Documented wiring and layout

2026-04-21 00:52:18 +02:00
parent 9f5deba0ed
commit 9912fe82cc
4 changed files with 1091 additions and 1 deletions
--- a/wiring.md
+++ b/wiring.md
@@ -0,0 +1,267 @@
+# Wiring
+
+This document describes the wiring required for the current integrated system:
+
+- `Arduino Mega 2560`
+- `HV5812P` VFD driver
+- 4-digit VFD tube with decimal point and alarm bell
+- 3 stepper-driven gauges
+- WS2812B LEDs
+- ESP32 running `gauge.py` as the MQTT / Home Assistant bridge
+
+It is intentionally based on the code that is in the repository now:
+
+- [Gaugecontroller.ino](/home/adebaumann/development/arduino_gauge_controller/Gaugecontroller/Gaugecontroller.ino:1)
+- [gauge.py](/home/adebaumann/development/arduino_gauge_controller/gauge.py:1)
+
+## System Power
+
+You effectively have three power domains:
+
+1. `5V logic`
+   for the Arduino Mega logic, the HV5812 logic side, and usually the step/dir logic inputs
+2. `high voltage for the VFD`
+   for `HV5812P VPP` and the VFD segment/grid drive
+3. `motor / actuator power`
+   for the stepper gauges and their driver hardware
+
+Minimum common rule:
+
+- all logic grounds must be common
+
+That means these must share `GND`:
+
+- Arduino Mega `GND`
+- ESP32 `GND`
+- HV5812P logic `GND`
+- stepper driver logic `GND`
+- WS2812B `GND`
+
+The VFD high-voltage supply still references the same ground, but its high-voltage nodes must never be connected directly to Arduino or ESP32 GPIO pins.
+
+## Arduino Mega 2560
+
+Use the Mega as the central logic controller.
+
+Power:
+
+- `Mega 5V` <- regulated `5V` logic supply
+- `Mega GND` <- common logic ground
+
+Serial bridge to ESP32:
+
+- `Mega RX1` pin `19` <- `ESP32 TX` GPIO `17`
+- `Mega TX1` pin `18` -> `ESP32 RX` GPIO `16`
+- `Mega GND` <-> `ESP32 GND`
+
+This matches the current code:
+
+- Arduino uses `Serial1` in [Gaugecontroller.ino](/home/adebaumann/development/arduino_gauge_controller/Gaugecontroller/Gaugecontroller.ino:12)
+- ESP32 uses `UART(1, tx=17, rx=16)` in [gauge.py](/home/adebaumann/development/arduino_gauge_controller/gauge.py:149)
+
+## VFD Control: Mega -> HV5812P
+
+These are the integrated pin assignments used by the merged controller:
+
+| Mega Pin | HV5812P Signal | Purpose |
+|---|---|---|
+| `D46` | `DATA IN / DIN` | serial data into HV5812P |
+| `D47` | `CLOCK / CLK` | shift clock |
+| `D48` | `STROBE / LATCH` | latch transfer |
+| `D49` | `BLANKING / OE` | output blanking |
+| `5V` | `VDD` | HV5812 logic supply |
+| `GND` | `GND` | common reference |
+| `VFD HV+` | `VPP` | HV5812 high-voltage rail |
+
+Important:
+
+- `VDD` is the low-voltage logic rail
+- `VPP` is the high-voltage output rail
+- do not connect Arduino `5V` to `VPP`
+
+## HV5812P -> VFD Tube
+
+The current output map is:
+
+| HV5812 Output | Tube Function |
+|---|---|
+| `HVOut1` | segment `A` |
+| `HVOut2` | segment `B` |
+| `HVOut3` | segment `C` |
+| `HVOut4` | segment `D` |
+| `HVOut5` | segment `E` |
+| `HVOut6` | segment `F` |
+| `HVOut7` | segment `G` |
+| `HVOut8` | decimal point segment |
+| `HVOut9` | alarm bell segment |
+| `HVOut10` | digit grid 1 |
+| `HVOut11` | digit grid 2 |
+| `HVOut12` | digit grid 3 |
+| `HVOut13` | digit grid 4 |
+| `HVOut14` | indicator grid between digits 2 and 3 |
+
+Logical segment layout:
+
+```text
+ ---A---
+|       |
+F       B
+|---G---|
+E       C
+|       |
+ ---D---
+```
+
+Additional VFD wiring notes:
+
+- the VFD filament/heater wiring is separate from the HV5812 outputs
+- the exact filament supply depends on your tube
+- the HV5812 only drives the segments and grids
+
+## Gauge Control Pins
+
+The current sketch drives three gauges.
+
+Each gauge needs a driver or actuator input that accepts:
+
+- `DIR`
+- `STEP`
+- optionally `ENABLE` if you later add one in code
+
+Current assignments:
+
+| Gauge | Mega DIR | Mega STEP |
+|---|---|---|
+| `Gauge 0` | `D50` | `D51` |
+| `Gauge 1` | `D8` | `D9` |
+| `Gauge 2` | `D52` | `D53` |
+
+Connect each pair to the matching stepper driver inputs.
+
+Example:
+
+- `Mega D50` -> Gauge 0 driver `DIR`
+- `Mega D51` -> Gauge 0 driver `STEP`
+- `Mega D8` -> Gauge 1 driver `DIR`
+- `Mega D9` -> Gauge 1 driver `STEP`
+- `Mega D52` -> Gauge 2 driver `DIR`
+- `Mega D53` -> Gauge 2 driver `STEP`
+
+Also connect:
+
+- `Mega GND` -> each driver logic ground
+
+If your driver boards need separate motor power, supply that from the proper motor supply. Do not power motors from the Mega `5V` pin.
+
+## WS2812B LED Strip
+
+The current sketch expects one shared WS2812B chain.
+
+| Mega Pin | WS2812B |
+|---|---|
+| `D22` | `DIN` |
+| `5V` | `5V` |
+| `GND` | `GND` |
+
+Notes:
+
+- the code expects `7 LEDs per gauge`, so `21 LEDs total`
+- use a proper 5V supply sized for the LED current
+- keep LED ground common with the Mega
+
+If the strip is powered from a separate 5V supply:
+
+- connect external `5V` -> LED `5V`
+- connect external `GND` -> LED `GND`
+- connect that same `GND` to `Mega GND`
+
+## ESP32 Bridge
+
+The ESP32 runs `gauge.py` and talks to the Mega over UART and to Home Assistant over MQTT/Wi-Fi.
+
+ESP32 to Mega:
+
+| ESP32 Pin | Mega Pin | Purpose |
+|---|---|---|
+| `GPIO17` | `RX1` pin `19` | ESP32 TX -> Mega RX |
+| `GPIO16` | `TX1` pin `18` | ESP32 RX <- Mega TX |
+| `GND` | `GND` | common ground |
+
+ESP32 power:
+
+- power the ESP32 from a proper `3.3V` or board-supported USB/5V input, depending on your board
+- do not feed raw `5V` into a bare `3.3V` ESP32 module unless the board has its own regulator
+
+## One-Page Wiring Summary
+
+### Power
+
+- `5V logic supply` -> Mega `5V`
+- `5V logic supply` -> HV5812 `VDD`
+- `5V logic supply` -> WS2812B `5V`
+- `motor supply` -> gauge driver motor power inputs
+- `VFD high-voltage supply` -> HV5812 `VPP`
+- all grounds common
+
+### Mega to ESP32
+
+- `Mega 19 (RX1)` <- `ESP32 GPIO17 (TX)`
+- `Mega 18 (TX1)` -> `ESP32 GPIO16 (RX)`
+- `Mega GND` <-> `ESP32 GND`
+
+### Mega to HV5812
+
+- `D46` -> `DIN`
+- `D47` -> `CLK`
+- `D48` -> `STROBE`
+- `D49` -> `BLANKING`
+- `5V` -> `VDD`
+- `GND` -> `GND`
+- `VFD HV+` -> `VPP`
+
+### HV5812 to Tube
+
+- `HVOut1..7` -> segments `A..G`
+- `HVOut8` -> decimal point
+- `HVOut9` -> alarm bell
+- `HVOut10..13` -> digit grids `1..4`
+- `HVOut14` -> indicator grid
+
+### Mega to Gauges
+
+- `D50/D51` -> gauge 0 `DIR/STEP`
+- `D8/D9` -> gauge 1 `DIR/STEP`
+- `D52/D53` -> gauge 2 `DIR/STEP`
+
+### Mega to LEDs
+
+- `D22` -> WS2812B `DIN`
+- `5V` -> WS2812B `5V`
+- `GND` -> WS2812B `GND`
+
+## Sanity Checklist Before Power-On
+
+- Mega, ESP32, HV5812 logic, LED strip, and driver logic grounds are all common
+- Mega `D46-D49` go to the HV5812, not to the gauge drivers
+- Mega `D50-D53` and `D8-D9` go only to the gauge drivers
+- HV5812 `VDD` is `5V`
+- HV5812 `VPP` is the VFD high-voltage rail, not `5V`
+- ESP32 UART is crossed correctly: TX -> RX, RX -> TX
+- WS2812B has its own adequate 5V supply if current draw is significant
+- motor power is not coming from the Mega
+
+## What This Does Not Define
+
+This document does not define:
+
+- the exact VFD filament supply voltage/current
+- the exact motor driver board power pins, because that depends on the driver hardware you are using
+- the physical PDIP package pin numbers of the HV5812P
+
+If you want, the next useful step is a second document with a literal bench-build checklist:
+
+- `wire 1 from Mega D46 to HV5812 pin ...`
+- `wire 2 from Mega D47 to HV5812 pin ...`
+- `wire 3 from ESP32 GPIO17 to Mega pin 19`
+
+That would be the most practical format for cleaning up the desk wiring.