""" gaugemqtt.py — MQTT-based gauge controller for ESP32 / MicroPython Deploy these files to the ESP32: 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) MQTT topics (all prefixed with mqtt_prefix from config.json): .../set ← HA publishes target value here .../state → ESP32 publishes current value .../status → ESP32 publishes online/offline .../zero ← publish anything to trigger zero .../led/red/set ← ON/OFF .../led/green/set ← ON/OFF .../led/backlight/set ← 0-100 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 from gauge_vid6008 import Gauge # --------------------------------------------------------------------------- # 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} {msg}") _DEBUG = False def info(msg): if _DEBUG: log("INFO", msg) def warn(msg): log("WARN", msg) def log_err(msg): log("ERROR", msg) # --------------------------------------------------------------------------- # Configuration # --------------------------------------------------------------------------- def _load_config(): try: with open("/config.json") as f: cfg = ujson.load(f) info("Config loaded from /config.json") return cfg except OSError: log_err("config.json not found — cannot continue") raise except Exception as e: log_err(f"config.json parse error: {e} — cannot continue") raise _cfg = _load_config() DEBUG = _cfg.get("debug", False) _DEBUG = DEBUG WIFI_SSID = _cfg["wifi_ssid"] WIFI_PASSWORD = _cfg["wifi_password"] MQTT_BROKER = _cfg["mqtt_broker"] MQTT_PORT = int(_cfg.get("mqtt_port", 1883)) MQTT_USER = _cfg["mqtt_user"] MQTT_PASSWORD = _cfg["mqtt_password"] MQTT_CLIENT_ID = _cfg["mqtt_client_id"] MQTT_PREFIX = _cfg["mqtt_prefix"] MICROSTEPS_PER_SECOND = int(_cfg.get("microsteps_per_second", 600)) HEARTBEAT_MS = int(_cfg.get("heartbeat_ms", 10000)) 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")) DEVICE_MODEL = device_cfg.get( "model", _cfg.get("device_model", "Chernobyl Selsyn-inspired gauge") ) DEVICE_MFR = device_cfg.get( "manufacturer", _cfg.get("device_manufacturer", "AdeBaumann") ) DEVICE_AREA = device_cfg.get("area", _cfg.get("device_area", "Control Panels")) gauges = [] if "gauges" in _cfg: for i, g in enumerate(_cfg["gauges"]): led_cfg = g.get("leds", {}) gauges.append( { "id": i, "name": g.get("name", f"Gauge {i + 1}"), "pins": tuple(g.get("pins", [12, 13])), "mode": g.get("mode", "stepdir"), "min": float(g.get("min", 0)), "max": float(g.get("max", 100)), "step_us": int(g.get("step_us", 200)), "entity_name": g.get("entity_name", f"Gauge {i + 1}"), "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: gauges.append( { "id": 0, "name": "Gauge 1", "pins": tuple(_cfg.get("gauge_pins", [12, 13])), "mode": _cfg.get("gauge_mode", "stepdir"), "min": float(_cfg.get("gauge_min", 0)), "max": float(_cfg.get("gauge_max", 7300)), "step_us": int(_cfg.get("gauge_step_us", 200)), "entity_name": _cfg.get("gauge_entity_name", "Selsyn 1 Power"), "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 # --------------------------------------------------------------------------- gauge_objects = [] for g in gauges: gauge_objects.append( Gauge( pins=g["pins"], mode=g["mode"], min_val=g["min"], max_val=g["max"], step_us=g["step_us"], ) ) info( f"Gauge {g['id']}: {g['name']} pins={g['pins']} mode={g['mode']} range=[{g['min']}, {g['max']}]" ) gauge_targets = [g["min"] for g in gauges] # target value per gauge gauge_last_rezero = [utime.ticks_ms() for _ in gauges] # --------------------------------------------------------------------------- # Topics (per-gauge) # --------------------------------------------------------------------------- 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", } 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_RESET_DISCOVERY = f"{MQTT_PREFIX}/resetdiscovery" 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" _DEVICE = { "identifiers": [MQTT_CLIENT_ID], "name": DEVICE_NAME, "model": DEVICE_MODEL, "manufacturer": DEVICE_MFR, "suggested_area": DEVICE_AREA, } # --------------------------------------------------------------------------- # 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) _wifi_sta.active(True) if _wifi_sta.isconnected(): ip, mask, gw, dns = _wifi_sta.ifconfig() info("WiFi already connected") info(f" IP:{ip} mask:{mask} gw:{gw} dns:{dns}") return ip info(f"WiFi connecting to '{ssid}' ...") _wifi_sta.connect(ssid, password) deadline = utime.time() + timeout_s while not _wifi_sta.isconnected(): if utime.time() > deadline: log_err(f"WiFi connect timeout after {timeout_s}s") raise OSError("WiFi connect timeout") utime.sleep_ms(200) ip, mask, gw, dns = _wifi_sta.ifconfig() mac = ":".join(f"{b:02x}" for b in _wifi_sta.config("mac")) info("WiFi connected!") info(f" SSID : {ssid}") info(f" MAC : {mac}") info(f" IP : {ip} mask:{mask} gw:{gw} dns:{dns}") return ip def check_wifi(): 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 _last_wifi_check = now if _wifi_sta is None: _wifi_sta = network.WLAN(network.STA_IF) if _wifi_sta.isconnected(): return log_err("WiFi lost connection — attempting reconnect...") try: _wifi_sta.active(True) _wifi_sta.connect(WIFI_SSID, WIFI_PASSWORD) deadline = utime.time() + 15 while not _wifi_sta.isconnected(): if utime.time() > deadline: log_err("WiFi reconnect timeout") return utime.sleep_ms(200) ip, mask, gw, dns = _wifi_sta.ifconfig() info(f"WiFi reconnected! IP:{ip}") except Exception as e: log_err(f"WiFi reconnect failed: {e}") 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) 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)] _bl_dirty_since = None _BL_SAVE_DELAY_MS = 5000 def _publish(topic, payload, retain=False): """Safely publish MQTT message, returning True on success.""" if client_ref is None: return False try: client_ref.publish(topic, payload, retain=retain) return True except Exception as e: log_err(f"MQTT publish failed: {e}") return False # --------------------------------------------------------------------------- # MQTT callbacks # --------------------------------------------------------------------------- def on_message(topic, payload): global backlight_brightness, backlight_color if client_ref is None: return topic = topic.decode() payload = payload.decode().strip() info(f"MQTT rx {topic} {payload}") for i, gt in enumerate(gauge_topics): if topic == gt["zero"]: info(f"Zero command received for gauge {i}") gauge_objects[i].zero() gauge_last_rezero[i] = utime.ticks_ms() info(f"Zero complete gauge {i}") return if topic == gt["set"]: g = gauges[i] try: gauge_targets[i] = max(g["min"], min(g["max"], float(payload))) info(f"Gauge {i} target → {gauge_targets[i]:.1f}") except ValueError: 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 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 if topic == T_RESET_DISCOVERY: info("Reset discovery triggered") try: import uos uos.remove(".discovery_ok") info("Discovery flag file removed") except: pass import machine machine.reset() 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) _publish(gt["led_red_state"], "ON" if state else "OFF", retain=True) info(f"Gauge {i} red LED → {'ON' if state else 'OFF'}") return if topic == gt["led_green"]: state = payload.upper() == "ON" leds_green[i].value(1 if state else 0) _publish(gt["led_green_state"], "ON" if state else "OFF", retain=True) info(f"Gauge {i} green LED → {'ON' if state else 'OFF'}") return if topic == gt["led_bl"]: try: data = ujson.loads(payload) if data.get("state", "ON").upper() == "OFF": set_backlight_brightness(i, 0) _publish( gt["led_bl_state"], ujson.dumps({"state": "OFF"}), retain=True ) info(f"Gauge {i} backlight → OFF") return color = data.get("color", {}) r = max(0, min(255, int(color.get("r", backlight_color[i][0])))) g = max(0, min(255, int(color.get("g", backlight_color[i][1])))) b = max(0, min(255, int(color.get("b", backlight_color[i][2])))) raw_br = data.get("brightness", None) if raw_br is not None: brightness = max(0, min(100, round(int(raw_br) / 2.55))) elif backlight_brightness[i] > 0: brightness = backlight_brightness[i] else: brightness = 100 except Exception as e: warn(f"Invalid backlight payload for gauge {i}: '{payload}' ({e})") return set_backlight_color(i, r, g, b, brightness) state = { "state": "ON", "color_mode": "rgb", "brightness": int(brightness * 2.55), "color": {"r": r, "g": g, "b": b}, } _publish(gt["led_bl_state"], ujson.dumps(state), retain=True) 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 # --------------------------------------------------------------------------- # MQTT connect + discovery # --------------------------------------------------------------------------- def connect_mqtt(): global client_ref, _mqtt_connected info(f"Connecting to MQTT broker {MQTT_BROKER}:{MQTT_PORT} ...") client = MQTTClient( client_id=MQTT_CLIENT_ID, server=MQTT_BROKER, port=MQTT_PORT, user=MQTT_USER, password=MQTT_PASSWORD, keepalive=30, ) # 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 # Subscriptions def _subscribe_all(c): c.subscribe("#") _subscribe_all(client) _mqtt_connected = True info(f"MQTT connected client_id={MQTT_CLIENT_ID}") _mqtt_check_interval_ms = 30000 _last_mqtt_check = 0 def check_mqtt(): global client_ref, _mqtt_connected, _last_mqtt_check now = utime.ticks_ms() if utime.ticks_diff(now, _last_mqtt_check) < _mqtt_check_interval_ms: return _mqtt_connected _last_mqtt_check = now if client_ref is None: return False try: client_ref.ping() _mqtt_connected = True return True except Exception as e: log_err(f"MQTT connection lost: {e}") _mqtt_connected = False # Try to reconnect log_err("Attempting MQTT reconnection...") for attempt in range(3): try: client_ref = MQTTClient( client_id=MQTT_CLIENT_ID, server=MQTT_BROKER, port=MQTT_PORT, user=MQTT_USER, password=MQTT_PASSWORD, keepalive=60, ) client_ref.set_last_will(T_STATUS, b"offline", retain=True, qos=0) client_ref.set_callback(on_message) client_ref.connect() _subscribe_all(client_ref) _mqtt_connected = True info("MQTT reconnected!") publish_discovery(client_ref) publish_state(client_ref) return True except Exception as e2: log_err(f"MQTT reconnect attempt {attempt + 1} failed: {e2}") utime.sleep_ms(2000) log_err("MQTT reconnection failed after 3 attempts") return False def publish_discovery(client): """Publish all HA MQTT discovery payloads for gauges and LEDs.""" _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] client.publish( gt["disc"], ujson.dumps( { "name": g["entity_name"], "unique_id": f"{MQTT_CLIENT_ID}_g{i}", "cmd_t": gt["set"], "stat_t": gt["state"], "avty_t": gt["status"], "min": g["min"], "max": g["max"], "step": 1, "unit_of_meas": g["unit"], "icon": "mdi:gauge", "dev": _dev_ref, } ), retain=True, ) info(f"Discovery: gauge {i} ({g['name']})") # Process MQTT messages between publishes client.check_msg() utime.sleep_ms(30) client.publish( gt["led_red_disc"], ujson.dumps( { "name": f"{g['name']} Red LED", "uniq_id": f"{MQTT_CLIENT_ID}_g{i}_red", "cmd_t": gt["led_red"], "stat_t": gt["led_red_state"], "pl_on": "ON", "pl_off": "OFF", "icon": "mdi:led-on", "dev": _dev_ref, "ret": True, } ), retain=True, ) info(f"Discovery: gauge {i} red LED") client.publish( gt["led_green_disc"], ujson.dumps( { "name": f"{g['name']} Green LED", "uniq_id": f"{MQTT_CLIENT_ID}_g{i}_green", "cmd_t": gt["led_green"], "stat_t": gt["led_green_state"], "pl_on": "ON", "pl_off": "OFF", "icon": "mdi:led-on", "dev": _dev_ref, "ret": True, } ), retain=True, ) 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( { "name": f"{g['name']} Backlight", "uniq_id": f"{MQTT_CLIENT_ID}_g{i}_bl", "cmd_t": gt["led_bl"], "stat_t": gt["led_bl_state"], "schema": "json", "supported_color_modes": ["rgb"], "icon": "mdi:led-strip", "dev": _dev_ref, "ret": True, } ), retain=True, ) 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") 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["status"], "online", retain=True) info(f"Gauge {i} state: {val:.1f} step={g._current_step}") # --------------------------------------------------------------------------- # Main # --------------------------------------------------------------------------- def main(): info("=" * 48) info("Gauge MQTT controller starting") info("=" * 48) connect_wifi(WIFI_SSID, WIFI_PASSWORD) # Check if we need to publish discovery try: with open(".discovery_ok", "r") as f: discovery_published = f.read() info("Discovery flag file exists, skipping discovery") discovery_published = True except: info("No discovery flag file - publishing discovery") discovery_published = False # Connect MQTT first (needed for discovery) connect_mqtt() # Give MQTT time to process subscriptions info("Processing initial MQTT messages...") for i in range(50): client_ref.check_msg() utime.sleep_ms(20) info("Done with initial processing") # Publish discovery if needed (before gauge initialization) if not discovery_published: info("Publishing discovery...") publish_discovery(client_ref) # Write flag file try: with open(".discovery_ok", "w") as f: f.write("ok") info("Discovery flag file created") except Exception as e: warn(f"Could not write discovery flag: {e}") info("Discovery published, resetting...") import machine machine.reset() # 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("Publishing state...") 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) # Initialize variables for main loop last_heartbeat = utime.ticks_ms() now = 0 while True: try: now = utime.ticks_ms() check_wifi() if not check_mqtt(): utime.sleep_ms(1000) continue client_ref.check_msg() 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 if moved_any: delay_us = 1_000_000 // MICROSTEPS_PER_SECOND utime.sleep_us(delay_us) else: utime.sleep_ms(10) if utime.ticks_diff(utime.ticks_ms(), last_heartbeat) > 10000: info(f"Heartbeat: {gauge_targets}") last_heartbeat = utime.ticks_ms() if utime.ticks_diff(now, last_heartbeat) >= HEARTBEAT_MS: 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) main()