Troubleshooting

gauge_vid6008.py

@@ -108,7 +108,7 @@ class Gauge:
         else:
             for _ in range(abs(delta)):
                 self._step(1 if delta > 0 else -1)
-                utime.sleep_us(self._step_us)
+                utime.sleep_ms(self._step_us)
 
         self._current_step = target_step
 

gaugemqttcontinuous.py

@@ -23,7 +23,6 @@ Serial log format: [HH:MM:SS.mmm] LEVEL  message
 import network
 import utime
 import ujson
-import urandom
 from umqtt.robust import MQTTClient
 from machine import Pin
 from neopixel import NeoPixel
@@ -156,6 +155,7 @@ BL_UNIT = _cfg.get("backlight_unit", "%")
 # Gauge initialization
 # ---------------------------------------------------------------------------
 
+info("Initialising gauge objects...")
 gauge_objects = []
 for g in gauges:
     gauge_objects.append(
@@ -170,6 +170,7 @@ for g in gauges:
     info(
         f"Gauge {g['id']}: {g['name']} pins={g['pins']} mode={g['mode']} range=[{g['min']}, {g['max']}]"
     )
+info("Gauge objects done")
 
 gauge_targets = [g["min"] for g in gauges]  # target value per gauge
 gauge_last_rezero = [utime.ticks_ms() for _ in gauges]
@@ -206,7 +207,6 @@ def make_gauge_topics(prefix, gauge_id):
 
 gauge_topics = [make_gauge_topics(MQTT_PREFIX, g["id"]) for g in gauges]
 
-
 T_SET = f"{MQTT_PREFIX}/set"
 T_STATE = f"{MQTT_PREFIX}/state"
 T_STATUS = f"{MQTT_PREFIX}/status"
@@ -218,6 +218,31 @@ T_DISC_GREEN = f"homeassistant/switch/{MQTT_CLIENT_ID}_green/config"
 T_DISC_BL = f"homeassistant/light/{MQTT_CLIENT_ID}_bl/config"
 
 
+def make_gauge_topics(prefix, gauge_id):
+    return {
+        "set": f"{prefix}/gauge{gauge_id}/set",
+        "state": f"{prefix}/gauge{gauge_id}/state",
+        "status": f"{prefix}/gauge{gauge_id}/status",
+        "zero": f"{prefix}/gauge{gauge_id}/zero",
+        "disc": f"homeassistant/number/{MQTT_CLIENT_ID}_g{gauge_id}/config",
+        "led_red": f"{prefix}/gauge{gauge_id}/led/red/set",
+        "led_green": f"{prefix}/gauge{gauge_id}/led/green/set",
+        "led_bl": f"{prefix}/gauge{gauge_id}/led/backlight/set",
+        "led_red_state": f"{prefix}/gauge{gauge_id}/led/red/state",
+        "led_green_state": f"{prefix}/gauge{gauge_id}/led/green/state",
+        "led_bl_state": f"{prefix}/gauge{gauge_id}/led/backlight/state",
+        "led_red_disc": f"homeassistant/switch/{MQTT_CLIENT_ID}_g{gauge_id}_red/config",
+        "led_green_disc": f"homeassistant/switch/{MQTT_CLIENT_ID}_g{gauge_id}_green/config",
+        "led_bl_disc": f"homeassistant/light/{MQTT_CLIENT_ID}_g{gauge_id}_bl/config",
+        "status_red": f"{prefix}/gauge{gauge_id}/status_led/red/set",
+        "status_green": f"{prefix}/gauge{gauge_id}/status_led/green/set",
+        "status_red_state": f"{prefix}/gauge{gauge_id}/status_led/red/state",
+        "status_green_state": f"{prefix}/gauge{gauge_id}/status_led/green/state",
+        "status_red_disc": f"homeassistant/switch/{MQTT_CLIENT_ID}_g{gauge_id}_status_red/config",
+        "status_green_disc": f"homeassistant/switch/{MQTT_CLIENT_ID}_g{gauge_id}_status_green/config",
+    }
+
+
 _DEVICE = {
     "identifiers": [MQTT_CLIENT_ID],
     "name": DEVICE_NAME,
@@ -235,6 +260,7 @@ _wifi_check_interval_ms = 30000
 _last_wifi_check = 0
 _wifi_sta = None
 
+
 def connect_wifi(ssid, password, timeout_s=15):
     global _wifi_sta
     _wifi_sta = network.WLAN(network.STA_IF)
@@ -290,6 +316,11 @@ def check_wifi():
         log_err(f"WiFi reconnect failed: {e}")
 
 
+# ---------------------------------------------------------------------------
+# LEDs (per gauge)
+# ---------------------------------------------------------------------------
+
+info("Initialising LEDs...")
 num_gauges = len(gauges)
 leds_red = []
 leds_green = []
@@ -299,7 +330,13 @@ for g in gauges:
     leds_green.append(Pin(g["green_pin"], Pin.OUT, value=0))
 
 total_backlight_leds = num_gauges * (BACKLIGHT_LEDS_PER_GAUGE + STATUS_LEDS_PER_GAUGE)
-leds_bl = NeoPixel(Pin(BACKLIGHT_PIN), total_backlight_leds)
+info(f"Total backlight LEDs: {total_backlight_leds}")
+leds_bl = (
+    NeoPixel(Pin(BACKLIGHT_PIN), total_backlight_leds)
+    if total_backlight_leds > 0
+    else None
+)
+info("LEDs done")
 
 backlight_color = [(0, 0, 0) for _ in range(num_gauges)]
 backlight_brightness = [100 for _ in range(num_gauges)]
@@ -312,6 +349,24 @@ _bl_dirty_since = None
 _BL_SAVE_DELAY_MS = 5000
 
 
+def _flush_backlight(client):
+    for i in range(num_gauges):
+        gt = gauge_topics[i]
+        payload = {
+            "state": "ON" if backlight_on[i] else "OFF",
+            "color": {
+                "r": backlight_color[i][0],
+                "g": backlight_color[i][1],
+                "b": backlight_color[i][2],
+            },
+            "brightness": int(backlight_brightness[i] * 2.55),
+        }
+        client.publish(gt["led_bl_state"], ujson.dumps(payload), retain=True)
+        info(
+            f"Gauge {i} backlight: {payload['state']} {backlight_color[i]} @ {backlight_brightness[i]}%"
+        )
+
+
 def _backlight_changed(gauge_idx, new_color, new_on, new_brightness):
     return (
         new_color != backlight_color[gauge_idx]
@@ -341,8 +396,10 @@ def set_backlight_color(gauge_idx, r, g, b, brightness=None):
     leds_per_gauge = BACKLIGHT_LEDS_PER_GAUGE + STATUS_LEDS_PER_GAUGE
     base_idx = gauge_idx * leds_per_gauge
     for j in range(BACKLIGHT_LEDS_PER_GAUGE):
+        if leds_bl:
             leds_bl[base_idx + j] = (int(g * scale), int(r * scale), int(b * scale))
     _update_status_leds(gauge_idx)
+    if leds_bl:
         leds_bl.write()
     _mark_bl_dirty()
 
@@ -361,13 +418,17 @@ def set_backlight_brightness(gauge_idx, brightness):
     leds_per_gauge = BACKLIGHT_LEDS_PER_GAUGE + STATUS_LEDS_PER_GAUGE
     base_idx = gauge_idx * leds_per_gauge
     for j in range(BACKLIGHT_LEDS_PER_GAUGE):
+        if leds_bl:
             leds_bl[base_idx + j] = (int(g * scale), int(r * scale), int(b * scale))
     _update_status_leds(gauge_idx)
+    if leds_bl:
         leds_bl.write()
     _mark_bl_dirty()
 
 
 def _update_status_leds(gauge_idx):
+    if not leds_bl:
+        return
     leds_per_gauge = BACKLIGHT_LEDS_PER_GAUGE + STATUS_LEDS_PER_GAUGE
     base_idx = gauge_idx * leds_per_gauge + BACKLIGHT_LEDS_PER_GAUGE
 
@@ -393,38 +454,18 @@ def set_status_led(gauge_idx, led_type, state):
     elif led_type == "green":
         status_led_green[gauge_idx] = state
     _update_status_leds(gauge_idx)
+    if leds_bl:
         leds_bl.write()
 
 
-def publish_backlight_states(client):
+# ---------------------------------------------------------------------------
-    """Publish current backlight state for all gauges as retained MQTT messages."""
+# State
-    for i in range(num_gauges):
+# ---------------------------------------------------------------------------
-        gt = gauge_topics[i]
-        r, g, b = backlight_color[i]
-        brightness = backlight_brightness[i]
-        state = {
-            "state": "ON" if backlight_on[i] else "OFF",
-            "color_mode": "rgb",
-            "brightness": int(brightness * 2.55),
-            "color": {"r": r, "g": g, "b": b},
-        }
-        try:
-            client.publish(gt["led_bl_state"], ujson.dumps(state), retain=True)
-        except Exception as e:
-            log_err(f"Backlight state publish failed for gauge {i}: {e}")
 
-
+_last_rezero_ms = None  # set to ticks_ms() in main()
-def _flush_backlight_state():
+client_ref = None
-    global _bl_dirty_since
+_mqtt_connected = False
-    if _bl_dirty_since is None:
+_last_mqtt_check = 0
-        return
-    if utime.ticks_diff(utime.ticks_ms(), _bl_dirty_since) < _BL_SAVE_DELAY_MS:
-        return
-    if client_ref is None:
-        return
-    publish_backlight_states(client_ref)
-    _bl_dirty_since = None
-    info("Backlight state flushed to MQTT")
 
 
 def _publish(topic, payload, retain=False):
@@ -445,7 +486,6 @@ def _publish(topic, payload, retain=False):
 
 
 def on_message(topic, payload):
-    global backlight_brightness, backlight_color
     if client_ref is None:
         return
     topic = topic.decode()
@@ -469,6 +509,15 @@ def on_message(topic, payload):
                 warn(f"Invalid set value for gauge {i}: '{payload}'")
             return
 
+    if topic == T_ZERO:
+        for i, g in enumerate(gauge_objects):
+            info(f"Zeroing all gauges")
+            g.zero()
+            gauge_last_rezero[i] = utime.ticks_ms()
+        info("All gauges zeroed")
+        return
+
+    for i, gt in enumerate(gauge_topics):
         if topic == gt["led_red"]:
             state = payload.upper() == "ON"
             leds_red[i].value(1 if state else 0)
@@ -532,59 +581,12 @@ def on_message(topic, payload):
             info(f"Gauge {i} status green → {'ON' if state else 'OFF'}")
             return
 
-    if topic == T_ZERO:
-        for i, g in enumerate(gauge_objects):
-            g.zero()
-            gauge_last_rezero[i] = utime.ticks_ms()
-        info("All gauges zeroed")
-        return
-
-    if topic == T_SET:
-        try:
-            data = ujson.loads(payload)
-            if isinstance(data, dict):
-                for i, val in enumerate(data.values()):
-                    if i < len(gauges):
-                        g = gauges[i]
-                        gauge_targets[i] = max(g["min"], min(g["max"], float(val)))
-                        info(f"Gauge {i} target → {gauge_targets[i]:.1f}")
-            else:
-                val = float(payload)
-                for i in range(len(gauges)):
-                    gauge_targets[i] = max(gauges[i]["min"], min(gauges[i]["max"], val))
-                info(f"All gauges target → {val:.1f}")
-        except Exception:
-            try:
-                val = float(payload)
-                for i in range(len(gauges)):
-                    gauge_targets[i] = max(gauges[i]["min"], min(gauges[i]["max"], val))
-                info(f"All gauges target → {val:.1f}")
-            except:
-                warn(f"Invalid set value: '{payload}'")
-        return
-
-
-
 
 # ---------------------------------------------------------------------------
 # MQTT connect + discovery
 # ---------------------------------------------------------------------------
 
 
-def _subscribe_all(c):
-    c.subscribe(f"{MQTT_PREFIX}/set")
-    c.subscribe(f"{MQTT_PREFIX}/zero")
-    for i in range(num_gauges):
-        prefix = f"{MQTT_PREFIX}/gauge{i}"
-        c.subscribe(f"{prefix}/set")
-        c.subscribe(f"{prefix}/zero")
-        c.subscribe(f"{prefix}/led/red/set")
-        c.subscribe(f"{prefix}/led/green/set")
-        c.subscribe(f"{prefix}/led/backlight/set")
-        c.subscribe(f"{prefix}/status_led/red/set")
-        c.subscribe(f"{prefix}/status_led/green/set")
-
-
 def connect_mqtt():
     global client_ref, _mqtt_connected
     info(f"Connecting to MQTT broker {MQTT_BROKER}:{MQTT_PORT} ...")
@@ -594,22 +596,29 @@ def connect_mqtt():
         port=MQTT_PORT,
         user=MQTT_USER,
         password=MQTT_PASSWORD,
-        keepalive=30,
+        keepalive=60,
     )
-    # Don't set last will - it might be causing issues
+    client.set_last_will(gauge_topics[0]["status"], b"offline", retain=True, qos=0)
-    # client.set_last_will(T_STATUS, b"offline", retain=True, qos=0)
     client.set_callback(on_message)
     client.connect()
     client_ref = client
+    client.subscribe(T_SET)
+    client.subscribe(T_ZERO)
+    for gt in gauge_topics:
+        client.subscribe(gt["set"])
+        client.subscribe(gt["zero"])
+        client.subscribe(gt["led_red"])
+        client.subscribe(gt["led_green"])
+        client.subscribe(gt["led_bl"])
+        client.subscribe(gt["status_red"])
+        client.subscribe(gt["status_green"])
     _mqtt_connected = True
     info(f"MQTT connected  client_id={MQTT_CLIENT_ID}")
+    return client
 
 
 _mqtt_check_interval_ms = 30000
 _last_mqtt_check = 0
-client_ref = None
-_mqtt_connected = False
-
 
 
 def check_mqtt():
@@ -642,10 +651,21 @@ def check_mqtt():
                 password=MQTT_PASSWORD,
                 keepalive=60,
             )
-            client_ref.set_last_will(T_STATUS, b"offline", retain=True, qos=0)
+            client_ref.set_last_will(
+                gauge_topics[0]["status"], b"offline", retain=True, qos=0
+            )
             client_ref.set_callback(on_message)
             client_ref.connect()
-            _subscribe_all(client_ref)
+            client_ref.subscribe(T_SET)
+            client_ref.subscribe(T_ZERO)
+            for gt in gauge_topics:
+                client_ref.subscribe(gt["set"])
+                client_ref.subscribe(gt["zero"])
+                client_ref.subscribe(gt["led_red"])
+                client_ref.subscribe(gt["led_green"])
+                client_ref.subscribe(gt["led_bl"])
+                client_ref.subscribe(gt["status_red"])
+                client_ref.subscribe(gt["status_green"])
             _mqtt_connected = True
             info("MQTT reconnected!")
             publish_discovery(client_ref)
@@ -659,10 +679,15 @@ def check_mqtt():
     return False
 
 
-
 def publish_discovery(client):
     """Publish all HA MQTT discovery payloads for gauges and LEDs."""
-    _dev_ref = _DEVICE
+    _dev_ref = {
+        "identifiers": [MQTT_CLIENT_ID],
+        "name": DEVICE_NAME,
+        "model": DEVICE_MODEL,
+        "manufacturer": DEVICE_MFR,
+        "suggested_area": DEVICE_AREA,
+    }
 
     for i, g in enumerate(gauges):
         gt = gauge_topics[i]
@@ -688,11 +713,6 @@ def publish_discovery(client):
         )
         info(f"Discovery: gauge {i} ({g['name']})")
 
-        # Process MQTT messages between gauges
-        for _ in range(5):
-            client.check_msg()
-            utime.sleep_ms(10)
-        
         client.publish(
             gt["led_red_disc"],
             ujson.dumps(
@@ -731,11 +751,6 @@ def publish_discovery(client):
         )
         info(f"Discovery: gauge {i} green LED")
 
-        # Process MQTT messages
-        for _ in range(5):
-            client.check_msg()
-            utime.sleep_ms(10)
-
         client.publish(
             gt["led_bl_disc"],
             ujson.dumps(
@@ -793,17 +808,14 @@ def publish_discovery(client):
         )
         info(f"Discovery: gauge {i} status green")
 
-        # Process between gauges to avoid MQTT blocking
-        for _ in range(5):
-            client.check_msg()
-            utime.sleep_ms(10)
-
 
 def publish_state(client):
     for i, g in enumerate(gauge_objects):
         gt = gauge_topics[i]
         val = g.get()
-        client.publish(gt["state"], str(val))
+        client.publish(gt["state"], str(round(val, 1)), retain=True)
+        client.publish(gt["status"], "online", retain=True)
+        info(f"Gauge {i} state: {val:.1f} step={g._current_step}")
 
 
 # ---------------------------------------------------------------------------
@@ -812,58 +824,47 @@ def publish_state(client):
 
 
 def main():
+    utime.sleep_ms(0)
     info("=" * 48)
     info("Gauge MQTT controller starting")
     info("=" * 48)
 
+    info("Connecting WiFi...")
     connect_wifi(WIFI_SSID, WIFI_PASSWORD)
+    info("WiFi done")
 
-    # Connect MQTT (no subscriptions yet — keeps broker silent during discovery)
-    connect_mqtt()
-
-    # Publish discovery — broker has nothing to send back yet
-    info("Publishing discovery...")
-    publish_discovery(client_ref)
-
-    # Subscribe now — retained messages will start arriving from here
-    _subscribe_all(client_ref)
-    info("Draining initial retained messages...")
-    for _ in range(50):
-        client_ref.check_msg()
-        utime.sleep_ms(20)
-
-    # Now initialize gauges
     info("Zeroing gauges on startup ...")
     for i, g in enumerate(gauge_objects):
         g.zero()
         info(f"Zeroed gauge {i}")
-    info("Zero complete")
+    info("Zero done")
 
-    info("Publishing state...")
+    info("Connecting MQTT...")
+    connect_mqtt()
+    info("MQTT done")
+
+    info("Publishing discovery...")
+    publish_discovery(client_ref)
     publish_state(client_ref)
-    utime.sleep_ms(50)
+    info("Discovery done")
-    for _ in range(5):
-        client_ref.check_msg()
-        utime.sleep_ms(20)
 
     info("Entering main loop")
     info("-" * 48)
 
     try:
         import ota
+
         ota.mark_ok()
-    except:
+        info("OTA OK flag set")
+    except ImportError:
         pass
 
-    # Initialize variables for main loop
+    global _bl_dirty_since
     last_heartbeat = utime.ticks_ms()
-    now = 0
-    was_moving = False
 
     while True:
+        utime.sleep_ms(0)
         try:
-            now = utime.ticks_ms()
-
             check_wifi()
 
             if not check_mqtt():
@@ -872,35 +873,49 @@ def main():
 
             client_ref.check_msg()
 
-            pending = []
+            now = utime.ticks_ms()
-            for i, g in enumerate(gauge_objects):
-                delta = g._val_to_step(gauge_targets[i]) - g._current_step
-                steps = max(-5, min(5, delta))
-                pending.append(steps)
 
-            moved_any = any(s != 0 for s in pending)
+            moved_any = False
-            if moved_any:
-                was_moving = True
-                delay_us = 1_000_000 // MICROSTEPS_PER_SECOND
-                for tick in range(max(abs(s) for s in pending)):
             for i, g in enumerate(gauge_objects):
-                        if tick < abs(pending[i]):
+                current_target = g._val_to_step(gauge_targets[i])
-                            g.step(1 if pending[i] > 0 else -1)
+                if current_target != g._current_step:
+                    direction = 1 if current_target > g._current_step else -1
+                    steps_to_move = current_target - g._current_step
+                    steps_to_move = max(-5, min(5, steps_to_move))
+                    for _ in range(abs(steps_to_move)):
+                        g.step(direction)
+                    moved_any = True
+
+            if moved_any:
+                delay_us = 1_000_000 // MICROSTEPS_PER_SECOND
                 utime.sleep_us(delay_us)
-            else:
+
-                if was_moving:
+            if (
+                REZERO_INTERVAL_MS > 0
+                and utime.ticks_diff(now, gauge_last_rezero[0]) >= REZERO_INTERVAL_MS
+            ):
+                for i, g in enumerate(gauge_objects):
+                    info(f"Auto-rezero gauge {i}")
+                    saved = gauge_targets[i]
+                    g.zero()
+                    if saved > gauges[i]["min"]:
+                        g.set(saved)
+                    gauge_last_rezero[i] = now
                 publish_state(client_ref)
-                    was_moving = False
+                info("Auto-rezero complete")
-                utime.sleep_ms(10)
+
+            if (
+                _bl_dirty_since is not None
+                and utime.ticks_diff(now, _bl_dirty_since) >= _BL_SAVE_DELAY_MS
+            ):
+                _flush_backlight(client_ref)
+                _bl_dirty_since = None
 
             if utime.ticks_diff(now, last_heartbeat) >= HEARTBEAT_MS:
-                info(f"Heartbeat: {gauge_targets}")
                 publish_state(client_ref)
                 last_heartbeat = now
 
         except Exception as e:
-            import sys
-            sys.print_exception(e)
             log_err(f"Main loop error: {e} — continuing")
             utime.sleep_ms(100)