Troubleshooting

config.example.json

@@ -28,5 +28,5 @@
   "red_led_entity_name": "Selsyn 1 Red LED",
   "green_led_entity_name": "Selsyn 1 Green LED",
   "backlight_entity_name": "Selsyn 1 Backlight",
-  "ws2812_order": "GRB"
+  "backlight_unit": "%"
 }

config.multi.example.json

@@ -47,7 +47,6 @@
     "pin": 23,
     "num_leds_per_gauge": 3,
     "num_status_leds_per_gauge": 2
-    "ws2812_order": "GRB"
   },
   
   "device": {

gauge_vid6008.py

@@ -75,7 +75,6 @@ class Gauge:
 
         self._current_step = 0
         self._zeroed = False
-        self._last_dir = None
 
     def zero(self):
         overrun = _OVERRUN_STEPS
@@ -109,7 +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
 
@@ -129,20 +128,6 @@ class Gauge:
         self._pin_step.value(0)
         utime.sleep_us(delay_us)
 
-    def steps_toward(self, value, limit=5, deadband=0.5):
-        """Return the step delta needed to move toward value, clamped to ±limit.
-
-        deadband: If error is less than this fraction of one step, return 0 to prevent
-        micro-corrections due to floating-point rounding. Default 0.5 means
-        no movement if error < half a step.
-        """
-        target_step = self._val_to_step(value)
-        delta = target_step - self._current_step
-        deadband_steps = deadband
-        if abs(delta) < deadband_steps:
-            return 0
-        return max(-limit, min(limit, delta))
-
     def get(self):
         return self._step_to_val(self._current_step)
 

gaugemqttcontinuous.py

@@ -1,9 +1,9 @@
 """
-gaugemqttcontinuous.py — MQTT-based gauge controller for ESP32 / MicroPython
+gaugemqtt.py — MQTT-based gauge controller for ESP32 / MicroPython
 
 Deploy these files to the ESP32:
-  gauge_vid6008.py        — stepper driver
-  gaugemqttcontinuous.py  — this file
+  gauge.py        — stepper driver
+  gaugemqtt.py    — this file
   umqtt/simple.py — MicroPython built-in
   umqtt/robust.py — https://raw.githubusercontent.com/micropython/micropython-lib/master/micropython/umqtt.robust/umqtt/robust.py
   config.json     — configuration (see below)
@@ -81,7 +81,6 @@ _cfg = _load_config()
 
 DEBUG = _cfg.get("debug", False)
 _DEBUG = DEBUG
-_WS2812_ORDER = _cfg.get("ws2812_order", "GRB").upper()
 
 WIFI_SSID = _cfg["wifi_ssid"]
 WIFI_PASSWORD = _cfg["wifi_password"]
@@ -150,11 +149,13 @@ else:
             "ws2812_green": tuple(_cfg.get("ws2812_green", [0, 255, 0])),
         }
     )
+BL_UNIT = _cfg.get("backlight_unit", "%")
 
 # ---------------------------------------------------------------------------
 # Gauge initialization
 # ---------------------------------------------------------------------------
 
+info("Initialising gauge objects...")
 gauge_objects = []
 for g in gauges:
     gauge_objects.append(
@@ -169,6 +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]
@@ -205,10 +207,41 @@ 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"
 T_ZERO = f"{MQTT_PREFIX}/zero"
 
+T_DISC_GAUGE = f"homeassistant/number/{MQTT_CLIENT_ID}/config"
+T_DISC_RED = f"homeassistant/switch/{MQTT_CLIENT_ID}_red/config"
+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],
@@ -222,10 +255,12 @@ _DEVICE = {
 # WiFi
 # ---------------------------------------------------------------------------
 
+_wifi_reconnect_delay_s = 5
 _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)
@@ -253,7 +288,7 @@ def connect_wifi(ssid, password, timeout_s=15):
 
 
 def check_wifi():
-    global _wifi_sta, _last_wifi_check
+    global _wifi_sta, _last_wifi_check, _wifi_reconnect_delay_s
     now = utime.ticks_ms()
     if utime.ticks_diff(now, _last_wifi_check) < _wifi_check_interval_ms:
         return
@@ -281,15 +316,27 @@ def check_wifi():
         log_err(f"WiFi reconnect failed: {e}")
 
 
+# ---------------------------------------------------------------------------
+# LEDs (per gauge)
+# ---------------------------------------------------------------------------
+
+info("Initialising LEDs...")
 num_gauges = len(gauges)
 leds_red = []
 leds_green = []
+leds_bl = []
 for g in gauges:
     leds_red.append(Pin(g["red_pin"], Pin.OUT, value=0))
     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)]
@@ -302,11 +349,22 @@ _bl_dirty_since = None
 _BL_SAVE_DELAY_MS = 5000
 
 
-def _to_pixel(r, g, b):
-    """Reorder RGB to match the WS2812 variant's byte order (GRB or RGB)."""
-    if _WS2812_ORDER == "GRB":
-        return (g, r, b)
-    return (r, g, b)
+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):
@@ -322,19 +380,6 @@ def _mark_bl_dirty():
     _bl_dirty_since = utime.ticks_ms()
 
 
-def _apply_backlight(gauge_idx, r, g, b, brightness):
-    """Write RGB+brightness to the physical LEDs and mark dirty."""
-    scale = brightness / 100
-    leds_per_gauge = BACKLIGHT_LEDS_PER_GAUGE + STATUS_LEDS_PER_GAUGE
-    base_idx = gauge_idx * leds_per_gauge
-    pixel = _to_pixel(int(r * scale), int(g * scale), int(b * scale))
-    for j in range(BACKLIGHT_LEDS_PER_GAUGE):
-        leds_bl[base_idx + j] = pixel
-    _update_status_leds(gauge_idx)
-    leds_bl.write()
-    _mark_bl_dirty()
-
-
 def set_backlight_color(gauge_idx, r, g, b, brightness=None):
     global backlight_color, backlight_brightness, backlight_on
     if brightness is None:
@@ -346,7 +391,17 @@ def set_backlight_color(gauge_idx, r, g, b, brightness=None):
     if brightness > 0:
         backlight_brightness[gauge_idx] = brightness
     backlight_on[gauge_idx] = new_on
-    _apply_backlight(gauge_idx, r, g, b, brightness)
+
+    scale = brightness / 100
+    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 set_backlight_brightness(gauge_idx, brightness):
@@ -359,10 +414,21 @@ def set_backlight_brightness(gauge_idx, brightness):
         backlight_brightness[gauge_idx] = clamped
     backlight_on[gauge_idx] = new_on
     r, g, b = backlight_color[gauge_idx]
-    _apply_backlight(gauge_idx, r, g, b, clamped)
+    scale = clamped / 100
+    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
 
@@ -371,12 +437,12 @@ def _update_status_leds(gauge_idx):
     green_color = g_cfg["ws2812_green"]
 
     if status_led_red[gauge_idx]:
-        leds_bl[base_idx] = _to_pixel(*red_color)
+        leds_bl[base_idx] = (red_color[1], red_color[0], red_color[2])
     else:
         leds_bl[base_idx] = (0, 0, 0)
 
     if status_led_green[gauge_idx]:
-        leds_bl[base_idx + 1] = _to_pixel(*green_color)
+        leds_bl[base_idx + 1] = (green_color[1], green_color[0], green_color[2])
     else:
         leds_bl[base_idx + 1] = (0, 0, 0)
 
@@ -388,38 +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."""
-    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}")
+# ---------------------------------------------------------------------------
+# State
+# ---------------------------------------------------------------------------
 
-
-def _flush_backlight_state():
-    global _bl_dirty_since
-    if _bl_dirty_since is None:
-        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")
+_last_rezero_ms = None  # set to ticks_ms() in main()
+client_ref = None
+_mqtt_connected = False
+_last_mqtt_check = 0
 
 
 def _publish(topic, payload, retain=False):
@@ -463,6 +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)
@@ -526,59 +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} ...")
@@ -588,22 +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(T_STATUS, b"offline", retain=True, qos=0)
+    client.set_last_will(gauge_topics[0]["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():
@@ -634,16 +649,27 @@ def check_mqtt():
                 port=MQTT_PORT,
                 user=MQTT_USER,
                 password=MQTT_PASSWORD,
-                keepalive=30,
+                keepalive=60,
+            )
+            client_ref.set_last_will(
+                gauge_topics[0]["status"], b"offline", retain=True, qos=0
             )
             client_ref.set_callback(on_message)
             client_ref.connect()
+            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)
-            _subscribe_all(client_ref)
             publish_state(client_ref)
-            publish_backlight_states(client_ref)
             return True
         except Exception as e2:
             log_err(f"MQTT reconnect attempt {attempt + 1} failed: {e2}")
@@ -653,10 +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]
@@ -682,11 +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(
@@ -725,11 +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(
@@ -787,17 +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}")
 
 
 # ---------------------------------------------------------------------------
@@ -806,58 +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)
-    for _ in range(5):
-        client_ref.check_msg()
-        utime.sleep_ms(20)
+    info("Discovery done")
 
     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():
@@ -865,33 +872,50 @@ def main():
                 continue
 
             client_ref.check_msg()
-            _flush_backlight_state()
 
-            pending = [g.steps_toward(gauge_targets[i],limit=50) for i, g in enumerate(gauge_objects)]
+            now = utime.ticks_ms()
 
-            moved_any = any(s != 0 for s in pending)
-            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)):
+            moved_any = False
             for i, g in enumerate(gauge_objects):
-                        if tick < abs(pending[i]):
-                            g.step(1 if pending[i] > 0 else -1)
+                current_target = g._val_to_step(gauge_targets[i])
+                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
-                utime.sleep_ms(10)
+                info("Auto-rezero complete")
+
+            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)
 

ota.py

@@ -198,9 +198,9 @@ def _fetch_manifest():
     )
     try:
         r = urequests.get(url, headers=_headers())
-        try:
         if r.status_code == 200:
             data = r.json()
+            r.close()
             if data.get("content"):
                 import ubinascii
 
@@ -209,7 +209,6 @@ def _fetch_manifest():
                 return [p for p in patterns if p and not p.startswith("#")]
         else:
             warn(f"Manifest not found at {OTA_MANIFEST}")
-        finally:
         r.close()
     except Exception as e:
         log_err(f"Failed to fetch manifest: {e}")
@@ -285,6 +284,13 @@ def _save_manifest(manifest, commit_sha=None):
         warn(f"Could not save manifest: {e}")
 
 
+def _wipe_manifest():
+    try:
+        os.remove(MANIFEST_FILE)
+        info("Manifest wiped — full re-fetch on next update")
+    except OSError:
+        pass
+
 
 def _ok_flag_exists():
     try:
@@ -343,6 +349,8 @@ def _fetch_file_list():
                         break
             else:
                 name = entry["name"]
+                if not name.endswith(".py"):
+                    continue
                 for p in patterns:
                     p = p.rstrip("/")
                     if _match_pattern(name, p) or _match_pattern(entry["path"], p):