/* * psu_monitor_esp32.ino * TM-PWR-001 Rev A — Power Supply Monitor and Controller * * Hardware: ESP32-2432S028 (CYD) or ESP32-WROOM-32 + ILI9341 TFT * Sensors: INA219 (I2C 0x40/0x41), INA226 (I2C 0x45), ADS1115 (I2C 0x48) * JK BMS UART (GPIO16 RX, GPIO17 TX, 115200 baud) * Outputs: 4× relay GPIO (power sequencer), PWM fan control * Display: 2.8" 320×240 TFT via SPI (CYD built-in) * WiFi: Web server for remote monitoring and configuration * NVS: Energy accumulator (Wh), configuration, alarm thresholds */ #include #include #include #include #include #include #include #include #include #include // ─── Pin Assignments ───────────────────────────────────────────────────────── #define PIN_RELAY1 12 // Power sequencer relay 1 (PSU enable) #define PIN_RELAY2 13 // Power sequencer relay 2 (radio audio) #define PIN_RELAY3 14 // Power sequencer relay 3 (radio RF) #define PIN_RELAY4 15 // Power sequencer relay 4 (amplifier) #define PIN_FAN_PWM 26 // Fan speed control (PWM) #define PIN_ALERT_INA 35 // INA226 ALERT interrupt (active LOW) #define PIN_MPPT_PWM 25 // Optional: direct MPPT PWM output #define PIN_BMS_RX 16 // JK BMS UART receive #define PIN_BMS_TX 17 // JK BMS UART transmit (not used; BMS is one-way) #define PIN_BUZZER 32 // Piezo buzzer for alarms // CYD TFT backlight (CYD-specific — adjust for other boards) #define PIN_BL 21 // Backlight PWM (some CYD variants use 27) // ─── I2C Addresses ─────────────────────────────────────────────────────────── #define INA219_ADDR_IN 0x40 // Input / panel current sensor #define INA219_ADDR_OUT 0x41 // Output current sensor #define INA226_ADDR 0x45 // High-accuracy output (A0=VCC, A1=VCC) #define ADS1115_ADDR 0x48 // Temperature ADC // ─── Constants ─────────────────────────────────────────────────────────────── #define SHUNT_OHMS_IN 0.050f // Shunt for INA219 input channel #define SHUNT_OHMS_OUT 0.025f // Shunt for INA219 output channel #define NTC_R_REF 10000.0f #define NTC_B 3950.0f #define NTC_T0 298.15f #define V_SUPPLY 3.3f // Alarm thresholds (configurable via web) #define V_OV_DEFAULT 15.0f // Overvoltage trip (V) #define V_UV_DEFAULT 11.5f // Undervoltage trip (V) #define I_OC_DEFAULT 22.0f // Overcurrent trip (A) #define T_OT_DEFAULT 65.0f // Over-temperature trip (°C) #define T_FAN_ON 35.0f // Fan turn-on temperature (°C) #define T_FAN_FULL 55.0f // Fan full-speed temperature (°C) // ─── Display Dimensions ────────────────────────────────────────────────────── #define SCREEN_W 320 #define SCREEN_H 240 // ─── Global Objects ────────────────────────────────────────────────────────── TFT_eSPI tft; TFT_eSprite spr(&tft); Adafruit_INA219 ina_in(INA219_ADDR_IN); Adafruit_INA219 ina_out(INA219_ADDR_OUT); WebServer server(80); Preferences prefs; HardwareSerial bmsSerial(1); // UART1 for JK BMS // ─── Measurement Data ──────────────────────────────────────────────────────── struct PowerData { float v_in, i_in, p_in; // Input (panel or mains) measurements float v_out, i_out, p_out; // Output measurements float v_bat; // Battery pack voltage float temp_pass; // Pass element / MOSFET temperature (°C) float temp_bat; // Battery temperature (°C) float efficiency; // η = P_out / P_in × 100% float wh_in; // Wh in (from solar/mains) — accumulated float wh_out; // Wh out (to load) — accumulated unsigned long timestamp; // millis() of last update }; PowerData g_data = {}; float g_wh_in_accum = 0; float g_wh_out_accum = 0; unsigned long g_last_accum_ms = 0; // ─── BMS Data ───────────────────────────────────────────────────────────── struct BMSData { float cell_v[4]; // Individual cell voltages (V) float pack_v; // Pack voltage (V) float pack_i; // Pack current (A); negative = discharge float soc; // State of charge (%) float temp1, temp2; // BMS temperatures (°C) bool ov_fault; // Overvoltage fault flag bool uv_fault; // Undervoltage fault flag bool oc_fault; // Overcurrent fault flag bool valid; // True if recent valid packet received unsigned long last_rx_ms; // Timestamp of last valid packet }; BMSData g_bms = {}; uint8_t g_bms_buf[256]; int g_bms_len = 0; // ─── Alarm State ────────────────────────────────────────────────────────── struct AlarmConfig { float v_ov, v_uv, i_oc, t_ot; bool relay_on_ov, relay_on_oc; // True = de-energize relay on alarm }; AlarmConfig g_alarms = { V_OV_DEFAULT, V_UV_DEFAULT, I_OC_DEFAULT, T_OT_DEFAULT, true, true }; bool g_alarm_active = false; bool g_alarm_latched = false; // Requires manual reset via web // ─── Display Mode ───────────────────────────────────────────────────────── enum DisplayMode { DM_MAIN, DM_BATTERY, DM_SOLAR, DM_ALARM, DM_CONFIG }; DisplayMode g_disp_mode = DM_MAIN; unsigned long g_disp_rotate_ms = 0; #define DISP_ROTATE_INTERVAL 8000 // Auto-rotate screens every 8 s // ─── WiFi Config ────────────────────────────────────────────────────────── char g_ssid[64] = "FieldStation"; char g_password[64] = "hamradio"; // ─── Relay Sequencer State ──────────────────────────────────────────────── bool g_relays[4] = { false, false, false, false }; unsigned long g_relay_on_time[4] = { 0, 200, 500, 1000 }; // Sequence delay (ms) bool g_sequencer_active = false; // ───────────────────────────────────────────────────────────────────────────── // SETUP // ───────────────────────────────────────────────────────────────────────────── void setup() { Serial.begin(115200); Wire.begin(21, 22); bmsSerial.begin(115200, SERIAL_8N1, PIN_BMS_RX, PIN_BMS_TX); // Relay outputs for (int i = 0; i < 4; i++) { int pins[] = { PIN_RELAY1, PIN_RELAY2, PIN_RELAY3, PIN_RELAY4 }; pinMode(pins[i], OUTPUT); digitalWrite(pins[i], LOW); } // Fan PWM ledcSetup(0, 25000, 8); // Channel 0, 25 kHz, 8-bit (fan; above audible range) ledcAttachPin(PIN_FAN_PWM, 0); ledcWrite(0, 0); // Fan off initially // Alert interrupt pinMode(PIN_ALERT_INA, INPUT_PULLUP); attachInterrupt(digitalPinToInterrupt(PIN_ALERT_INA), isr_ina_alert, FALLING); // Buzzer pinMode(PIN_BUZZER, OUTPUT); digitalWrite(PIN_BUZZER, LOW); // TFT backlight pinMode(PIN_BL, OUTPUT); digitalWrite(PIN_BL, HIGH); // TFT init tft.init(); tft.setRotation(1); // Landscape tft.fillScreen(TFT_BLACK); spr.createSprite(SCREEN_W, SCREEN_H); // Sensor init if (!ina_in.begin()) { Serial.println("INA219 (input) not found"); } if (!ina_out.begin()) { Serial.println("INA219 (output) not found"); } ina_in.setCalibration_16V_400mA(); // Adjust for actual shunt value ina_out.setCalibration_16V_400mA(); // Adjust for actual shunt value // Load configuration from NVS prefs.begin("psu", false); g_wh_in_accum = prefs.getFloat("wh_in", 0.0f); g_wh_out_accum = prefs.getFloat("wh_out", 0.0f); g_alarms.v_ov = prefs.getFloat("v_ov", V_OV_DEFAULT); g_alarms.v_uv = prefs.getFloat("v_uv", V_UV_DEFAULT); g_alarms.i_oc = prefs.getFloat("i_oc", I_OC_DEFAULT); g_alarms.t_ot = prefs.getFloat("t_ot", T_OT_DEFAULT); strlcpy(g_ssid, prefs.getString("ssid", "FieldStation").c_str(), 64); strlcpy(g_password, prefs.getString("pass", "hamradio").c_str(), 64); prefs.end(); // WiFi WiFi.mode(WIFI_AP_STA); WiFi.softAP("PSU-Monitor", "hamradio"); // Always-on AP WiFi.begin(g_ssid, g_password); // Web server routes server.on("/", HTTP_GET, handle_root); server.on("/api/status", HTTP_GET, handle_api_status); server.on("/api/relay", HTTP_POST, handle_api_relay); server.on("/api/reset_alarm", HTTP_POST, handle_api_reset_alarm); server.on("/api/reset_energy", HTTP_POST, handle_api_reset_energy); server.on("/config", HTTP_GET, handle_config_get); server.on("/config", HTTP_POST, handle_config_post); server.begin(); Serial.println("PSU Monitor ready"); g_last_accum_ms = millis(); draw_splash(); delay(1500); } // ───────────────────────────────────────────────────────────────────────────── // MAIN LOOP // ───────────────────────────────────────────────────────────────────────────── void loop() { static unsigned long t_sensor_ms = 0; static unsigned long t_display_ms = 0; static unsigned long t_nvs_ms = 0; server.handleClient(); bms_receive(); unsigned long now = millis(); // Sensor poll: 500 ms if (now - t_sensor_ms >= 500) { t_sensor_ms = now; read_sensors(); accumulate_energy(); check_alarms(); update_fan(); update_relays(); } // Display update: 250 ms if (now - t_display_ms >= 250) { t_display_ms = now; if (now - g_disp_rotate_ms >= DISP_ROTATE_INTERVAL) { g_disp_rotate_ms = now; g_disp_mode = (DisplayMode)((g_disp_mode + 1) % 3); // Rotate main/battery/solar } draw_display(); } // NVS save: every 60 s if (now - t_nvs_ms >= 60000) { t_nvs_ms = now; save_energy_nvs(); } } // ───────────────────────────────────────────────────────────────────────────── // SENSOR READING // ───────────────────────────────────────────────────────────────────────────── void read_sensors() { // INA219 input channel g_data.v_in = ina_in.getBusVoltage_V() + (ina_in.getShuntVoltage_mV() / 1000.0f); g_data.i_in = ina_in.getCurrent_mA() / 1000.0f; g_data.p_in = g_data.v_in * g_data.i_in; // INA219 output channel g_data.v_out = ina_out.getBusVoltage_V() + (ina_out.getShuntVoltage_mV() / 1000.0f); g_data.i_out = ina_out.getCurrent_mA() / 1000.0f; g_data.p_out = g_data.v_out * g_data.i_out; // Efficiency if (g_data.p_in > 0.1f) { g_data.efficiency = (g_data.p_out / g_data.p_in) * 100.0f; } else { g_data.efficiency = 0; } // Temperature via ADS1115 channels 0 and 1 g_data.temp_pass = read_ntc_ads1115(0); g_data.temp_bat = read_ntc_ads1115(1); // Battery voltage from BMS or INA219 output if (g_bms.valid && (millis() - g_bms.last_rx_ms < 5000)) { g_data.v_bat = g_bms.pack_v; } else { g_data.v_bat = g_data.v_out; } g_data.timestamp = millis(); } // Read NTC thermistor via ADS1115 float read_ntc_ads1115(uint8_t channel) { // Write config register: single-shot, channel selection, ±4.096V, 128 SPS Wire.beginTransmission(ADS1115_ADDR); Wire.write(0x01); // Config register // MUX: channels 0=AIN0+GND(0x4000), 1=AIN1+GND(0x5000), etc. uint16_t mux = 0x4000 + (channel << 12); uint16_t config = mux | 0x0183; // ±4.096V, single-shot, 128 SPS config |= 0x8000; // OS bit = start conversion Wire.write((config >> 8) & 0xFF); Wire.write(config & 0xFF); Wire.endTransmission(); delay(9); // Wait for 128 SPS conversion (7.8 ms + margin) // Read conversion register Wire.beginTransmission(ADS1115_ADDR); Wire.write(0x00); // Conversion register Wire.endTransmission(); Wire.requestFrom(ADS1115_ADDR, (uint8_t)2); int16_t raw = ((int16_t)Wire.read() << 8) | Wire.read(); float v_adc = (raw / 32768.0f) * 4.096f; if (v_adc < 0) v_adc = 0; return ntc_temp(v_adc); } float ntc_temp(float v_adc) { if (v_adc <= 0.01f || v_adc >= (V_SUPPLY - 0.01f)) return -99.0f; // Sensor error float r_ntc = NTC_R_REF * v_adc / (V_SUPPLY - v_adc); float t_k = NTC_B / (NTC_B / NTC_T0 + log(r_ntc / NTC_R_REF)); return t_k - 273.15f; } // ───────────────────────────────────────────────────────────────────────────── // JK BMS UART PARSER // ───────────────────────────────────────────────────────────────────────────── /* * JK BMS protocol: frames begin with 0x4E 0x57, followed by frame length, * terminal number, command word, and data. Checksum is XOR of all bytes. * Reference: github.com/jblance/jkbms (open-source decoder) * * Simplified: parse the most common frame (0x4E 0x57 ... cell voltages, pack V, * current, SOC, temperature). */ void bms_receive() { while (bmsSerial.available()) { uint8_t b = bmsSerial.read(); if (g_bms_len == 0 && b != 0x4E) return; // Wait for frame start if (g_bms_len == 1 && b != 0x57) { g_bms_len = 0; return; } if (g_bms_len < 256) g_bms_buf[g_bms_len++] = b; if (g_bms_len >= 4) { // Byte 2 and 3 are frame length (big-endian) uint16_t frame_len = ((uint16_t)g_bms_buf[2] << 8) | g_bms_buf[3]; if (g_bms_len >= frame_len + 1) { bms_parse_frame(g_bms_buf, g_bms_len); g_bms_len = 0; } } } } void bms_parse_frame(uint8_t* buf, int len) { // Minimal JK BMS frame parser (cell info response, command 0x06) // Offset 11 onward: cell voltage records (2 bytes each, big-endian, mV) if (len < 20) return; // Check frame type: byte 10 should be 0x02 (cell info response) or 0x01 // Full protocol parsing omitted for brevity; parse key fields by offset: // Offsets below valid for JK BMS 24S frame; adjust for your version. // Cell voltages: offset 11, 2 bytes each, N_cells determined from frame uint8_t n_cells = buf[10]; // Number of cells (typically 4 for 4S) if (n_cells > 4) n_cells = 4; for (uint8_t i = 0; i < n_cells && i < 4; i++) { int ofs = 11 + i * 2; if (ofs + 1 < len) { g_bms.cell_v[i] = ((uint16_t)buf[ofs] << 8 | buf[ofs + 1]) / 1000.0f; } } // Pack voltage: after cell voltages int v_ofs = 11 + n_cells * 2; if (v_ofs + 1 < len) { g_bms.pack_v = ((uint16_t)buf[v_ofs] << 8 | buf[v_ofs + 1]) / 100.0f; } // Current: next 2 bytes (signed, 10 mA/bit) if (v_ofs + 3 < len) { int16_t raw_i = (int16_t)((uint16_t)buf[v_ofs + 2] << 8 | buf[v_ofs + 3]); g_bms.pack_i = raw_i / 100.0f; // Positive = charging } // SOC: next byte (%) if (v_ofs + 4 < len) { g_bms.soc = buf[v_ofs + 4]; } // Temperature: next 2 bytes (0.1°C/bit, offset 2731 = 0°C) if (v_ofs + 7 < len) { g_bms.temp1 = (((uint16_t)buf[v_ofs + 5] << 8 | buf[v_ofs + 6]) - 2731) / 10.0f; } g_bms.valid = true; g_bms.last_rx_ms = millis(); } // ───────────────────────────────────────────────────────────────────────────── // ENERGY ACCUMULATION // ───────────────────────────────────────────────────────────────────────────── void accumulate_energy() { unsigned long now = millis(); float dt_h = (now - g_last_accum_ms) / 3600000.0f; // Delta time in hours g_last_accum_ms = now; if (g_data.p_in > 0) g_wh_in_accum += g_data.p_in * dt_h; if (g_data.p_out > 0) g_wh_out_accum += g_data.p_out * dt_h; g_data.wh_in = g_wh_in_accum; g_data.wh_out = g_wh_out_accum; } void save_energy_nvs() { prefs.begin("psu", false); prefs.putFloat("wh_in", g_wh_in_accum); prefs.putFloat("wh_out", g_wh_out_accum); prefs.end(); } // ───────────────────────────────────────────────────────────────────────────── // ALARM CHECKING // ───────────────────────────────────────────────────────────────────────────── void check_alarms() { bool alarm = false; if (g_data.v_out > g_alarms.v_ov) alarm = true; // Overvoltage if (g_data.v_out < g_alarms.v_uv && g_data.v_out > 1.0f) alarm = true; // Undervoltage if (g_data.i_out > g_alarms.i_oc) alarm = true; // Overcurrent if (g_data.temp_pass > g_alarms.t_ot) alarm = true; // Over-temperature if (g_bms.valid) { if (g_bms.ov_fault || g_bms.uv_fault || g_bms.oc_fault) alarm = true; } if (alarm && !g_alarm_latched) { g_alarm_latched = true; g_alarm_active = true; tone_alarm(); if (g_alarms.relay_on_ov || g_alarms.relay_on_oc) { // De-energize all relays (failsafe — normally-closed contacts open load) for (int i = 0; i < 4; i++) { set_relay(i, false); } } } g_alarm_active = alarm; } void tone_alarm() { // Three short beeps for (int i = 0; i < 3; i++) { digitalWrite(PIN_BUZZER, HIGH); delay(100); digitalWrite(PIN_BUZZER, LOW); delay(100); } } // ISR for INA226 alert pin void IRAM_ATTR isr_ina_alert() { // Minimal ISR: just set a flag; main loop handles the alarm g_alarm_active = true; } // ───────────────────────────────────────────────────────────────────────────── // FAN CONTROL (thermal management) // ───────────────────────────────────────────────────────────────────────────── void update_fan() { float temp = max(g_data.temp_pass, g_data.temp_bat); uint8_t duty = 0; if (temp >= T_FAN_FULL) { duty = 255; } else if (temp >= T_FAN_ON) { duty = (uint8_t)(255.0f * (temp - T_FAN_ON) / (T_FAN_FULL - T_FAN_ON)); if (duty < 80) duty = 80; // Minimum duty to keep fan spinning } ledcWrite(0, duty); } // ───────────────────────────────────────────────────────────────────────────── // RELAY SEQUENCER // ───────────────────────────────────────────────────────────────────────────── void set_relay(int idx, bool on) { int pins[] = { PIN_RELAY1, PIN_RELAY2, PIN_RELAY3, PIN_RELAY4 }; if (idx < 0 || idx > 3) return; g_relays[idx] = on; digitalWrite(pins[idx], on ? HIGH : LOW); } void sequence_on() { g_sequencer_active = true; for (int i = 0; i < 4; i++) { delay(g_relay_on_time[i]); set_relay(i, true); } g_sequencer_active = false; } void sequence_off() { // Reverse order: amplifier first for (int i = 3; i >= 0; i--) { set_relay(i, false); delay(200); } } void update_relays() { // Nothing to do in main loop unless sequencer is running (handled in sequence_on/off) } // ───────────────────────────────────────────────────────────────────────────── // DISPLAY // ───────────────────────────────────────────────────────────────────────────── // Color palette #define C_BG TFT_BLACK #define C_TITLE 0x07FF // Cyan #define C_VALUE TFT_WHITE #define C_UNIT 0x8410 // Gray #define C_GOOD TFT_GREEN #define C_WARN TFT_YELLOW #define C_ALARM TFT_RED #define C_GRID 0x2104 // Dark gray void draw_display() { spr.fillSprite(C_BG); if (g_alarm_active && g_alarm_latched) { draw_alarm_screen(); } else { switch (g_disp_mode) { case DM_MAIN: draw_main_screen(); break; case DM_BATTERY: draw_battery_screen(); break; case DM_SOLAR: draw_solar_screen(); break; default: draw_main_screen(); break; } } spr.pushSprite(0, 0); } void draw_main_screen() { // Title bar spr.fillRect(0, 0, SCREEN_W, 24, C_TITLE); spr.setTextColor(TFT_BLACK); spr.setTextSize(2); spr.drawString("PSU MONITOR", 5, 4); // WiFi icon (top right) spr.setTextColor(WiFi.status() == WL_CONNECTED ? C_GOOD : C_WARN); spr.drawString("WiFi", 255, 4); // Large value display: V_out, I_out, P_out spr.setTextColor(C_UNIT); spr.setTextSize(1); spr.drawString("OUTPUT VOLTAGE", 5, 30); spr.drawString("OUTPUT CURRENT", 165, 30); // V_out spr.setTextColor(v_color(g_data.v_out)); spr.setTextSize(3); char buf[16]; snprintf(buf, sizeof(buf), "%5.2fV", g_data.v_out); spr.drawString(buf, 5, 42); // I_out snprintf(buf, sizeof(buf), "%5.2fA", g_data.i_out); spr.setTextColor(i_color(g_data.i_out)); spr.drawString(buf, 165, 42); // P_out (large) spr.setTextColor(C_UNIT); spr.setTextSize(1); spr.drawString("OUTPUT POWER", 5, 82); spr.setTextColor(C_VALUE); spr.setTextSize(3); snprintf(buf, sizeof(buf), "%6.1fW", g_data.p_out); spr.drawString(buf, 5, 94); // Efficiency spr.setTextColor(C_UNIT); spr.setTextSize(1); spr.drawString("EFFICIENCY", 200, 82); spr.setTextColor(C_VALUE); spr.setTextSize(2); snprintf(buf, sizeof(buf), "%4.1f%%", g_data.efficiency); spr.drawString(buf, 200, 95); // Bottom row: temperatures + relay status spr.drawFastHLine(0, 140, SCREEN_W, C_GRID); spr.setTextSize(1); spr.setTextColor(C_UNIT); spr.drawString("PASS TEMP", 5, 148); spr.drawString("BAT TEMP", 100, 148); spr.drawString("ENERGY IN", 195, 148); spr.setTextSize(2); snprintf(buf, sizeof(buf), "%3.0fC", g_data.temp_pass); spr.setTextColor(t_color(g_data.temp_pass)); spr.drawString(buf, 5, 160); snprintf(buf, sizeof(buf), "%3.0fC", g_data.temp_bat); spr.setTextColor(t_color(g_data.temp_bat)); spr.drawString(buf, 100, 160); snprintf(buf, sizeof(buf), "%5.1fWh", g_data.wh_in); spr.setTextColor(C_VALUE); spr.drawString(buf, 195, 160); // Relay status dots spr.drawString("RELAYS:", 5, 195); const char* rnames[] = { "PSU", "AUD", "RF ", "AMP" }; for (int i = 0; i < 4; i++) { spr.fillCircle(90 + i * 55, 201, 8, g_relays[i] ? C_GOOD : C_GRID); spr.setTextColor(C_VALUE); spr.drawString(rnames[i], 80 + i * 55, 215); } } void draw_battery_screen() { spr.fillRect(0, 0, SCREEN_W, 24, 0x0200); // Dark green header spr.setTextColor(TFT_WHITE); spr.setTextSize(2); spr.drawString("LIFEPO4 BATTERY", 5, 4); char buf[32]; if (!g_bms.valid || (millis() - g_bms.last_rx_ms > 5000)) { spr.setTextColor(C_WARN); spr.drawString("BMS not connected", 5, 50); spr.setTextColor(C_UNIT); spr.drawString("(Check UART wiring)", 5, 75); return; } // SOC bar spr.setTextColor(C_UNIT); spr.setTextSize(1); spr.drawString("STATE OF CHARGE", 5, 30); spr.setTextSize(3); spr.setTextColor(soc_color(g_bms.soc)); snprintf(buf, sizeof(buf), "%3.0f%%", g_bms.soc); spr.drawString(buf, 5, 42); // SOC bar graph int bar_w = (int)(g_bms.soc * 2.5f); // Max 250px at 100% spr.fillRect(5, 75, 250, 16, C_GRID); spr.fillRect(5, 75, bar_w, 16, soc_color(g_bms.soc)); // Pack voltage spr.setTextSize(1); spr.setTextColor(C_UNIT); spr.drawString("PACK V", 5, 98); spr.drawString("CURRENT", 100, 98); spr.setTextSize(2); snprintf(buf, sizeof(buf), "%5.2fV", g_bms.pack_v); spr.setTextColor(C_VALUE); spr.drawString(buf, 5, 110); snprintf(buf, sizeof(buf), "%+5.2fA", g_bms.pack_i); spr.setTextColor(g_bms.pack_i >= 0 ? C_GOOD : C_WARN); spr.drawString(buf, 100, 110); // Cell voltages (4 cells) spr.drawFastHLine(0, 135, SCREEN_W, C_GRID); spr.setTextColor(C_UNIT); spr.setTextSize(1); spr.drawString("CELL VOLTAGES", 5, 142); for (int i = 0; i < 4; i++) { float cv = g_bms.cell_v[i]; uint16_t cc = (cv > 3.55f) ? C_GOOD : (cv > 3.0f) ? C_VALUE : C_WARN; if (cv < 2.8f) cc = C_ALARM; spr.setTextColor(cc); spr.setTextSize(2); snprintf(buf, sizeof(buf), "C%d:%4.2fV", i + 1, cv); spr.drawString(buf, 5 + (i / 2) * 160, 155 + (i % 2) * 22); } // Temperature spr.drawFastHLine(0, 200, SCREEN_W, C_GRID); spr.setTextSize(1); spr.setTextColor(C_UNIT); spr.drawString("BMS T1:", 5, 208); spr.drawString("BMS T2:", 100, 208); spr.setTextColor(t_color(g_bms.temp1)); snprintf(buf, sizeof(buf), "%3.0fC", g_bms.temp1); spr.setTextSize(2); spr.drawString(buf, 55, 205); spr.setTextColor(t_color(g_bms.temp2)); snprintf(buf, sizeof(buf), "%3.0fC", g_bms.temp2); spr.drawString(buf, 150, 205); } void draw_solar_screen() { spr.fillRect(0, 0, SCREEN_W, 24, 0x6200); // Dark orange spr.setTextColor(TFT_WHITE); spr.setTextSize(2); spr.drawString("SOLAR MPPT", 5, 4); char buf[32]; spr.setTextSize(1); spr.setTextColor(C_UNIT); spr.drawString("PANEL VOLTAGE", 5, 30); spr.drawString("PANEL CURRENT", 165, 30); spr.setTextSize(3); spr.setTextColor(C_VALUE); snprintf(buf, sizeof(buf), "%5.1fV", g_data.v_in); spr.drawString(buf, 5, 42); snprintf(buf, sizeof(buf), "%4.2fA", g_data.i_in); spr.drawString(buf, 165, 42); spr.setTextSize(1); spr.setTextColor(C_UNIT); spr.drawString("PANEL POWER", 5, 82); spr.drawString("CHARGE POWER", 165, 82); spr.setTextSize(2); spr.setTextColor(C_GOOD); snprintf(buf, sizeof(buf), "%5.1fW", g_data.p_in); spr.drawString(buf, 5, 95); snprintf(buf, sizeof(buf), "%5.1fW", g_data.p_out); spr.drawString(buf, 165, 95); // Energy today spr.drawFastHLine(0, 120, SCREEN_W, C_GRID); spr.setTextSize(1); spr.setTextColor(C_UNIT); spr.drawString("ENERGY IN (session)", 5, 128); spr.drawString("ENERGY OUT (session)", 165, 128); spr.setTextSize(2); spr.setTextColor(C_VALUE); snprintf(buf, sizeof(buf), "%5.1fWh", g_data.wh_in); spr.drawString(buf, 5, 140); snprintf(buf, sizeof(buf), "%5.1fWh", g_data.wh_out); spr.drawString(buf, 165, 140); // Efficiency bar spr.setTextSize(1); spr.setTextColor(C_UNIT); spr.drawString("MPPT EFFICIENCY", 5, 168); int eff_w = (int)(g_data.efficiency * 2.5f); spr.fillRect(5, 180, 250, 14, C_GRID); spr.fillRect(5, 180, eff_w, 14, C_GOOD); spr.setTextColor(TFT_WHITE); spr.setTextSize(2); snprintf(buf, sizeof(buf), "%4.1f%%", g_data.efficiency); spr.drawString(buf, 255, 178); // Battery SOC spr.setTextSize(1); spr.setTextColor(C_UNIT); spr.drawString("BATTERY SOC:", 5, 205); spr.setTextSize(2); spr.setTextColor(g_bms.valid ? soc_color(g_bms.soc) : C_UNIT); snprintf(buf, sizeof(buf), g_bms.valid ? "%3.0f%%" : "---", g_bms.soc); spr.drawString(buf, 110, 202); } void draw_alarm_screen() { spr.fillScreen(C_ALARM); spr.setTextColor(TFT_WHITE); spr.setTextSize(3); spr.drawString("!! ALARM !!", 50, 30); spr.setTextSize(2); char buf[64]; int y = 70; if (g_data.v_out > g_alarms.v_ov) { snprintf(buf, sizeof(buf), "OVERVOLT: %4.2fV", g_data.v_out); spr.drawString(buf, 5, y); y += 25; } if (g_data.v_out < g_alarms.v_uv && g_data.v_out > 1.0f) { snprintf(buf, sizeof(buf), "UNDERVOLT: %4.2fV", g_data.v_out); spr.drawString(buf, 5, y); y += 25; } if (g_data.i_out > g_alarms.i_oc) { snprintf(buf, sizeof(buf), "OVERCURRENT: %4.2fA", g_data.i_out); spr.drawString(buf, 5, y); y += 25; } if (g_data.temp_pass > g_alarms.t_ot) { snprintf(buf, sizeof(buf), "OVER-TEMP: %3.0fC", g_data.temp_pass); spr.drawString(buf, 5, y); y += 25; } if (g_bms.valid && (g_bms.ov_fault || g_bms.uv_fault || g_bms.oc_fault)) { spr.drawString("BMS FAULT (see app)", 5, y); y += 25; } spr.setTextSize(1); spr.drawString("Use web UI to reset alarm", 5, 215); char ip[20]; snprintf(ip, sizeof(ip), "AP: 192.168.4.1", ""); spr.drawString(ip, 180, 215); } void draw_splash() { tft.fillScreen(TFT_BLACK); tft.setTextColor(TFT_CYAN); tft.setTextSize(3); tft.drawString("PSU MONITOR", 20, 60); tft.setTextColor(TFT_WHITE); tft.setTextSize(2); tft.drawString("TM-PWR-001 Rev A", 30, 100); tft.setTextColor(TFT_DARKGREY); tft.setTextSize(1); tft.drawString("Solar / Linear / LiFePO4", 60, 135); tft.drawString("Initializing...", 110, 155); } // Color helpers uint16_t v_color(float v) { if (v > g_alarms.v_ov || (v < g_alarms.v_uv && v > 1.0f)) return C_ALARM; if (v > 14.6f || v < 12.0f) return C_WARN; return C_GOOD; } uint16_t i_color(float i) { if (i > g_alarms.i_oc) return C_ALARM; if (i > g_alarms.i_oc * 0.8f) return C_WARN; return C_VALUE; } uint16_t t_color(float t) { if (t > g_alarms.t_ot) return C_ALARM; if (t > g_alarms.t_ot * 0.8f) return C_WARN; return C_GOOD; } uint16_t soc_color(float soc) { if (soc > 60) return C_GOOD; if (soc > 20) return C_WARN; return C_ALARM; } // ───────────────────────────────────────────────────────────────────────────── // WEB SERVER // ───────────────────────────────────────────────────────────────────────────── void handle_root() { String html = R"html( PSU Monitor

PSU Monitor — TM-PWR-001

Output

Voltage: --
Current: --
Power: --

Efficiency & Temp

Efficiency: --
Pass temp: --
Bat temp: --

Battery SOC

--
Wh in: --
Wh out: --

Alarm Status: OK

Power Sequencer



     

Configuration

)html"; server.send(200, "text/html", html); } void handle_api_status() { StaticJsonDocument<512> doc; doc["v_out"] = g_data.v_out; doc["i_out"] = g_data.i_out; doc["p_out"] = g_data.p_out; doc["v_in"] = g_data.v_in; doc["i_in"] = g_data.i_in; doc["p_in"] = g_data.p_in; doc["eff"] = g_data.efficiency; doc["temp_pass"] = g_data.temp_pass; doc["temp_bat"] = g_data.temp_bat; doc["wh_in"] = g_data.wh_in; doc["wh_out"] = g_data.wh_out; doc["alarm"] = g_alarm_active; doc["soc"] = g_bms.valid ? g_bms.soc : -1.0f; doc["bms_ok"] = g_bms.valid; for (int i = 0; i < 4; i++) doc["relay"][i] = g_relays[i]; String out; serializeJson(doc, out); server.send(200, "application/json", out); } void handle_api_relay() { if (!server.hasArg("relay") || !server.hasArg("state")) { server.send(400, "text/plain", "Missing args"); return; } String r = server.arg("relay"); bool on = server.arg("state") == "1"; if (r == "all") { if (on) sequence_on(); else sequence_off(); } else { int idx = r.toInt(); if (idx >= 0 && idx <= 3) set_relay(idx, on); } server.send(200, "text/plain", "OK"); } void handle_api_reset_alarm() { g_alarm_latched = false; g_alarm_active = false; server.send(200, "text/plain", "OK"); } void handle_api_reset_energy() { g_wh_in_accum = 0; g_wh_out_accum = 0; save_energy_nvs(); server.send(200, "text/plain", "OK"); } void handle_config_get() { char html[2048]; snprintf(html, sizeof(html), "PSU Config" "" "

PSU Configuration

" "
" "

WiFi

" "

" "

" "

Alarm Thresholds

" "

" "

" "

" "

" "" "

Back

" "", g_ssid, g_password, g_alarms.v_ov, g_alarms.v_uv, g_alarms.i_oc, g_alarms.t_ot); server.send(200, "text/html", html); } void handle_config_post() { if (server.hasArg("ssid")) strlcpy(g_ssid, server.arg("ssid").c_str(), 64); if (server.hasArg("pass")) strlcpy(g_password, server.arg("pass").c_str(), 64); if (server.hasArg("v_ov")) g_alarms.v_ov = server.arg("v_ov").toFloat(); if (server.hasArg("v_uv")) g_alarms.v_uv = server.arg("v_uv").toFloat(); if (server.hasArg("i_oc")) g_alarms.i_oc = server.arg("i_oc").toFloat(); if (server.hasArg("t_ot")) g_alarms.t_ot = server.arg("t_ot").toFloat(); prefs.begin("psu", false); prefs.putString("ssid", g_ssid); prefs.putString("pass", g_password); prefs.putFloat("v_ov", g_alarms.v_ov); prefs.putFloat("v_uv", g_alarms.v_uv); prefs.putFloat("i_oc", g_alarms.i_oc); prefs.putFloat("t_ot", g_alarms.t_ot); prefs.end(); WiFi.begin(g_ssid, g_password); server.sendHeader("Location", "/config"); server.send(303); } // ─── TFT_eSPI User_Setup.h required for CYD ───────────────────────────────── /* In User_Setup.h for ESP32-2432S028 (CYD): #define ILI9341_DRIVER #define TFT_MISO 12 #define TFT_MOSI 13 #define TFT_SCLK 14 #define TFT_CS 15 #define TFT_DC 2 #define TFT_RST -1 #define TOUCH_CS 33 #define TFT_BL 21 #define TFT_BACKLIGHT_ON HIGH #define LOAD_GLCD #define LOAD_FONT2 #define LOAD_FONT4 #define SPI_FREQUENCY 27000000 #define SPI_READ_FREQUENCY 20000000 #define SPI_TOUCH_FREQUENCY 2500000 */