84a0668c54
Complete IoT monitoring platform for Acuvim II power meters via ESP32. Firmware (Phases 1-7): - ESP32-WROVER-B (TTGO T-Call v1.4) with RS485 Modbus RTU - WiFi STA+AP concurrent mode with GSM/GPRS failover - Transport abstraction layer with 4 priority modes - MQTT protocol with 20 commands, LWT, QoS, exponential backoff - SD card offline buffering with JSONL rotation and non-blocking drain - OTA firmware updates with dual partition rollback protection - Watchdog timer, crash loop detection, Acuvim health monitoring - Captive portal provisioning with AP mode Console backend (Phase 8): - .NET 10 minimal API with PostgreSQL + EF Core - JWT authentication, SignalR real-time updates - MQTTnet 5.x bridge service with health monitoring - Device, telemetry, firmware, alert, group management - Rate limiting, security headers, Swagger/OpenAPI Frontend (Phase 9): - React 18 + TypeScript + Vite with Ant Design 5 - ECharts telemetry visualization, TanStack Query - SignalR live updates, device management UI - Dashboard, fleet management, firmware deployment Testing & Production (Phase 10): - 28 firmware unit tests (Modbus, JSON, config, version) - 23 xUnit backend tests (device, telemetry, command, alert) - Docker Compose with nginx, TLS MQTT, PostgreSQL - Production deployment, commissioning, and troubleshooting docs Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
247 lines
11 KiB
Markdown
247 lines
11 KiB
Markdown
# Hardware Wiring Guide
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Wiring diagrams for ESP32 TTGO T-Call v1.4 with RS485 Modbus connection to Acuvim II power meter, optional SD card module, and GSM antenna.
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---
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## ESP32 TTGO T-Call v1.4 Pinout (Relevant Pins)
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```
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┌──────────────┐
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│ TTGO T-Call │
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│ v1.4 │
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3V3 ───┤ 3V3 VIN ├─── 5V
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GND ───┤ GND GND ├─── GND
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┤ GPIO36 GPIO23├─── SPI MOSI (SD)
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┤ GPIO39 GPIO22├───
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┤ GPIO34 GPIO1 ├─── TX0 (USB Serial)
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┤ GPIO35 GPIO3 ├─── RX0 (USB Serial)
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┤ GPIO32 GPIO21├───
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┤ GPIO33 GPIO19├─── SPI MISO (SD)
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┤ GPIO25 GPIO18├─── SPI SCK (SD)
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RS485 DE/RE ───┤ GPIO4 GPIO5 ├─── SD CS
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┤ GPIO0 GPIO17├─── TX2 (RS485 DI)
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┤ GPIO2 GPIO16├─── RX2 (RS485 RO)
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┤ GPIO15 GPIO14├───
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┤ GPIO13 GPIO12├───
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└──────────────┘
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Built-in SIM800L: GPIO26 (TX), GPIO27 (RX)
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Built-in SIM slot on bottom of board
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```
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**Note:** The TTGO T-Call v1.4 has SIM800L built into the board. No external GSM module wiring is needed.
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---
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## RS485 Module Connection (MAX485 / MAX3485)
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Connect the ESP32 to an RS485 transceiver module, then to the Acuvim II.
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### Wiring Table
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| RS485 Module Pin | ESP32 Pin | Description |
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|------------------|-----------|-------------|
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| DI (Data In) | GPIO17 (TX2) | UART2 transmit |
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| RO (Receiver Out) | GPIO16 (RX2) | UART2 receive |
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| DE (Driver Enable) | GPIO4 | Direction control |
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| RE (Receiver Enable) | GPIO4 | Direction control (active low, tied to DE) |
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| VCC | 3.3V | Power supply |
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| GND | GND | Ground |
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| A | Acuvim II A (+) | RS485 bus positive |
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| B | Acuvim II B (-) | RS485 bus negative |
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### Wiring Diagram
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```
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ESP32 TTGO T-Call MAX485 Module Acuvim II
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┌─────────────────┐ ┌──────────────┐ ┌────────────┐
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│ │ │ │ │ │
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│ GPIO17 (TX2) ───┼──────────┤ DI A ├──────────┤ A (+) │
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│ │ │ │ │ │
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│ GPIO16 (RX2) ───┼──────────┤ RO B ├──────────┤ B (-) │
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│ │ │ │ │ │
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│ GPIO4 ──────────┼────┬─────┤ DE │ │ GND ───────┤
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│ │ └─────┤ RE │ │ │
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│ │ │ │ │ │
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│ 3V3 ───────────┼──────────┤ VCC │ │ │
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│ │ │ │ │ │
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│ GND ───────────┼──────────┤ GND │ │ │
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│ │ │ │ │ │
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└─────────────────┘ └──────────────┘ └────────────┘
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```
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**DE and RE tied together:** GPIO4 drives both pins. HIGH = transmit mode, LOW = receive mode. The firmware toggles this automatically during Modbus transactions.
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---
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## Acuvim II RS485 Terminal Block
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The Acuvim II has an RS485 terminal block on the bottom of the meter.
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```
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Acuvim II Bottom Terminal Block
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┌─────────────────────────────────┐
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│ ... │ A (+) │ B (-) │ GND │ ...│
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└─────────────────────────────────┘
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```
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- **A (+):** Connect to MAX485 module A pin
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- **B (-):** Connect to MAX485 module B pin
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- **GND:** Connect to common ground with ESP32
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### Acuvim II Modbus Settings
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Configure on the meter's front panel:
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- **Protocol:** Modbus RTU
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- **Address:** 1 (default, configurable 1-247)
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- **Baud Rate:** 9600 (default, configurable)
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- **Parity:** None
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- **Stop Bits:** 1
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---
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## SD Card Module Connection (Optional)
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For offline buffering, connect a standard SPI SD card module.
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| SD Module Pin | ESP32 Pin | Description |
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|---------------|-----------|-------------|
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| MOSI | GPIO23 | SPI Master Out Slave In |
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| MISO | GPIO19 | SPI Master In Slave Out |
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| SCK | GPIO18 | SPI Clock |
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| CS | GPIO5 | Chip Select |
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| VCC | 3.3V | Power (use 3.3V modules only) |
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| GND | GND | Ground |
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```
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ESP32 TTGO T-Call SD Card Module
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┌─────────────────┐ ┌──────────────┐
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│ │ │ │
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│ GPIO23 (MOSI) ──┼──────────┤ MOSI 3V3 ├─── 3V3
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│ │ │ │
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│ GPIO19 (MISO) ──┼──────────┤ MISO GND ├─── GND
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│ │ │ │
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│ GPIO18 (SCK) ───┼──────────┤ SCK │
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│ │ │ │
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│ GPIO5 (CS) ─────┼──────────┤ CS │
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│ │ │ │
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└─────────────────┘ └──────────────┘
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```
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Use a micro SD card formatted as FAT32. The firmware creates the `/telemetry/` directory on first use.
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---
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## SIM Card Insertion
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The TTGO T-Call v1.4 has a SIM card slot on the bottom of the board.
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```
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Bottom of TTGO T-Call v1.4
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┌─────────────────────────────┐
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│ │
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│ ┌─────────────────┐ │
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│ │ SIM Card Slot │ │
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│ │ (micro SIM) │ │
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│ │ Insert with │ │
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│ │ contacts DOWN │ │
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│ └─────────────────┘ │
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│ │
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└─────────────────────────────┘
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```
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- Use a **micro SIM** (not nano — use adapter if needed)
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- Insert with contacts facing **down** toward the PCB
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- SIM must have data plan enabled
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- SIM PIN must be disabled (or configure PIN in firmware)
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---
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## GSM Antenna
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The TTGO T-Call v1.4 has an IPX (U.FL) connector for the GSM antenna.
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- Attach the supplied GSM antenna to the IPX connector
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- For better signal in metal enclosures, use an external antenna with SMA connector and IPX-to-SMA pigtail
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- Position antenna away from the ESP32 and RS485 module to reduce interference
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---
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## Power Supply
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### USB Power (Development)
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Connect micro-USB cable to the TTGO T-Call. Provides 5V via USB.
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### External Power (Production)
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| Parameter | Value |
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|-----------|-------|
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| Input voltage | 5V DC (via VIN pin) |
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| Current requirement | 500mA minimum (GSM peaks at 2A) |
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| Recommended supply | 5V 2A regulated DC adapter |
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For GSM operation, a supply capable of 2A peak current is required due to SIM800L transmission bursts.
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```
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DC Power Supply ESP32 TTGO T-Call
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┌──────────────┐ ┌──────────────────┐
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│ │ │ │
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│ +5V ─────────┼────────────┤ VIN │
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│ │ │ │
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│ GND ─────────┼────────────┤ GND │
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│ │ │ │
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└──────────────┘ └──────────────────┘
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```
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**Do not power via USB and VIN simultaneously** unless the USB is only for serial monitoring.
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---
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## Complete Wiring Diagram
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```
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ESP32 TTGO T-Call v1.4
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┌───────────────────────┐
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│ │
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┌─────────┐ GPIO17 (TX2)──┤ 3V3──┼──┐
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│ MAX485 ├──DI │ │ │
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│ │ │ GND──┼──┼──┐
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│ ├──RO──GPIO16 (RX2)┤ │ │ │
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│ │ │ [SIM800L BUILT-IN] │ │ │
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│ ├──DE──GPIO4───────┤ [SIM SLOT BOTTOM] │ │ │
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│ ├──RE──┘ │ │ │ │
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│ │ │ GPIO23───┼──┼──┼──MOSI──┐
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│ VCC───┼──────────────────┼── 3V3 │ │ │ │
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│ GND───┼──────────────────┼── GND GPIO19───┼──┼──┼──MISO─┤ SD Card
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│ │ │ GPIO18───┼──┼──┼──SCK──┤ Module
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│ A────┼──Acuvim A (+) │ GPIO5────┼──┼──┼──CS───┤
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│ B────┼──Acuvim B (-) │ │ │ │ VCC──┘
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└─────────┘ │ │ └──┼──GND
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│ VIN──────┼──5V │
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GSM Antenna ─────IPX─┤ │ │
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└───────────────────────┘ │
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│
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┌─────────────────┐ │
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│ Acuvim II │ │
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│ RS485 Terminal │ │
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│ A (+) ├─ MAX485 A│
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│ B (-) ├─ MAX485 B│
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│ GND ├──────────┘
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└─────────────────┘
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```
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---
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## Cable Recommendations
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| Connection | Cable Type | Max Length |
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|------------|-----------|-----------|
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| RS485 (ESP32 to Acuvim) | Shielded twisted pair (STP), 22-24 AWG | 1200m |
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| SPI (ESP32 to SD) | Short jumper wires | 15cm |
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| USB (development) | Micro-USB data cable | 2m |
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| Power (production) | 22 AWG stranded | 3m |
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For RS485 runs over 10m, use 120 ohm termination resistors at each end of the bus.
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