266 lines
7.4 KiB
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266 lines
7.4 KiB
Markdown
---
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pageType: source
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id: source.brewery-pid-replacement
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title: brewery-pid-replacement
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sourceType: local-file
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sourcePath: /home/topher/.openclaw/workspace-crash-bot/projects/brewery-pid-replacement.md
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ingestedAt: 2026-05-02T21:16:19.602Z
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updatedAt: 2026-05-02T21:16:19.602Z
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status: active
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growth: seed
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---
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# brewery-pid-replacement
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## Source
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- Type: `local-file`
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- Path: `/home/topher/.openclaw/workspace-crash-bot/projects/brewery-pid-replacement.md`
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- Bytes: 6887
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- Updated: 2026-05-02T21:16:19.602Z
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## Content
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````text
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# Brewery PID Controller Replacement
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**Status:** Prototyping — Path Decided
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**Created:** 2026-04-16
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**Updated:** 2026-04-16 (major revision)
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**Tags:** `brewery`, `esp32-s3`, `esphome`, `pid`, `home-assistant`, `pt100`, `max31865`, `nextion`, `custom-pcb`
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---
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## Summary
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Replace 8 existing Chinese commodity PID controllers in a commercial brewery with custom ESP32-S3-based PID controllers with Nextion displays, ESPHome firmware, and Home Assistant integration. All 8 units are interchangeable — heating vs cooling is a software setting.
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---
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## System Overview
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**8 PIDs total:**
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| # | Vessel | Type | Control |
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|---|--------|------|---------|
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| 1 | Fermenter 1 | Cooling | Glycol valve |
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| 2 | Fermenter 2 | Cooling | Glycol valve |
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| 3 | Fermenter 3 | Cooling | Glycol valve |
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| 4 | Fermenter 4 | Cooling | Glycol valve |
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| 5 | Glycol Chiller | Monitoring/Control | Chiller |
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| 6 | HLT | Heating | 4× SSR → contactors |
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| 7 | Mash RIMS | Heating | 1× SSR → contactor |
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| 8 | Kettle | Heating | 4× SSR → contactors |
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**Existing sensors:** PT100 (3-wire) in all vessels
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**Control signals:**
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- **Hot side:** ESP32 → G3MB-202P → 120V AC contactor coil → heating element
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- **Cold side:** ESP32 → G3MB-202P → 120V AC coil relay → 24V relay → glycol valve
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- Both sides use identical output hardware — mode is set in ESPHome YAML
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---
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## Architecture (2026-04-16 revision)
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**Per-PID architecture — one unit per vessel:**
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```
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[Surenoo NX4880E043] ← UART ← [Custom PCB]
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4.3" 480×800 display ├── ESP32-S3 Supermini
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├── MAX31865 (PT100)
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└── G3MB-202P (SSR output)
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```
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**Why per-PID over central:**
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- Each vessel is independently controlled
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- Hot-swappable — swap a board without affecting others
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- No single point of failure
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- Simpler wiring (sensors/outputs local to each vessel)
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- Interchangeable like-for-like with original PIDs
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**Software: ESPHome** (not Arduino)
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- Native HA integration — no custom MQTT code
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- `climate.pid` component for PID loop
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- `max31865` sensor component
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- `nextion` display component
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- OTA updates
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---
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## Hardware Decisions (2026-04-16)
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### Per-Unit Hardware Add-ons (Protection & Reliability)
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| Component | Unit Cost | Notes |
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|-----------|-----------|-------|
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| 100nF decoupling caps (×3) | ~$0.10 | On VCC pins |
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| TVS diodes (SMBJ5.0A) | ~$0.20 | 5V rail clamping |
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| 220Ω resistor (SSR gate) | ~$0.05 | G3MB-202P LED input |
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| Reverse polarity diode (SMB5819) | ~$0.10 | 5V input protection |
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| Hardware watchdog (TPS3823) | ~$0.50 | Reset on ESP32 hang |
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| RC filter (49.9K + 100nF) | ~$0.15 | PT100 input filtering |
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| **Total add-ons** | **~$1.10** | |
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**Hardware Watchdog (TPS3823):**
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- 3-pin voltage supervisor chip
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- Watches ESP32's heartbeat (toggle a GPIO periodically)
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- If ESP32 hangs and stops toggling, watchdog resets it after ~1.6 seconds
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- Essential for unattended commercial installations
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- Research: search "TPS3823 ESP32 watchdog" for wiring diagram
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- Alternative: software watchdog in ESPHome handles most cases, hardware is belt-and-suspenders
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### Per-unit total
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| Section | Cost |
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|---------|------|
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| Custom PCB (components) | ~$11-12 |
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| Protection add-ons | ~$1.10 |
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| Display (NX4880E043) | ~$37 |
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| **Per unit total** | **~$49-50** |
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**8-unit system total: ~$392-400**
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### Output Driver Detail
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**G3MB-202P SSR:**
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- 2A output, 120-380V AC
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- DIP-4 package, PCB-mount
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- Logic-level input (3.3V from ESP32 works)
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- Random fire (fine for coil loads)
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- ~$1.50 in quantity
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**Why G3MB-202P over SSR-10DA module:**
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- DIP-4 is much smaller than panel-mount SSR modules
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- Enough current rating for contactor coils (50-100mA)
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- One part to stock for both hot and cold sides
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**MOV across output terminals** — spike protection for inductive coil
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### ESP32-S3 Supermini (AITRIP)
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- 5-pack ~$13 on Amazon
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- GP1-GP48 GPIO broken out
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- Type-C USB for programming
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- 160MHz (underclocked but fine for PID)
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- Dual-core ESP32-S3
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---
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## Display: Surenoo NX4880E043
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**Specs:**
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| Spec | Value |
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|------|-------|
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| Size | 4.3" |
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| Resolution | 480×800 (tall) |
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| Touch | Capacitive (CTP) |
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| MCU | 200MHz |
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| Flash | 128MB |
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| GPIOs | 8 available |
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| RTC | Yes (coin cell backup) |
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| Interface | Serial UART |
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| Bezel | Slim/flush mount |
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| Price | ~$35-40 |
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**Why NX4880E043 over JC4827W543:**
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- Nextion editor — drag-drop UI design
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- ESPHome native `nextion` component support
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- 128MB flash for fonts and assets
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- 8 GPIOs on the display module itself
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- RTC built-in
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**Why NX4880E043 over official Nextion:**
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- ~$35-40 vs $89+ for equivalent Nextion
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- Same Nextion instruction set and editor
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- Slimmer bezel
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---
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## Software: ESPHome
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### YAML Components Needed
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```yaml
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# ESPHome config per unit
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climate:
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- platform: pid
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name: "${vessel_name} PID"
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sensor: pt100_sensor
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output: ssr_output
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default_target_temperature: 70°F
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heat_output: ssr_output # or separate heat/cool outputs
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# PID tuning parameters
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sensor:
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- platform: max31865
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name: "${vessel_name} Temperature"
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cs_pin: GPIOXX
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# 3-wire PT100 config
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output:
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- platform: gpio
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pin: GPIOXX
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id: ssr_output
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display:
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- platform: nextion
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# Bind to temperature sensor, setpoint, mode
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```
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### HA Integration
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- Native ESPHome API — zero-config discovery
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- HA sees each PID as a `climate` entity
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- Setpoint control from HA UI
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- Temperature history graphing
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- Automation triggers on temp reached
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---
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## Next Steps
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- [ ] Find Nextion in lab (or order NX4880E043)
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- [ ] Write starter ESPHome YAML for one unit
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- [ ] Prototype: ESP32-S3 + MAX31865 + G3MB-202P wired up
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- [ ] Test PID loop and HA integration
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- [ ] Design custom PCB in EasyEDA
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- [ ] Order PCB prototypes (JLCPCB)
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- [ ] Build and test first complete unit
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- [ ] Flash all 8 units with vessel-specific YAML
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- [ ] Scale to full installation
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---
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## Decision Log
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### 2026-04-16 — Major revision
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**Changes from original plan:**
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- ✅ **Switched from Arduino to ESPHome** — user prefers ESPHome + easy HA integration
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- ✅ **Switched from central architecture to per-PID** — hot-swappable, no single point of failure
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- ✅ **Display: NX4880E043 Surenoo Nextion** instead of CrowPanel 7"
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- ✅ **Custom PCB** using AITRIP ESP32-S3 Supermini + MAX31865 module + G3MB-202P
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- ✅ **Per-unit BOM: ~$48-49** (down from ~$93 central architecture)
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- ✅ **8-unit total: ~$390-395** (vs $700+ for official Nextion)
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- ✅ **Hot/cold is software switch** — same hardware for all 8 units
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### 2026-04-16 — Original architecture (superseded)
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- Central ESP32 + 2× CrowPanel 7" = ~$213
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- Custom Arduino firmware (not ESPHome)
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- Per-vessel architecture also considered
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---
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## Related Projects
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- [[fermentation-dashboard.md]] — separate brewery HA dashboard (TILT hydrometer)
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- [[pihole-blocker.md]] — CM4 board could be brewery server
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````
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## Notes
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<!-- openclaw:human:start -->
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<!-- openclaw:human:end -->
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## Related
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<!-- openclaw:wiki:related:start -->
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### Referenced By
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- [README](sources/readme.md)
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<!-- openclaw:wiki:related:end -->
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