

Active Measurement

Once calibrated, PowderSense is ready to measure:

Display Shows:

• Current measurement in real-time
• Last measurement details (timestamp, weight, status)
• Configuration in use (shows "Calibrated" in green)
• Session statistics

Workflow:

1. Dispense Powder: Use your powder measure to dispense charge
2. Position Case: Place case with powder under probe
3. Insert Probe: Probe compresses into powder
4. Read Display: Check physical display or web interface
5. Adjust if Needed: Add or remove powder based on color indicator
6. Auto-Record: When stable, measurement is automatically recorded
7. Next Round: Remove case and repeat

Color Indicators:

• Blue: Below target (add powder)
• Green: On target (perfect)
• Red: Above target (remove powder, alarm)

Session Tracking

Starting a Session:

1. Click "Start Session" button
2. Session counter resets to 0
3. Begin measuring rounds

During Session:

• Each stable measurement increments counter
• Statistics update in real-time:
  • Average: Mean weight
  • Std Dev: Consistency indicator (lower is better)
  • Min/Max: Range of measurements
  • Count: Number of rounds measured

Ending a Session:

1. Click "End Session" button
2. Session is saved to log with:
   • Date and time
   • Bullet count
   • Total weight
   • Duration
3. Ready to start new session

Exporting Data:

• Click "Export Data" button
• Downloads CSV file with all measurements
• Open in Excel or Google Sheets for analysis

Manual vs Auto-Measurement

Auto-Measurement (Default):

• System automatically detects stable readings
• When reading is stable for 750ms within ±0.1 grain tolerance, measurement is recorded
• 10-second cooldown prevents duplicate recordings
• Best for production reloading

Manual Measurement:

• Click "Measure" button to force recording
• Useful for testing or verification
• No automatic detection

Firmware Update

Checking for Updates

The latest firmware version is displayed on the firmware update page on the PowderSense website.

Updating the Firmware

1. Connect your PowderSense to your computer via USB-C.
2. Use a browser that supports Web Serial (Chrome, Edge, Opera).
3. Navigate to the firmware update page on the PowderSense website.
4. Click the "Connect" button.
5. Select the port your device is connected to.
6. Follow the on-screen instructions to install the latest firmware.

🔧 Troubleshooting

Display Issues

Problem: Display is blank

• Check USB-C power connection
• Try different power adapter (5V, >1A)
• Check for loose ribbon cable inside device

Problem: Display shows wrong values

• Perform calibration
• Check that correct configuration is selected
• Restart device (unplug and replug power)

Measurement Issues

Problem: Readings are unstable or jumping

• Check for vibration or movement
• Ensure probe moves smoothly
• Check for mechanical binding
• Recalibrate

Problem: Measurements seem inaccurate

• Verify calibration with known weight
• Recalibrate using precision scale
• Check that correct configuration is active
• Ensure probe is fully inserted into powder

Problem: Device doesn't detect measurements

• Check auto-measurement settings (stable duration, tolerance)
• Ensure reading is actually stable
• Try manual measurement with "Measure" button

WiFi Issues

Problem: Can't connect to PowderSense AP

• Check display for correct network name
• Verify password: "powdersense" (all lowercase)
• Move closer to device
• Restart device

Problem: Device won't connect to home WiFi

• Verify WiFi password is correct
• Check that WiFi is 2.4GHz (device doesn't support 5GHz)
• Ensure WiFi network is not hidden
• Try resetting WiFi configuration

Problem: Lost IP address

• Check display (IP is shown on screen)
• Check router DHCP client list
• Use network scanner to find device
• Reset to AP mode if needed

Calibration Issues

Problem: Calibration fails or gives errors

• Ensure probe is stable during zero setting
• Use precise reference weight from scale
• Wait longer for readings to stabilize
• Try recalibrating with different reference weight

Problem: Calibration seems incorrect

• Verify reference weight on precision scale
• Use mid-range weight (not extreme low or high)
• Ensure powder is evenly distributed in case
• Check for mechanical issues with probe

🛠️ Maintenance & Safety

Regular Maintenance

Weekly (for frequent use):

• Clean probe tip with soft brush
• Check probe movement is smooth
• Verify calibration accuracy

Monthly:

• Clean display with soft cloth
• Check all connections inside device
• Backup measurement data (export CSV)

As Needed:

• Recalibrate when switching powders
• Update firmware when available
• Replace worn components

Cleaning

Probe:

• Use soft brush to remove powder residue
• Do not use solvents or lubricants
• Ensure probe moves freely

Display:

• Use soft, lint-free cloth
• Slightly damp if needed
• Do not use harsh chemicals

Enclosure:

• Wipe with damp cloth
• Keep away from powder dust
• Ensure ventilation holes are clear

Safety Information

Electrical Safety:

• Use only 5V DC power supply
• Do not expose to water or liquids
• Unplug during cleaning or maintenance
• Do not open device while powered

Reloading Safety:

• Always verify charges with precision scale
• PowderSense is a measurement aid, not a replacement for safe reloading practices
• Follow published load data
• Never exceed maximum loads
• Use appropriate safety equipment

Important: PowderSense measures powder depth and converts to grain weight based on calibration. Accuracy depends on proper calibration and consistent powder density. Always verify critical measurements with a precision scale.

📞 Support & Resources

Getting Help

For Pre-Built Units:

• Email: order@powdersense.nl
• 1 year warranty on assembled units
• Support for setup and calibration

References

[1] PowderSense Website. (2025). Retrieved from https://powdersense.nl
[2] PowderSense Local Device. (2025). Retrieved from http://powdersense.local