jazzymc
2f783dbc41
3-zone PWM fan controller (intake/central/outtake) with DS18B20 temp sensors, RPM monitoring, ST7789 LCD display, and Home Assistant integration via ESPHome native API. USB-C PD powered. Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
527 lines
14 KiB
YAML
527 lines
14 KiB
YAML
substitutions:
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device_name: rack-fan-ctrl
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friendly_name: "Rack Fan Controller"
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# Temperature thresholds (Celsius)
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temp_min: "28.0" # Below this: minimum fan speed
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temp_low: "35.0" # Ramp midpoint
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temp_high: "42.0" # Ramp to max
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temp_crit: "50.0" # Emergency: 100% + alert
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# Fan duty limits (0.0 - 1.0)
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fan_min_duty: "0.20"
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fan_max_duty: "1.0"
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# Outtake offset (extra duty for negative pressure)
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outtake_offset: "0.05"
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# GPIO assignments - Waveshare ESP32-C6 LCD 1.47"
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pin_pwm_intake: GPIO0
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pin_pwm_central: GPIO1
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pin_pwm_outtake: GPIO2
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pin_tach_intake: GPIO3
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pin_tach_central: GPIO10
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pin_tach_outtake: GPIO11
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pin_onewire: GPIO9
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# LCD pins (Waveshare ESP32-C6 LCD 1.47" defaults)
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pin_lcd_mosi: GPIO6
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pin_lcd_clk: GPIO7
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pin_lcd_cs: GPIO14
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pin_lcd_dc: GPIO15
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pin_lcd_rst: GPIO21
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pin_lcd_bl: GPIO22
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esphome:
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name: ${device_name}
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friendly_name: ${friendly_name}
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on_boot:
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priority: -100
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then:
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- output.set_level:
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id: lcd_backlight
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level: 80%
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- switch.turn_on: auto_mode
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esp32:
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board: esp32-c6-devkitc-1
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framework:
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type: esp-idf
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logger:
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level: INFO
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api:
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encryption:
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key: !secret api_encryption_key
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ota:
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- platform: esphome
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password: !secret ota_password
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wifi:
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ssid: !secret wifi_ssid
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password: !secret wifi_password
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ap:
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ssid: "${device_name}-fallback"
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password: "rackfan123"
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captive_portal:
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# --- SPI bus (shared by LCD) ---
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spi:
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clk_pin: ${pin_lcd_clk}
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mosi_pin: ${pin_lcd_mosi}
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# --- LCD Backlight ---
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output:
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- platform: ledc
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pin: ${pin_lcd_bl}
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id: lcd_backlight
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frequency: 1000Hz
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# --- Fan PWM outputs (25kHz per Intel 4-pin spec) ---
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- platform: ledc
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pin: ${pin_pwm_intake}
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id: pwm_intake
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frequency: 25000Hz
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- platform: ledc
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pin: ${pin_pwm_central}
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id: pwm_central
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frequency: 25000Hz
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- platform: ledc
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pin: ${pin_pwm_outtake}
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id: pwm_outtake
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frequency: 25000Hz
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# --- 1-Wire bus for DS18B20 sensors ---
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one_wire:
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- platform: gpio
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pin: ${pin_onewire}
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# --- Temperature sensors ---
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sensor:
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# DS18B20 sensors - addresses auto-discovered on first boot
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# After first boot, check logs for addresses and pin them here
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- platform: dallas_temp
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name: "Rack Temp Intake"
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id: temp_intake
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update_interval: 5s
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filters:
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- sliding_window_moving_average:
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window_size: 3
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send_every: 1
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- platform: dallas_temp
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name: "Rack Temp Central"
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id: temp_central
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update_interval: 5s
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filters:
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- sliding_window_moving_average:
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window_size: 3
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send_every: 1
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- platform: dallas_temp
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name: "Rack Temp Outtake"
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id: temp_outtake
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update_interval: 5s
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filters:
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- sliding_window_moving_average:
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window_size: 3
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send_every: 1
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# Fan tachometer (RPM) - 2 pulses per revolution
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- platform: pulse_counter
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pin:
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number: ${pin_tach_intake}
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mode:
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input: true
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pullup: true
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name: "Rack Fan RPM Intake"
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id: rpm_intake
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update_interval: 5s
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count_mode:
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rising_edge: INCREMENT
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falling_edge: DISABLE
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filters:
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- multiply: 0.5 # 2 pulses per rev -> divide by 2
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- multiply: 12 # per-5s count * 12 = per-minute
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- platform: pulse_counter
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pin:
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number: ${pin_tach_central}
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mode:
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input: true
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pullup: true
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name: "Rack Fan RPM Central"
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id: rpm_central
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update_interval: 5s
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count_mode:
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rising_edge: INCREMENT
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falling_edge: DISABLE
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filters:
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- multiply: 0.5
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- multiply: 12
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- platform: pulse_counter
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pin:
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number: ${pin_tach_outtake}
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mode:
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input: true
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pullup: true
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name: "Rack Fan RPM Outtake"
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id: rpm_outtake
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update_interval: 5s
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count_mode:
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rising_edge: INCREMENT
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falling_edge: DISABLE
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filters:
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- multiply: 0.5
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- multiply: 12
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# Computed fan duty percentages (for display and HA)
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- platform: template
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name: "Rack Fan Duty Intake"
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id: duty_intake
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unit_of_measurement: "%"
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accuracy_decimals: 0
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update_interval: 5s
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- platform: template
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name: "Rack Fan Duty Central"
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id: duty_central
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unit_of_measurement: "%"
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accuracy_decimals: 0
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update_interval: 5s
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- platform: template
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name: "Rack Fan Duty Outtake"
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id: duty_outtake
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unit_of_measurement: "%"
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accuracy_decimals: 0
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update_interval: 5s
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# WiFi signal for diagnostics
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- platform: wifi_signal
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name: "Rack Controller WiFi"
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update_interval: 60s
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# --- Auto/Manual mode switch ---
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switch:
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- platform: template
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name: "Rack Fan Auto Mode"
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id: auto_mode
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optimistic: true
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restore_mode: RESTORE_DEFAULT_ON
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# --- Configurable setpoints from HA ---
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number:
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- platform: template
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name: "Rack Target Temp"
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id: target_temp
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min_value: 20
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max_value: 50
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step: 1
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initial_value: 35
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optimistic: true
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unit_of_measurement: "C"
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restore_value: true
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- platform: template
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name: "Rack Fan Min Duty"
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id: min_duty
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min_value: 0
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max_value: 100
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step: 5
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initial_value: 20
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optimistic: true
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unit_of_measurement: "%"
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restore_value: true
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- platform: template
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name: "Rack Fan Max Duty"
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id: max_duty
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min_value: 20
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max_value: 100
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step: 5
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initial_value: 100
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optimistic: true
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unit_of_measurement: "%"
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restore_value: true
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# --- Binary sensor for overheat alert ---
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binary_sensor:
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- platform: template
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name: "Rack Overheat Alert"
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id: overheat_alert
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device_class: heat
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lambda: |-
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if (!id(temp_central).has_state()) return false;
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return id(temp_central).state >= ${temp_crit};
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# --- Fan control automation ---
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interval:
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- interval: 5s
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then:
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- lambda: |-
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if (!id(auto_mode).state) return;
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// Get max temperature from all sensors (use central as primary)
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float temp = 0;
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int count = 0;
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if (id(temp_intake).has_state()) { temp += id(temp_intake).state; count++; }
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if (id(temp_central).has_state()) { temp += id(temp_central).state; count++; }
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if (id(temp_outtake).has_state()) { temp += id(temp_outtake).state; count++; }
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// Use central temp if available, otherwise average
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if (id(temp_central).has_state()) {
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temp = id(temp_central).state;
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} else if (count > 0) {
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temp = temp / count;
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} else {
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// No sensors reporting - run at 50% as safety
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auto call_i = id(pwm_intake).make_call();
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call_i.set_level(0.5);
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call_i.perform();
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auto call_c = id(pwm_central).make_call();
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call_c.set_level(0.5);
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call_c.perform();
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auto call_o = id(pwm_outtake).make_call();
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call_o.set_level(0.55);
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call_o.perform();
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return;
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}
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// Get configurable limits
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float d_min = id(min_duty).state / 100.0;
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float d_max = id(max_duty).state / 100.0;
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float t_target = id(target_temp).state;
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// Calculate duty: linear ramp from min to max
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// Ramp starts 7C below target, reaches max at 8C above target
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float t_start = t_target - 7.0;
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float t_end = t_target + 8.0;
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float duty = 0;
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if (temp <= t_start) {
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duty = d_min;
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} else if (temp >= t_end) {
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duty = d_max;
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} else {
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duty = d_min + (d_max - d_min) * (temp - t_start) / (t_end - t_start);
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}
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// Clamp
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if (duty < d_min) duty = d_min;
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if (duty > 1.0) duty = 1.0;
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// Outtake runs slightly faster for negative pressure
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float outtake_duty = duty + ${outtake_offset};
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if (outtake_duty > 1.0) outtake_duty = 1.0;
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// Apply PWM
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auto call_i = id(pwm_intake).make_call();
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call_i.set_level(duty);
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call_i.perform();
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auto call_c = id(pwm_central).make_call();
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call_c.set_level(duty);
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call_c.perform();
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auto call_o = id(pwm_outtake).make_call();
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call_o.set_level(outtake_duty);
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call_o.perform();
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// Update duty sensors for HA / display
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id(duty_intake).publish_state(duty * 100.0);
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id(duty_central).publish_state(duty * 100.0);
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id(duty_outtake).publish_state(outtake_duty * 100.0);
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# --- Display (Waveshare ESP32-C6 1.47" ST7789 172x320) ---
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font:
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- file: "gfonts://Roboto"
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id: font_title
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size: 18
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glyphs: "ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz0123456789 .:%/-"
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- file: "gfonts://Roboto"
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id: font_value
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size: 28
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glyphs: "0123456789.C%RPM "
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- file: "gfonts://Roboto"
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id: font_label
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size: 14
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glyphs: "ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz0123456789 .:%/-"
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- file: "gfonts://Roboto"
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id: font_small
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size: 11
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glyphs: "ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz0123456789 .:%/-"
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color:
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- id: color_white
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white: 100%
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- id: color_bg
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red: 10%
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green: 10%
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blue: 15%
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- id: color_blue
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red: 30%
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green: 60%
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blue: 100%
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- id: color_cyan
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red: 0%
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green: 90%
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blue: 90%
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- id: color_green
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red: 20%
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green: 90%
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blue: 20%
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- id: color_yellow
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red: 100%
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green: 90%
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blue: 0%
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- id: color_orange
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red: 100%
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green: 60%
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blue: 0%
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- id: color_red
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red: 100%
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green: 20%
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blue: 20%
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- id: color_gray
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red: 50%
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green: 50%
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blue: 50%
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display:
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- platform: st7789v
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id: lcd
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cs_pin: ${pin_lcd_cs}
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dc_pin: ${pin_lcd_dc}
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reset_pin: ${pin_lcd_rst}
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model: Custom
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width: 172
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height: 320
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offset_height: 34
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offset_width: 0
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eightbitcolor: false
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update_interval: 2s
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rotation: 0
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lambda: |-
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// Background
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it.fill(id(color_bg));
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// Title bar
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it.filled_rectangle(0, 0, 172, 24, id(color_blue));
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it.printf(86, 3, id(font_title), id(color_white), TextAlign::TOP_CENTER, "RACK FANS");
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// Helper: pick color based on temperature
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auto temp_color = [&](float t) -> Color {
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if (t < 28) return id(color_green);
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if (t < 35) return id(color_cyan);
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if (t < 42) return id(color_yellow);
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if (t < 50) return id(color_orange);
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return id(color_red);
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};
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// Helper: pick color based on duty
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auto duty_color = [&](float d) -> Color {
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if (d < 30) return id(color_green);
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if (d < 60) return id(color_cyan);
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if (d < 80) return id(color_yellow);
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return id(color_orange);
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};
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int y = 30;
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int section_h = 90;
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// --- INTAKE ZONE ---
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it.printf(6, y, id(font_label), id(color_blue), "INTAKE");
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y += 16;
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if (id(temp_intake).has_state()) {
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float t = id(temp_intake).state;
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it.printf(6, y, id(font_value), temp_color(t), "%.1fC", t);
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} else {
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it.printf(6, y, id(font_value), id(color_gray), "--.-C");
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}
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y += 30;
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if (id(rpm_intake).has_state()) {
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it.printf(6, y, id(font_label), id(color_white), "%.0f RPM", id(rpm_intake).state);
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}
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if (id(duty_intake).has_state()) {
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it.printf(166, y, id(font_label), duty_color(id(duty_intake).state), TextAlign::TOP_RIGHT, "%.0f%%", id(duty_intake).state);
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}
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y += 18;
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// Separator
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it.horizontal_line(10, y, 152, id(color_gray));
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y += 6;
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// --- CENTRAL ZONE ---
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it.printf(6, y, id(font_label), id(color_blue), "CENTRAL");
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y += 16;
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if (id(temp_central).has_state()) {
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float t = id(temp_central).state;
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it.printf(6, y, id(font_value), temp_color(t), "%.1fC", t);
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} else {
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it.printf(6, y, id(font_value), id(color_gray), "--.-C");
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}
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y += 30;
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if (id(rpm_central).has_state()) {
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it.printf(6, y, id(font_label), id(color_white), "%.0f RPM", id(rpm_central).state);
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}
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if (id(duty_central).has_state()) {
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it.printf(166, y, id(font_label), duty_color(id(duty_central).state), TextAlign::TOP_RIGHT, "%.0f%%", id(duty_central).state);
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}
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y += 18;
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// Separator
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it.horizontal_line(10, y, 152, id(color_gray));
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y += 6;
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// --- OUTTAKE ZONE ---
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it.printf(6, y, id(font_label), id(color_blue), "OUTTAKE");
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y += 16;
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if (id(temp_outtake).has_state()) {
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float t = id(temp_outtake).state;
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it.printf(6, y, id(font_value), temp_color(t), "%.1fC", t);
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} else {
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it.printf(6, y, id(font_value), id(color_gray), "--.-C");
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}
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y += 30;
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if (id(rpm_outtake).has_state()) {
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it.printf(6, y, id(font_label), id(color_white), "%.0f RPM", id(rpm_outtake).state);
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}
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if (id(duty_outtake).has_state()) {
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it.printf(166, y, id(font_label), duty_color(id(duty_outtake).state), TextAlign::TOP_RIGHT, "%.0f%%", id(duty_outtake).state);
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}
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y += 22;
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// --- STATUS BAR ---
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it.horizontal_line(0, y, 172, id(color_blue));
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y += 4;
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// Auto/Manual mode indicator
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if (id(auto_mode).state) {
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it.printf(6, y, id(font_small), id(color_green), "AUTO");
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} else {
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it.printf(6, y, id(font_small), id(color_yellow), "MANUAL");
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}
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// WiFi indicator
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if (WiFi.isConnected()) {
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it.printf(166, y, id(font_small), id(color_green), TextAlign::TOP_RIGHT, "WiFi OK");
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} else {
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it.printf(166, y, id(font_small), id(color_red), TextAlign::TOP_RIGHT, "NO WiFi");
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}
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// Overheat warning
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if (id(overheat_alert).state) {
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it.filled_rectangle(30, 140, 112, 30, id(color_red));
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it.printf(86, 143, id(font_title), id(color_white), TextAlign::TOP_CENTER, "OVERHEAT!");
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}
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