various tidyups and esphome adds

2026-02-23 21:01:07 +13:00
parent 83e4040b84
commit 61b0c64a1e
28 changed files with 4052 additions and 3808 deletions
@@ -0,0 +1,595 @@
+##########################################################################################
+##########################################################################################
+# DATA CUPBOARD FAN CONTROL
+# Fan control for Data Cupboard
+#
+# Hardware: Yunshan 7-30V 10A Relay Board (HW-622) with ESP8266MOD
+#
+# V1.3 2026-02-20 Remove invalid allow_other_uses on pulse_counter pins (ESPHome 2026.2.x)
+# V1.2 2026-02-20 Use common SNTP package, and publish fan fault/status via interval script
+# V1.1 2026-02-20 Fix template binary_sensor update method for ESPHome 2026.2.x
+# V1.0 2026-02-20 Initial Version
+#
+# NOTES
+# - Fan tach inputs are on GPIO1/GPIO3 (UART pins). Logger UART is disabled (baud_rate: 0).
+# - DHT22 data is on GPIO0 (boot-strap pin). Usually OK, but if you ever get boot issues,
+#   move the DHT22 to a different GPIO if your board allows.
+# - Using common/sntp_common.yaml for time and diagnostic time text sensors.
+##########################################################################################
+##########################################################################################
+
+##########################################################################################
+# SPECIFIC DEVICE VARIABLE SUBSTITUTIONS
+##########################################################################################
+substitutions:
+  # Device Naming
+  device_name: "esp-datacupboardfans"
+  friendly_name: "Data Cupboard Fans"
+  description_comment: "Fan control for Data Cupboard"
+  device_area: "Data Cupboard"
+
+  # Project Naming
+  project_name: "Yunshan.HW-622 ESP8266MOD Relay Board"
+  project_version: "v1.3"
+
+  # Passwords
+  api_key: !secret esp-api_key
+  ota_pass: !secret esp-ota_pass
+  static_ip_address: !secret esp-datacupboardfans_ip
+  mqtt_command_main_topic: !secret mqtt_command_main_topic
+
+  # MQTT Controls
+  mqtt_device_name: "data-cupboard-fans"
+  mqtt_main_topic: "${mqtt_command_main_topic}/${mqtt_device_name}"
+
+  # Device Settings
+  log_level: "ERROR"
+  update_interval: "60s"
+
+  # Names
+  relay_name: "Data Cupboard Fans Relay"
+  override_name: "Override Fans On"
+  door_name: "Data Cupboard Door Status"
+  temp_name: "Data Cupboard Temperature"
+  hum_name: "Data Cupboard Humidity"
+  fan1_rpm_name: "Data Cupboard Fan1 RPM"
+  fan2_rpm_name: "Data Cupboard Fan2 RPM"
+  fan_status_name: "Data Cupboard Fan Status"
+
+  # Fan tach assumptions (typical PC fan = 2 pulses per revolution)
+  fan_pulses_per_rev: "2"
+
+  # Fault thresholds
+  rpm_min_when_relay_off: "950"
+  rpm_min_when_relay_on: "2300"
+
+  # Default thermostat thresholds
+  default_temp_on: "35"
+  default_temp_off: "28"
+
+##########################################################################################
+# PACKAGES: Included Common Packages
+##########################################################################################
+packages:
+  #### WIFI, Network (Static/DHCP/IPV6 etc), Fallback AP, Safemode ####
+  common_wifi: !include
+    file: common/network_common.yaml
+    vars:
+      local_device_name: "${device_name}"
+      local_static_ip_address: "${static_ip_address}"
+      local_ota_pass: "${ota_pass}"
+
+  #### HOME ASSISTANT API ####
+  common_api: !include
+    file: common/api_common.yaml
+    vars:
+      local_api_key: "${api_key}"
+
+  #### MQTT ####
+  common_mqtt: !include
+    file: common/mqtt_common.yaml
+    vars:
+      local_device_name: "${device_name}"
+
+  #### SNTP ####
+  common_sntp: !include
+    file: common/sntp_common.yaml
+
+  #### DIAGNOSTICS Sensors ####
+  diag_basic: !include common/include_basic_diag_sensors.yaml
+  diag_more: !include common/include_more_diag_sensors.yaml
+
+##########################################################################################
+# ESPHome
+##########################################################################################
+esphome:
+  name: "${device_name}"
+  friendly_name: "${friendly_name}"
+  comment: "${description_comment}"
+  area: "${device_area}"
+  project:
+    name: "${project_name}"
+    version: "${project_version}"
+  on_boot:
+    priority: -100
+    then:
+      - lambda: |-
+          id(boot_ms) = millis();
+          id(relay_last_change_ms) = millis();
+      - delay: 2s
+      - script.execute: apply_fan_control
+      - script.execute: evaluate_fan_fault
+
+##########################################################################################
+# ESP Platform and Framework
+##########################################################################################
+esp8266:
+  board: esp12e
+  restore_from_flash: true
+
+preferences:
+  flash_write_interval: 5min
+
+mdns:
+  disabled: false
+
+##########################################################################################
+# LOGGING
+##########################################################################################
+logger:
+  level: "${log_level}"
+  baud_rate: 0
+
+##########################################################################################
+# GLOBALS
+##########################################################################################
+globals:
+  # Max temperature tracking
+  - id: g_max_temp_today
+    type: float
+    restore_value: yes
+    initial_value: "-1000.0"
+  - id: g_max_temp_yesterday
+    type: float
+    restore_value: yes
+    initial_value: "-1000.0"
+  - id: g_max_temp_month
+    type: float
+    restore_value: yes
+    initial_value: "-1000.0"
+  - id: g_max_temp_last_month
+    type: float
+    restore_value: yes
+    initial_value: "-1000.0"
+  - id: g_max_temp_year
+    type: float
+    restore_value: yes
+    initial_value: "-1000.0"
+
+  # Last seen date parts (for rollover)
+  - id: g_last_day
+    type: int
+    restore_value: yes
+    initial_value: "0"
+  - id: g_last_month
+    type: int
+    restore_value: yes
+    initial_value: "0"
+  - id: g_last_year
+    type: int
+    restore_value: yes
+    initial_value: "0"
+
+  # Fault evaluation grace timing
+  - id: boot_ms
+    type: uint32_t
+    restore_value: no
+    initial_value: "0"
+  - id: relay_last_change_ms
+    type: uint32_t
+    restore_value: no
+    initial_value: "0"
+
+##########################################################################################
+# INTERVAL (periodic evaluations)
+# NOTE: common_sntp also defines its own interval (60s) for its fallback clock.
+##########################################################################################
+interval:
+  - interval: 5s
+    then:
+      - script.execute: evaluate_fan_fault
+
+##########################################################################################
+# SWITCHES (Relay + Override)
+##########################################################################################
+switch:
+  # Relay output (GPIO4) - powers both fans
+  - platform: gpio
+    name: "${relay_name}"
+    id: fan_relay
+    pin: GPIO4
+    restore_mode: RESTORE_DEFAULT_OFF
+    icon: "mdi:fan"
+    on_turn_on:
+      then:
+        - lambda: |-
+            id(relay_last_change_ms) = millis();
+        - script.execute: apply_fan_control
+        - script.execute: evaluate_fan_fault
+    on_turn_off:
+      then:
+        - lambda: |-
+            id(relay_last_change_ms) = millis();
+        - script.execute: apply_fan_control
+        - script.execute: evaluate_fan_fault
+
+  # Override switch (forces fans ON, bypasses thermostat logic)
+  - platform: template
+    name: "${override_name}"
+    id: override_fans_on
+    restore_mode: RESTORE_DEFAULT_OFF
+    optimistic: true
+    icon: "mdi:fan-plus"
+    entity_category: config
+    turn_on_action:
+      - switch.turn_on: fan_relay
+      - script.execute: apply_fan_control
+      - script.execute: evaluate_fan_fault
+    turn_off_action:
+      - script.execute: apply_fan_control
+      - script.execute: evaluate_fan_fault
+
+##########################################################################################
+# NUMBERS (On/Off thresholds with hysteresis)
+##########################################################################################
+number:
+  - platform: template
+    name: "Fans On Temperature"
+    id: temp_on_threshold
+    unit_of_measurement: "degC"
+    min_value: 25
+    max_value: 40
+    step: 0.5
+    mode: slider
+    restore_value: true
+    initial_value: ${default_temp_on}
+    optimistic: true
+    entity_category: config
+    icon: "mdi:thermometer-chevron-up"
+    set_action:
+      - script.execute: apply_fan_control
+
+  - platform: template
+    name: "Fans Off Temperature"
+    id: temp_off_threshold
+    unit_of_measurement: "degC"
+    min_value: 25
+    max_value: 40
+    step: 0.5
+    mode: slider
+    restore_value: true
+    initial_value: ${default_temp_off}
+    optimistic: true
+    entity_category: config
+    icon: "mdi:thermometer-chevron-down"
+    set_action:
+      - script.execute: apply_fan_control
+
+##########################################################################################
+# BINARY SENSORS (Door + Fault)
+##########################################################################################
+binary_sensor:
+  # Door status on GPIO5
+  - platform: gpio
+    name: "${door_name}"
+    id: door_status
+    device_class: door
+    pin:
+      number: GPIO5
+      mode: INPUT_PULLUP
+      inverted: false
+    filters:
+      - delayed_on: 50ms
+      - delayed_off: 50ms
+
+  # Fan fault boolean (published by script)
+  - platform: template
+    name: "Data Cupboard Fan Fault"
+    id: fan_fault
+    device_class: problem
+
+##########################################################################################
+# STATUS LED (GPIO2)
+##########################################################################################
+status_led:
+  pin:
+    number: GPIO2
+    inverted: true
+
+##########################################################################################
+# SENSORS (Temp/Humidity + Fan RPM + Max temp templates)
+##########################################################################################
+sensor:
+  # DHT22 on GPIO0
+  - platform: dht
+    pin: GPIO0
+    model: DHT22
+    update_interval: 30s
+    temperature:
+      name: "${temp_name}"
+      id: cupboard_temp
+      unit_of_measurement: "degC"
+      accuracy_decimals: 1
+      on_value:
+        then:
+          - script.execute: update_temp_maxima
+          - script.execute: apply_fan_control
+    humidity:
+      name: "${hum_name}"
+      id: cupboard_humidity
+      unit_of_measurement: "%"
+      accuracy_decimals: 1
+
+  # Fan1 tach pulses on GPIO1 (UART TX pin)
+  - platform: pulse_counter
+    pin:
+      number: GPIO1
+      mode: INPUT_PULLUP
+      inverted: false
+    id: fan1_rpm
+    name: "${fan1_rpm_name}"
+    unit_of_measurement: "rpm"
+    accuracy_decimals: 0
+    update_interval: 10s
+    count_mode:
+      rising_edge: DISABLE
+      falling_edge: INCREMENT
+    filters:
+      # pulse_counter is pulses/minute; typical PC fan tach = 2 pulses per revolution
+      - lambda: |-
+          return x / (float) ${fan_pulses_per_rev};
+      - clamp:
+          min_value: 0
+          max_value: 20000
+
+  # Fan2 tach pulses on GPIO3 (UART RX pin)
+  - platform: pulse_counter
+    pin:
+      number: GPIO3
+      mode: INPUT_PULLUP
+      inverted: false
+    id: fan2_rpm
+    name: "${fan2_rpm_name}"
+    unit_of_measurement: "rpm"
+    accuracy_decimals: 0
+    update_interval: 10s
+    count_mode:
+      rising_edge: DISABLE
+      falling_edge: INCREMENT
+    filters:
+      - lambda: |-
+          return x / (float) ${fan_pulses_per_rev};
+      - clamp:
+          min_value: 0
+          max_value: 20000
+
+  # Max temperature sensors (derived from cupboard_temp)
+  - platform: template
+    name: "Data Cupboard Max Temp Today"
+    id: max_temp_today
+    unit_of_measurement: "degC"
+    accuracy_decimals: 1
+    update_interval: 60s
+    lambda: |-
+      return id(g_max_temp_today);
+
+  - platform: template
+    name: "Data Cupboard Max Temp Yesterday"
+    id: max_temp_yesterday
+    unit_of_measurement: "degC"
+    accuracy_decimals: 1
+    update_interval: 60s
+    lambda: |-
+      return id(g_max_temp_yesterday);
+
+  - platform: template
+    name: "Data Cupboard Max Temp This Month"
+    id: max_temp_month
+    unit_of_measurement: "degC"
+    accuracy_decimals: 1
+    update_interval: 60s
+    lambda: |-
+      return id(g_max_temp_month);
+
+  - platform: template
+    name: "Data Cupboard Max Temp Last Month"
+    id: max_temp_last_month
+    unit_of_measurement: "degC"
+    accuracy_decimals: 1
+    update_interval: 60s
+    lambda: |-
+      return id(g_max_temp_last_month);
+
+  - platform: template
+    name: "Data Cupboard Max Temp This Year"
+    id: max_temp_year
+    unit_of_measurement: "degC"
+    accuracy_decimals: 1
+    update_interval: 60s
+    lambda: |-
+      return id(g_max_temp_year);
+
+##########################################################################################
+# TEXT SENSOR (Normal/Fault status) - published by script
+# NOTE: common_sntp also defines its own text_sensors (time status etc).
+##########################################################################################
+text_sensor:
+  - platform: template
+    name: "${fan_status_name}"
+    id: fan_status
+    icon: "mdi:fan-alert"
+
+##########################################################################################
+# SCRIPTS
+##########################################################################################
+script:
+  # Apply fan control logic (override + hysteresis thresholds)
+  - id: apply_fan_control
+    mode: queued
+    then:
+      - lambda: |-
+          const float t = id(cupboard_temp).state;
+          if (isnan(t)) {
+            return;
+          }
+
+          float on_t = id(temp_on_threshold).state;
+          float off_t = id(temp_off_threshold).state;
+
+          // Guard against bad settings (keep at least 0.5C hysteresis)
+          if (off_t >= on_t) {
+            off_t = on_t - 0.5f;
+          }
+
+          if (id(override_fans_on).state) {
+            if (!id(fan_relay).state) {
+              id(fan_relay).turn_on();
+            }
+            return;
+          }
+
+          // Hysteresis-based control
+          if (!id(fan_relay).state) {
+            if (t >= on_t) {
+              id(fan_relay).turn_on();
+            }
+          } else {
+            if (t <= off_t) {
+              id(fan_relay).turn_off();
+            }
+          }
+
+  # Evaluate and publish fan fault and status
+  - id: evaluate_fan_fault
+    mode: restart
+    then:
+      - lambda: |-
+          const uint32_t now_ms = millis();
+
+          // Grace window after boot / relay change to allow RPM to stabilize
+          const bool in_grace =
+            (now_ms - id(boot_ms) < 20000) ||
+            (now_ms - id(relay_last_change_ms) < 15000);
+
+          if (in_grace) {
+            id(fan_fault).publish_state(false);
+            id(fan_status).publish_state("Normal");
+            return;
+          }
+
+          const float r1 = id(fan1_rpm).state;
+          const float r2 = id(fan2_rpm).state;
+
+          if (isnan(r1) || isnan(r2)) {
+            id(fan_fault).publish_state(true);
+            id(fan_status).publish_state("Fault");
+            return;
+          }
+
+          const float req = id(fan_relay).state ? ${rpm_min_when_relay_on} : ${rpm_min_when_relay_off};
+
+          // Requirement as requested:
+          // - Relay OFF => both fans must be > 1800 RPM
+          // - Relay ON  => both fans must be > 3000 RPM
+          const bool fault = (r1 < req) || (r2 < req);
+
+          id(fan_fault).publish_state(fault);
+          id(fan_status).publish_state(fault ? "Fault" : "Normal");
+
+  # Update daily/monthly/yearly maxima based on current temperature and current date
+  - id: update_temp_maxima
+    mode: queued
+    then:
+      - lambda: |-
+          const float t = id(cupboard_temp).state;
+          if (isnan(t)) {
+            return;
+          }
+
+          auto now = id(sntp_time).now();
+          if (!now.is_valid()) {
+            // Time not valid yet: still track as rolling maxima
+            if (t > id(g_max_temp_today)) id(g_max_temp_today) = t;
+            if (t > id(g_max_temp_month)) id(g_max_temp_month) = t;
+            if (t > id(g_max_temp_year)) id(g_max_temp_year) = t;
+          } else {
+            // Initialize date tracking on first valid time
+            if (id(g_last_year) == 0) {
+              id(g_last_year) = now.year;
+              id(g_last_month) = now.month;
+              id(g_last_day) = now.day_of_month;
+
+              id(g_max_temp_today) = t;
+              id(g_max_temp_yesterday) = t;
+              id(g_max_temp_month) = t;
+              id(g_max_temp_last_month) = t;
+              id(g_max_temp_year) = t;
+            } else {
+              // Year rollover
+              if (now.year != id(g_last_year)) {
+                id(g_last_year) = now.year;
+                id(g_max_temp_year) = t;
+              }
+
+              // Month rollover
+              if (now.month != id(g_last_month)) {
+                id(g_max_temp_last_month) = id(g_max_temp_month);
+                id(g_max_temp_month) = t;
+                id(g_last_month) = now.month;
+              }
+
+              // Day rollover
+              if (now.day_of_month != id(g_last_day)) {
+                id(g_max_temp_yesterday) = id(g_max_temp_today);
+                id(g_max_temp_today) = t;
+                id(g_last_day) = now.day_of_month;
+              }
+
+              // Update running maxima
+              if (t > id(g_max_temp_today)) id(g_max_temp_today) = t;
+              if (t > id(g_max_temp_month)) id(g_max_temp_month) = t;
+              if (t > id(g_max_temp_year)) id(g_max_temp_year) = t;
+            }
+          }
+
+          // Publish template sensors promptly
+          id(max_temp_today).publish_state(id(g_max_temp_today));
+          id(max_temp_yesterday).publish_state(id(g_max_temp_yesterday));
+          id(max_temp_month).publish_state(id(g_max_temp_month));
+          id(max_temp_last_month).publish_state(id(g_max_temp_last_month));
+          id(max_temp_year).publish_state(id(g_max_temp_year));
+
+##########################################################################################
+# MQTT COMMANDS (device-specific)
+##########################################################################################
+mqtt:
+  on_message:
+    # Relay control
+    - topic: "${mqtt_main_topic}/relay/set"
+      payload: "ON"
+      then:
+        - switch.turn_on: fan_relay
+    - topic: "${mqtt_main_topic}/relay/set"
+      payload: "OFF"
+      then:
+        - switch.turn_off: fan_relay
+
+    # Override control
+    - topic: "${mqtt_main_topic}/override/set"
+      payload: "ON"
+      then:
+        - switch.turn_on: override_fans_on
+    - topic: "${mqtt_main_topic}/override/set"
+      payload: "OFF"
+      then:
+        - switch.turn_off: override_fans_on