3d-models for more numberplates, case for 5 gauges and VFD-holder added

This reverts commit 7fb3b5e1fd.

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",
-  "backlight_unit": "%"
+  "ws2812_order": "GRB"
 }

config.multi.example.json

@@ -20,7 +20,9 @@
       "unit": "W",
       "leds": {
         "red_pin": 33,
-        "green_pin": 32
+        "green_pin": 32,
+        "ws2812_red": [255, 0, 0],
+        "ws2812_green": [0, 255, 0]
       }
     },
     {
@@ -34,14 +36,18 @@
       "unit": "C",
       "leds": {
         "red_pin": 21,
-        "green_pin": 20
+        "green_pin": 20,
+        "ws2812_red": [255, 0, 0],
+        "ws2812_green": [0, 255, 0]
       }
     }
   ],
   
   "backlight": {
     "pin": 23,
-    "num_leds_per_gauge": 3
+    "num_leds_per_gauge": 3,
+    "num_status_leds_per_gauge": 2
+    "ws2812_order": "GRB"
   },
   
   "device": {

gauge_vid6008.py

@@ -75,6 +75,7 @@ class Gauge:
 
         self._current_step = 0
         self._zeroed = False
+        self._last_dir = None
 
     def zero(self):
         overrun = _OVERRUN_STEPS
@@ -108,7 +109,7 @@ class Gauge:
         else:
             for _ in range(abs(delta)):
                 self._step(1 if delta > 0 else -1)
-                utime.sleep_ms(self._step_us)
+                utime.sleep_us(self._step_us)
 
         self._current_step = target_step
 
@@ -128,6 +129,20 @@ 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 @@
 """
-gaugemqtt.py — MQTT-based gauge controller for ESP32 / MicroPython
+gaugemqttcontinuous.py — MQTT-based gauge controller for ESP32 / MicroPython
 
 Deploy these files to the ESP32:
-  gauge.py        — stepper driver
+  gauge_vid6008.py        — stepper driver
-  gaugemqtt.py    — this file
+  gaugemqttcontinuous.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)
@@ -81,6 +81,7 @@ _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"]
@@ -98,6 +99,7 @@ REZERO_INTERVAL_MS = int(_cfg.get("rezero_interval_ms", 3600000))
 backlight_cfg = _cfg.get("backlight", {})
 BACKLIGHT_PIN = int(backlight_cfg.get("pin", _cfg.get("led_bl_pin", 23)))
 BACKLIGHT_LEDS_PER_GAUGE = int(backlight_cfg.get("num_leds_per_gauge", 3))
+STATUS_LEDS_PER_GAUGE = int(backlight_cfg.get("num_status_leds_per_gauge", 2))
 
 device_cfg = _cfg.get("device", {})
 DEVICE_NAME = device_cfg.get("name", _cfg.get("device_name", "Selsyn Multi"))
@@ -126,6 +128,8 @@ if "gauges" in _cfg:
                 "unit": g.get("unit", ""),
                 "red_pin": int(led_cfg.get("red_pin", 33)),
                 "green_pin": int(led_cfg.get("green_pin", 32)),
+                "ws2812_red": tuple(led_cfg.get("ws2812_red", [255, 0, 0])),
+                "ws2812_green": tuple(led_cfg.get("ws2812_green", [0, 255, 0])),
             }
         )
 else:
@@ -142,9 +146,10 @@ else:
             "unit": _cfg.get("gauge_unit", "W"),
             "red_pin": int(_cfg.get("led_red_pin", 33)),
             "green_pin": int(_cfg.get("led_green_pin", 32)),
+            "ws2812_red": tuple(_cfg.get("ws2812_red", [255, 0, 0])),
+            "ws2812_green": tuple(_cfg.get("ws2812_green", [0, 255, 0])),
         }
     )
-BL_UNIT = _cfg.get("backlight_unit", "%")
 
 # ---------------------------------------------------------------------------
 # Gauge initialization
@@ -189,48 +194,21 @@ def make_gauge_topics(prefix, gauge_id):
         "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",
     }
 
 
 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"
-
-
-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",
-    }
-
 
 _DEVICE = {
     "identifiers": [MQTT_CLIENT_ID],
@@ -244,12 +222,10 @@ _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)
@@ -277,7 +253,7 @@ def connect_wifi(ssid, password, timeout_s=15):
 
 
 def check_wifi():
-    global _wifi_sta, _last_wifi_check, _wifi_reconnect_delay_s
+    global _wifi_sta, _last_wifi_check
     now = utime.ticks_ms()
     if utime.ticks_diff(now, _last_wifi_check) < _wifi_check_interval_ms:
         return
@@ -305,52 +281,32 @@ def check_wifi():
         log_err(f"WiFi reconnect failed: {e}")
 
 
-# ---------------------------------------------------------------------------
-# LEDs (per gauge)
-# ---------------------------------------------------------------------------
-
 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
+total_backlight_leds = num_gauges * (BACKLIGHT_LEDS_PER_GAUGE + STATUS_LEDS_PER_GAUGE)
 leds_bl = NeoPixel(Pin(BACKLIGHT_PIN), total_backlight_leds)
 
-_backlight_color = (0, 0, 0)
-_backlight_brightness = 100
-_backlight_on = False
-_bl_dirty_since = None
-_BL_SAVE_DELAY_MS = 5000
-
 backlight_color = [(0, 0, 0) for _ in range(num_gauges)]
 backlight_brightness = [100 for _ in range(num_gauges)]
 backlight_on = [False for _ in range(num_gauges)]
 
+status_led_red = [False for _ in range(num_gauges)]
+status_led_green = [False for _ in range(num_gauges)]
 
-def _flush_backlight(client):
+_bl_dirty_since = None
-    for i in range(num_gauges):
+_BL_SAVE_DELAY_MS = 5000
-        gt = gauge_topics[i]
+
-        payload = {
+
-            "state": "ON" if backlight_on[i] else "OFF",
+def _to_pixel(r, g, b):
-            "color": {
+    """Reorder RGB to match the WS2812 variant's byte order (GRB or RGB)."""
-                "r": backlight_color[i][0],
+    if _WS2812_ORDER == "GRB":
-                "g": backlight_color[i][1],
+        return (g, r, b)
-                "b": backlight_color[i][2],
+    return (r, g, b)
-            },
-            "brightness": int(backlight_brightness[i] * 2.55),
-        }
-        client.publish(
-            f"{gt['set'].replace('/set', '/backlight/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):
@@ -366,6 +322,19 @@ 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:
@@ -377,13 +346,7 @@ 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
-    base_idx = gauge_idx * BACKLIGHT_LEDS_PER_GAUGE
-    for j in range(BACKLIGHT_LEDS_PER_GAUGE):
-        leds_bl[base_idx + j] = (int(g * scale), int(r * scale), int(b * scale))
-    leds_bl.write()
-    _mark_bl_dirty()
 
 
 def set_backlight_brightness(gauge_idx, brightness):
@@ -396,22 +359,67 @@ 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]
-    scale = clamped / 100
+    _apply_backlight(gauge_idx, r, g, b, clamped)
-    base_idx = gauge_idx * BACKLIGHT_LEDS_PER_GAUGE
+
-    for j in range(BACKLIGHT_LEDS_PER_GAUGE):
+
-        leds_bl[base_idx + j] = (int(g * scale), int(r * scale), int(b * scale))
+def _update_status_leds(gauge_idx):
+    leds_per_gauge = BACKLIGHT_LEDS_PER_GAUGE + STATUS_LEDS_PER_GAUGE
+    base_idx = gauge_idx * leds_per_gauge + BACKLIGHT_LEDS_PER_GAUGE
+
+    g_cfg = gauges[gauge_idx]
+    red_color = g_cfg["ws2812_red"]
+    green_color = g_cfg["ws2812_green"]
+
+    if status_led_red[gauge_idx]:
+        leds_bl[base_idx] = _to_pixel(*red_color)
+    else:
+        leds_bl[base_idx] = (0, 0, 0)
+
+    if status_led_green[gauge_idx]:
+        leds_bl[base_idx + 1] = _to_pixel(*green_color)
+    else:
+        leds_bl[base_idx + 1] = (0, 0, 0)
+
+
+def set_status_led(gauge_idx, led_type, state):
+    global status_led_red, status_led_green
+    if led_type == "red":
+        status_led_red[gauge_idx] = state
+    elif led_type == "green":
+        status_led_green[gauge_idx] = state
+    _update_status_leds(gauge_idx)
     leds_bl.write()
-    _mark_bl_dirty()
 
 
-# ---------------------------------------------------------------------------
+def publish_backlight_states(client):
-# State
+    """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}")
 
-_last_rezero_ms = None  # set to ticks_ms() in main()
+
-client_ref = None
+def _flush_backlight_state():
-_mqtt_connected = False
+    global _bl_dirty_since
-_last_mqtt_check = 0
+    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")
 
 
 def _publish(topic, payload, retain=False):
@@ -455,15 +463,6 @@ 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)
@@ -513,12 +512,73 @@ def on_message(topic, payload):
             info(f"Gauge {i} backlight → #{r:02x}{g:02x}{b:02x} @ {brightness}%")
             return
 
+        if topic == gt["status_red"]:
+            state = payload.upper() == "ON"
+            set_status_led(i, "red", state)
+            _publish(gt["status_red_state"], "ON" if state else "OFF", retain=True)
+            info(f"Gauge {i} status red → {'ON' if state else 'OFF'}")
+            return
+
+        if topic == gt["status_green"]:
+            state = payload.upper() == "ON"
+            set_status_led(i, "green", state)
+            _publish(gt["status_green_state"], "ON" if state else "OFF", retain=True)
+            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} ...")
@@ -528,27 +588,22 @@ def connect_mqtt():
         port=MQTT_PORT,
         user=MQTT_USER,
         password=MQTT_PASSWORD,
-        keepalive=60,
+        keepalive=30,
     )
-    client.set_last_will(T_STATUS, b"offline", retain=True, qos=0)
+    # Don't set last will - it might be causing issues
+    # 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"])
     _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():
@@ -579,23 +634,16 @@ def check_mqtt():
                 port=MQTT_PORT,
                 user=MQTT_USER,
                 password=MQTT_PASSWORD,
-                keepalive=60,
+                keepalive=30,
             )
-            client_ref.set_last_will(T_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"])
             _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}")
@@ -605,15 +653,10 @@ def check_mqtt():
     return False
 
 
+
 def publish_discovery(client):
     """Publish all HA MQTT discovery payloads for gauges and LEDs."""
-    _dev_ref = {
+    _dev_ref = _DEVICE
-        "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]
@@ -639,6 +682,11 @@ 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(
@@ -677,6 +725,11 @@ 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(
@@ -696,14 +749,55 @@ def publish_discovery(client):
         )
         info(f"Discovery: gauge {i} backlight")
 
+        client.publish(
+            gt["status_red_disc"],
+            ujson.dumps(
+                {
+                    "name": f"{g['name']} Status Red",
+                    "uniq_id": f"{MQTT_CLIENT_ID}_g{i}_status_red",
+                    "cmd_t": gt["status_red"],
+                    "stat_t": gt["status_red_state"],
+                    "pl_on": "ON",
+                    "pl_off": "OFF",
+                    "icon": "mdi:led-on",
+                    "dev": _dev_ref,
+                    "ret": True,
+                }
+            ),
+            retain=True,
+        )
+        info(f"Discovery: gauge {i} status red")
+
+        client.publish(
+            gt["status_green_disc"],
+            ujson.dumps(
+                {
+                    "name": f"{g['name']} Status Green",
+                    "uniq_id": f"{MQTT_CLIENT_ID}_g{i}_status_green",
+                    "cmd_t": gt["status_green"],
+                    "stat_t": gt["status_green_state"],
+                    "pl_on": "ON",
+                    "pl_off": "OFF",
+                    "icon": "mdi:led-on",
+                    "dev": _dev_ref,
+                    "ret": True,
+                }
+            ),
+            retain=True,
+        )
+        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(round(val, 1)), retain=True)
+        client.publish(gt["state"], str(val))
-        client.publish(gt["status"], "online", retain=True)
-        info(f"Gauge {i} state: {val:.1f} step={g._current_step}")
 
 
 # ---------------------------------------------------------------------------
@@ -718,32 +812,52 @@ def main():
 
     connect_wifi(WIFI_SSID, WIFI_PASSWORD)
 
+    # 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")
 
-    connect_mqtt()
+    info("Publishing state...")
-    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("Entering main loop")
     info("-" * 48)
 
     try:
         import ota
-
         ota.mark_ok()
-        info("OTA OK flag set")
+    except:
-    except ImportError:
         pass
 
-    global _bl_dirty_since
+    # Initialize variables for main loop
     last_heartbeat = utime.ticks_ms()
+    now = 0
+    was_moving = False
 
     while True:
         try:
+            now = utime.ticks_ms()
+
             check_wifi()
 
             if not check_mqtt():
@@ -751,50 +865,33 @@ def main():
                 continue
 
             client_ref.check_msg()
+            _flush_backlight_state()
 
-            now = utime.ticks_ms()
+            pending = [g.steps_toward(gauge_targets[i],limit=50) for i, g in enumerate(gauge_objects)]
-
-            moved_any = False
-            for i, g in enumerate(gauge_objects):
-                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
 
+            moved_any = any(s != 0 for s in pending)
             if moved_any:
+                was_moving = True
                 delay_us = 1_000_000 // MICROSTEPS_PER_SECOND
-                utime.sleep_us(delay_us)
+                for tick in range(max(abs(s) for s in pending)):
-
-            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}")
+                        if tick < abs(pending[i]):
-                    saved = gauge_targets[i]
+                            g.step(1 if pending[i] > 0 else -1)
-                    g.zero()
+                    utime.sleep_us(delay_us)
-                    if saved > gauges[i]["min"]:
+            else:
-                        g.set(saved)
+                if was_moving:
-                    gauge_last_rezero[i] = now
                     publish_state(client_ref)
-                info("Auto-rezero complete")
+                    was_moving = False
-
+                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)
 

ota.py

@@ -82,31 +82,55 @@ OTA_MANIFEST  = "ota_manifest.txt"
 # Logging
 # ---------------------------------------------------------------------------
 
+
 def _ts():
     ms = utime.ticks_ms()
     return f"{(ms // 3600000) % 24:02d}:{(ms // 60000) % 60:02d}:{(ms // 1000) % 60:02d}.{ms % 1000:03d}"
 
-def _log(level, msg): print(f"[{_ts()}] {level:5s}  [OTA] {msg}")
+
-def info(msg):    _log("INFO",  msg)
+def _log(level, msg):
-def warn(msg):    _log("WARN",  msg)
+    print(f"[{_ts()}] {level:5s}  [OTA] {msg}")
-def log_err(msg): _log("ERROR", msg)
+
+
+def info(msg):
+    _log("INFO", msg)
+
+
+def warn(msg):
+    _log("WARN", msg)
+
+
+def log_err(msg):
+    _log("ERROR", msg)
+
 
 # ---------------------------------------------------------------------------
 # HTTP helpers
 # ---------------------------------------------------------------------------
 
+
 def _headers():
     h = {"Accept": "application/json"}
     if API_TOKEN:
         h["Authorization"] = f"token {API_TOKEN}"
     return h
 
+
 # ---------------------------------------------------------------------------
 # Config loader
 # ---------------------------------------------------------------------------
 
+
 def load_config():
-    global GITEA_BASE, REPO_OWNER, REPO_NAME, REPO_FOLDER, REPO_BRANCH, API_TOKEN, WIFI_SSID, WIFI_PASSWORD
+    global \
+        GITEA_BASE, \
+        REPO_OWNER, \
+        REPO_NAME, \
+        REPO_FOLDER, \
+        REPO_BRANCH, \
+        API_TOKEN, \
+        WIFI_SSID, \
+        WIFI_PASSWORD
     try:
         with open(SETTINGS_FILE) as f:
             cfg = ujson.load(f)
@@ -124,10 +148,12 @@ def load_config():
     except Exception as e:
         warn(f"Config parse error: {e} — using defaults")
 
+
 # ---------------------------------------------------------------------------
 # Helpers
 # ---------------------------------------------------------------------------
 
+
 def _match_pattern(name, pattern):
     if "*" not in pattern:
         return name == pattern
@@ -150,11 +176,9 @@ def _match_pattern(name, pattern):
         i += 1
     return i == n and j == m
 
+
 def _fetch_commit_sha():
-    url = (
+    url = f"{GITEA_BASE}/api/v1/repos/{REPO_OWNER}/{REPO_NAME}/branches/{REPO_BRANCH}"
-        f"{GITEA_BASE}/api/v1/repos/{REPO_OWNER}/{REPO_NAME}"
-        f"/branches/{REPO_BRANCH}"
-    )
     try:
         r = urequests.get(url, headers=_headers())
         if r.status_code == 200:
@@ -166,6 +190,7 @@ def _fetch_commit_sha():
         log_err(f"Failed to fetch commit: {e}")
     return None
 
+
 def _fetch_manifest():
     url = (
         f"{GITEA_BASE}/api/v1/repos/{REPO_OWNER}/{REPO_NAME}"
@@ -173,21 +198,24 @@ 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
+
                     content = ubinascii.a2b_base64(data["content"]).decode()
                     patterns = [line.strip() for line in content.splitlines()]
                     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}")
     return None
 
+
 def _fetch_dir(path):
     url = (
         f"{GITEA_BASE}/api/v1/repos/{REPO_OWNER}/{REPO_NAME}"
@@ -195,6 +223,7 @@ def _fetch_dir(path):
     )
     return _api_get(url)
 
+
 def _api_get(url):
     """GET a URL and return parsed JSON, or None on failure."""
     try:
@@ -209,6 +238,7 @@ def _api_get(url):
         log_err(f"GET {url} failed: {e}")
     return None
 
+
 def _download(url, dest_path):
     """Download url to dest_path. Returns True on success."""
     tmp = dest_path + ".tmp"
@@ -236,6 +266,7 @@ def _download(url, dest_path):
             pass
         return False
 
+
 def _load_manifest():
     try:
         with open(MANIFEST_FILE) as f:
@@ -243,6 +274,7 @@ def _load_manifest():
     except Exception:
         return {}
 
+
 def _save_manifest(manifest, commit_sha=None):
     try:
         with open(MANIFEST_FILE, "w") as f:
@@ -252,12 +284,7 @@ def _save_manifest(manifest, commit_sha=None):
     except Exception as e:
         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:
@@ -266,12 +293,14 @@ def _ok_flag_exists():
     except OSError:
         return False
 
+
 def _clear_ok_flag():
     try:
         os.remove(OK_FLAG_FILE)
     except OSError:
         pass
 
+
 def mark_ok():
     """
     Call this from main.py after successful startup.
@@ -283,10 +312,12 @@ def mark_ok():
     except Exception as e:
         warn(f"Could not write OK flag: {e}")
 
+
 # ---------------------------------------------------------------------------
 # Core update logic
 # ---------------------------------------------------------------------------
 
+
 def _fetch_file_list():
     """
     Returns list of {name, sha, download_url} dicts based on the
@@ -312,18 +343,18 @@ 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):
                         if entry["path"] not in visited:
                             visited.add(entry["path"])
-                            files.append({
+                            files.append(
+                                {
                                     "name": entry["path"],
                                     "sha": entry["sha"],
                                     "download_url": entry["download_url"],
-                            })
+                                }
+                            )
                         break
 
     root = _fetch_dir(REPO_FOLDER)
@@ -333,12 +364,15 @@ def _fetch_file_list():
     fetch_matching(root, manifest_patterns)
     return files
 
+
 def _do_update(commit_sha=None):
     """
     Fetch file list, download changed files, update manifest.
     Returns True if all succeeded (or nothing needed updating).
     """
-    info(f"Checking {GITEA_BASE}/{REPO_OWNER}/{REPO_NAME}/{REPO_FOLDER} @ {REPO_BRANCH}")
+    info(
+        f"Checking {GITEA_BASE}/{REPO_OWNER}/{REPO_NAME}/{REPO_FOLDER} @ {REPO_BRANCH}"
+    )
     file_list = _fetch_file_list()
     if file_list is None:
         log_err("Could not fetch file list — skipping update")
@@ -382,10 +416,12 @@ def _do_update(commit_sha=None):
 
     return True
 
+
 # ---------------------------------------------------------------------------
 # Public entry point
 # ---------------------------------------------------------------------------
 
+
 def update():
     """
     Main entry point. Call from boot.py before importing application code.
@@ -408,9 +444,7 @@ def update():
 
     if not ok_flag:
         warn("OK flag missing — last boot may have failed")
-        warn("Wiping manifest to force full re-fetch")
+        warn("Re-checking all files, will only download changed ones")
-        _wipe_manifest()
-        manifest = {}
     else:
         info("OK flag present — last boot was good")