Adrian A. Baumann
8bdae1da9b
- Replace gauge.py (MicroPython) references with gaugecontroller.yaml (ESPHome) - Update CLAUDE.md and README.md to document ESPHome-native API integration - Update LED wiring docs for separate main/indicator strips (D22/D36) - Refactor Arduino firmware to drive two WS2812 strips independently - Add per-gauge physical offset caching for main and indicator LEDs - Frame-limit breathe effect (16ms) to reduce unnecessary strip refreshes
324 lines
7.1 KiB
Markdown
324 lines
7.1 KiB
Markdown
# Rewire Checklist
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This is a practical rebuild checklist for the current integrated setup:
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- `Arduino Mega 2560`
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- `ESP32` running `gauge.py`
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- `HV5812P`
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- 4-digit VFD with decimal point and alarm bell
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- 3 gauge drivers
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- WS2812B LED chain
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Use this to rebuild the bench wiring from scratch.
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## 1. Power Off Everything
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- disconnect all power supplies
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- disconnect USB power if it is currently feeding any board
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- do not move wires while the VFD high-voltage supply is live
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## 2. Place The Main Parts
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- place the `Arduino Mega 2560`
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- place the `ESP32`
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- place the `HV5812P`
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- place the 3 gauge driver boards
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- place the WS2812B strip connection point
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- place the VFD tube connection point
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## 3. Establish A Common Ground First
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Before anything else, create one common logic ground network.
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Connect:
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- `Mega GND` -> ground rail
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- `ESP32 GND` -> same ground rail
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- `HV5812P GND` -> same ground rail
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- `Gauge driver 0 logic GND` -> same ground rail
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- `Gauge driver 1 logic GND` -> same ground rail
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- `Gauge driver 2 logic GND` -> same ground rail
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- `WS2812B GND` -> same ground rail
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If your VFD high-voltage supply has a ground/reference return:
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- `VFD HV supply return` -> same common ground rail
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Do not continue until this common ground is in place.
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## 4. Wire The Arduino Mega Power
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Connect:
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- regulated `5V logic supply` -> `Mega 5V`
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- ground rail -> `Mega GND`
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Do not use the Mega to power motors.
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## 5. Wire The ESP32 Power
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Power the ESP32 in the way your board expects.
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Typical options:
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- via board USB
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- via board `5V/VIN` if your ESP32 board has its own regulator
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- via regulated `3.3V` if it is a bare module that requires that
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Also connect:
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- `ESP32 GND` -> common ground rail
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Do not feed raw `5V` into a bare `3.3V-only` ESP32 module.
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## 6. Wire The ESP32 UART To The Mega
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Connect:
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- `ESP32 GPIO17 (TX)` -> `Mega pin 19 (RX1)`
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- `ESP32 GPIO16 (RX)` <- `Mega pin 18 (TX1)`
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- `ESP32 GND` -> `Mega GND`
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This UART link is used by `gauge.py`.
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## 7. Wire The HV5812P Logic Side
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Connect:
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- `Mega D46` -> `HV5812P DATA IN / DIN`
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- `Mega D47` -> `HV5812P CLOCK / CLK`
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- `Mega D48` -> `HV5812P STROBE / LATCH`
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- `Mega D49` -> `HV5812P BLANKING / OE`
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- `Mega 5V` -> `HV5812P VDD`
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- `Mega GND` -> `HV5812P GND`
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Do not connect:
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- `Mega 5V` -> `HV5812P VPP`
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## 8. Wire The HV5812P High-Voltage Side
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Connect:
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- `VFD high-voltage positive supply` -> `HV5812P VPP`
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- `VFD high-voltage supply return / reference` -> common ground rail
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At this stage:
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- `VDD` must be `5V`
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- `VPP` must be your VFD high-voltage rail
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## 9. Wire The HV5812P Outputs To The VFD
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Connect these one by one:
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- `HVOut1` -> VFD segment `A`
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- `HVOut2` -> VFD segment `B`
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- `HVOut3` -> VFD segment `C`
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- `HVOut4` -> VFD segment `D`
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- `HVOut5` -> VFD segment `E`
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- `HVOut6` -> VFD segment `F`
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- `HVOut7` -> VFD segment `G`
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- `HVOut8` -> VFD decimal point segment
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- `HVOut9` -> VFD alarm bell segment
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- `HVOut10` -> VFD digit 1 grid
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- `HVOut11` -> VFD digit 2 grid
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- `HVOut12` -> VFD digit 3 grid
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- `HVOut13` -> VFD digit 4 grid
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- `HVOut14` -> VFD indicator grid between digits 2 and 3
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## 10. Wire The VFD Filament
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Wire the VFD filament/heater exactly as required by your tube.
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This checklist cannot specify the exact filament supply because it depends on the actual tube.
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Required reminder:
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- do not power the filament from an Arduino GPIO
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- use the correct filament supply for the tube
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## 11. Wire Gauge Driver 0
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Connect:
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- `Mega D50` -> `Gauge driver 0 DIR`
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- `Mega D51` -> `Gauge driver 0 STEP`
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- `Mega GND` -> `Gauge driver 0 logic GND`
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Then connect the motor side of that driver to:
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- its motor power supply
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- its gauge motor
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according to the driver board you are using.
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## 12. Wire Gauge Driver 1
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Connect:
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- `Mega D8` -> `Gauge driver 1 DIR`
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- `Mega D9` -> `Gauge driver 1 STEP`
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- `Mega GND` -> `Gauge driver 1 logic GND`
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Then connect the motor side of that driver to:
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- its motor power supply
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- its gauge motor
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according to the driver board you are using.
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## 13. Wire Gauge Driver 2
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Connect:
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- `Mega D52` -> `Gauge driver 2 DIR`
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- `Mega D53` -> `Gauge driver 2 STEP`
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- `Mega GND` -> `Gauge driver 2 logic GND`
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Then connect the motor side of that driver to:
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- its motor power supply
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- its gauge motor
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according to the driver board you are using.
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## 14. Wire The WS2812 LEDs
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Connect:
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- `Mega D22` -> main backlight/status strip `DIN`
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- `Mega D36` -> indicator strip `DIN`
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- `5V LED supply` -> both strip `5V` inputs
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- both strip `GND` inputs -> common ground rail
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If the LED chain is long or bright:
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- do not power it from the Mega `5V`
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- use a proper external `5V` supply
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## 15. Verify The Pins That Changed For The Integrated VFD
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The VFD is no longer on the old standalone pins.
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Old standalone pins:
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- `D51` -> DATA
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- `D52` -> CLOCK
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- `D53` -> STROBE
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- `D49` -> BLANK
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Current integrated pins:
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- `D46` -> DATA
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- `D47` -> CLOCK
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- `D48` -> STROBE
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- `D49` -> BLANK
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So make sure:
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- nothing VFD-related is still on `D51`
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- nothing VFD-related is still on `D52`
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- nothing VFD-related is still on `D53`
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- only `BLANK/OE` remains on `D49`
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## 16. Sanity Check Before Powering Logic
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Check each item physically:
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- `Mega D46` really goes to `HV5812 DATA`
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- `Mega D47` really goes to `HV5812 CLOCK`
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- `Mega D48` really goes to `HV5812 STROBE`
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- `Mega D49` really goes to `HV5812 BLANKING`
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- `Mega D50/D51` only go to gauge driver 0
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- `Mega D8/D9` only go to gauge driver 1
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- `Mega D52/D53` only go to gauge driver 2
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- `Mega D22` only goes to WS2812B `DIN`
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- `ESP32 GPIO17` goes to `Mega RX1`
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- `ESP32 GPIO16` goes to `Mega TX1`
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- all grounds are common
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- `HV5812 VDD` is `5V`
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- `HV5812 VPP` is high voltage, not `5V`
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## 17. Power Logic Only First
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Apply only logic power first:
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- Mega power
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- ESP32 power
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- HV5812 `VDD`
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- WS2812 `5V`
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Leave motor supply and VFD high voltage off for the first check if possible.
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Verify:
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- Mega boots
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- ESP32 boots
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- UART communication works
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## 18. Power The VFD High Voltage
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Now apply the VFD high-voltage supply to `HV5812 VPP`.
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Verify:
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- `VDD` remains `5V`
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- `VPP` is the expected high voltage
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- no logic wire is heating
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## 19. Power The Gauge Drivers
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Now apply motor power to the gauge drivers.
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Verify:
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- no driver fault LEDs
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- no motor heating or runaway movement immediately on power-up
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## 20. First Functional Test
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Test in this order:
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1. confirm the ESP32 can talk to the Mega
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2. send `VFD 8888`
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3. send `VFD DEAD.!`
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4. test one gauge movement from Home Assistant or MQTT
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5. test one LED output
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## 21. If Something Is Wrong
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Use this triage order:
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1. check grounds
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2. check `VDD` and `VPP`
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3. check Mega pin number mistakes
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4. check crossed UART lines
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5. check that the VFD is still on `46/47/48/49`, not `51/52/53/49`
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## 22. Quick Reference
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### Mega pins in use
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- `D8` -> gauge 1 DIR
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- `D9` -> gauge 1 STEP
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- `D22` -> WS2812 DIN
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- `D46` -> HV5812 DATA
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- `D47` -> HV5812 CLOCK
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- `D48` -> HV5812 STROBE
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- `D49` -> HV5812 BLANKING
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- `D50` -> gauge 0 DIR
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- `D51` -> gauge 0 STEP
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- `D52` -> gauge 2 DIR
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- `D53` -> gauge 2 STEP
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- `D18` -> UART TX1 to ESP32 RX
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- `D19` -> UART RX1 from ESP32 TX
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### VFD outputs
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- `HVOut1..7` -> `A..G`
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- `HVOut8` -> decimal point
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- `HVOut9` -> alarm bell
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- `HVOut10..13` -> digit grids 1..4
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- `HVOut14` -> indicator grid
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