Hotel test illustrative

Herc Hotel test-board operator firmware

Rev A ESP32-P4 Nano bench simulator/operator1.2. Companion: https://github.com/rovshop/herc-hotel-p4-firmware

Build

ESP-IDF5.5.1, target esp32p4, committed sdkconfig/partitions. Run python tools/embed_ui.py, then idf.py build in the activated ESP-IDF environment. Fresh-board installation: idf.py -p YOUR_PORT flash monitor. Existing app-only image is build/herc_simulator_comms_probe.bin at0x10000. Verify the correct device/port and preserve other boards. Ethernet control is implemented; Ethernet OTA is NOT implemented, so USB is still the update/recovery path.

Operator UI and safety

Open the device DHCP address over HTTP (bench lease192.168.65.98). No password/key is required; use a trusted isolated LAN. Editable UI: ui/index.html; regenerate its committed embedded header before rebuilding.

Four0–5V pressure outputs; two4–20mA level sources;100–500uA temperature injection (uA=C+273.15); five independent leak switches; UART test bytes or four Bender Rev F BGF reports every500ms; JSON/CSV report export. Bender ASCII frames have additive checksum and CR/LF/NUL termination. Values are simulated reports, not resistance inferred from duty cycle.

• Boot/reset leave outputs off; Apply stages an atomic configuration; global OFF shuts down all domains.
• Absolute limit1–900s; a2s browser heartbeat maintains a10s lease. Status reads do not renew it and heartbeats do not extend the absolute deadline.
• Analog/UART require power and shared ARM. Leak-only tests require power but not ARM. GPIO pad readbacks do not prove external contact closure.
• ARM connects all analog switches. Disabled pressure/temperature are zero; levels Hi-Z. This is not per-port physical isolation.
• LDO4 must power GPIO44–48 bank at3.3V; firmware preserves that startup fix.
• Fit JP1 for armed tests. Power off before rewiring. Hotel has separate power. Use Hotel250ohm level shunts; remove temporary parallel loads.
• No simulator ADC, system galvanic isolation or certified hardware emergency-stop guarantee. Compare with Hotel telemetry/meter; remove physical power if software cannot respond.

Wiring and drawings

Five same-numbered cables: J1 temperature,J2 leaks,J3 level,J4 pressure,J5 Bender. J1-3 and J5-4 are unconnected on the test PCB. Hotel leak4/5 share one ADC channel. Assigned colors by pin:1 BRN,2 RED,3 ORN,4 YEL,5 GRN,6 BLU. Check continuity and top-view versus mating-face orientation.

Both repositories contain the same complete drawing bundle for both boards. Bench verification records the physical tests and qualification limits. No binaries, camera captures, broker runtime files or credential backups are included.