test: skip OLED setup assertion for LilyGO cargo board

This reverts commit ac6b0475ff.

docs/CHANGELOG.md

@@ -2,6 +2,18 @@
 
 ## Unreleased
 
+### Added
+- Cargo ESP local OTA firmware upload page at `/ota`.
+- Cargo ESP OTA API endpoint at `POST /api/v1/system/ota`.
+
+## Unreleased
+
+### Fixed
+- Cargo ESP starts AP and Web UI/API before attempting STA WiFi reconnects.
+- STA reconnect attempts now service the web server during short connection windows so AP mode remains usable when no saved WiFi is available.
+
+## Unreleased
+
 ### Changed
 - Reworked ESP32-S3 dashboard page navigation to use screen-wide LVGL swipe gestures.
 - Removed failed temporary double-tap and transparent hitbox navigation experiments.

docs/HARDWARE.md

@@ -239,3 +239,30 @@ Important guardrails:
 ## M9N GPS Module
 
 The dashboard enclosure will include an M9N GPS module connected to the ESP32-S3 dashboard over UART. It will provide GPS fix status, satellite count, position, speed, and UTC time. Future work will use GPS time/location for automatic timezone and DST handling.
+
+
+### LilyGO T-Relay-S3 6-relay cargo controller
+
+The cargo ESP now targets the LilyGO T-Relay-S3 6-relay board.
+
+Relay control is handled through the onboard 74HC595 shift register, not direct ESP32 GPIO relay outputs.
+
+| Function | GPIO |
+| --- | --- |
+| 74HC595 DATA | GPIO7 |
+| 74HC595 CLOCK | GPIO5 |
+| 74HC595 LATCH | GPIO6 |
+| 74HC595 nOE | GPIO4 |
+
+| Firmware ID | LilyGO relay channel | Shift-register output |
+| --- | --- | --- |
+| relay_1 | CH1 | SR1 |
+| relay_2 | CH2 | SR2 |
+| relay_3 | CH3 | SR3 |
+| relay_4 | CH4 | SR4 |
+| relay_5 | CH5 | SR5 |
+| relay_6 | CH6 | SR6 |
+
+GPIO4 is reserved for relay output-enable on this board, so the DS18B20 OneWire bus is moved to GPIO14.
+
+Avoid GPIO35-GPIO37 on the LilyGO T-Relay-S3 because they are used by Octal SPI flash.

docs/cargo-api-contract.md

@@ -157,7 +157,7 @@ Expected output object fields:
 Example 2-channel profile:
 
     {
-      "hardware_profile": "generic_esp32_2ch_relay",
+      "hardware_profile": "lilygo_t_relay_s3_6ch",
       "outputs": [
         {"id": 1, "name": "Fridge", "role": "fridge", "hardware_channel": 1},
         {"id": 2, "name": "Starlink", "role": "starlink", "hardware_channel": 2}
@@ -190,7 +190,7 @@ The Cargo ESP firmware now exposes relay/output state as an output-count-agnosti
 
 The current active hardware profile remains:
 
-    generic_esp32_2ch_relay
+    lilygo_t_relay_s3_6ch
 
 The API includes:
 

docs/dashboard-esp32s3.md

@@ -311,3 +311,11 @@ The diagnostics overlay shows dashboard version, uptime, heap, WiFi RSSI/IP, Car
 - Swipe right from the main dashboard to open Battery Detail.
 - Swipe left from Battery Detail to return to the main dashboard.
 - Diagnostics remains hidden behind the multi-tap system-card gesture.
+
+
+## OBD-II Coolant Polling
+- Dashboard ESP32-S3 Touch LCD 5B uses onboard CAN/TWAI via GPIO15 CANTX and GPIO16 CANRX.
+- First implemented PID is Mode 01 PID 05 coolant temperature.
+- Sends standard 11-bit functional request ID `0x7DF` and accepts ECU responses from `0x7E8` through `0x7EF`.
+- Diagnostics page shows TWAI state, coolant value, TX/RX counts, and last OBD status.
+- Overview coolant gauge shows `--°` until a valid OBD response is received.

docs/project-state.md

@@ -270,7 +270,7 @@ The Cargo ESP API now represents relays/outputs as a hardware-profile-aware list
 
 Current active hardware profile:
 
-    generic_esp32_2ch_relay
+    lilygo_t_relay_s3_6ch
 
 Future planned profile:
 

docs/roadmap.md

@@ -192,3 +192,34 @@ Next Dashboard Milestones:
 ## M9N GPS Module
 
 The dashboard enclosure will include an M9N GPS module connected to the ESP32-S3 dashboard over UART. It will provide GPS fix status, satellite count, position, speed, and UTC time. Future work will use GPS time/location for automatic timezone and DST handling.
+
+## Planned: WebSocket live dashboard updates
+
+Add a WebSocket push channel alongside the existing `/api/v1` REST API. The REST API remains the stable snapshot/debug/control contract, while WebSockets provide lower-latency live status updates for the dashboard.
+
+Planned behavior:
+
+- Cargo ESP continues to expose `/api/v1/status` and existing `/api/v1/...` endpoints.
+- Cargo ESP adds a WebSocket endpoint, likely `/ws`.
+- Dashboard ESP connects once to `/ws` and receives pushed status updates.
+- Relay commands may continue using REST initially, with pushed status updates confirming state changes.
+- Future high-rate data such as CAN/OBD, GPS, inclinometer, and temperature updates can use the WebSocket path.
+- If WebSocket disconnects, dashboard should fall back to the existing REST polling behavior.
+
+Rationale:
+
+- Keeps the current API architecture intact and easy to debug.
+- Avoids ESP-NOW channel-management complexity for now.
+- Improves perceived responsiveness without a major communication rewrite.
+- Supports future live gauges better than fixed-interval polling.
+
+
+
+## LilyGO T-Relay-S3 6-relay migration
+
+- [x] Expand cargo relay model from 2 outputs to 6 outputs.
+- [x] Replace direct GPIO relay writes with LilyGO 74HC595 shift-register writes.
+- [x] Map relay_1 through relay_6 to CH1 through CH6.
+- [x] Move DS18B20 OneWire default from GPIO4 to GPIO14 because GPIO4 is relay nOE.
+- [ ] Bench test relay boot behavior with no vehicle loads connected.
+- [ ] Confirm CH1-CH6 order with a meter or test lamp before wiring vehicle loads.

firmware/esp32-s3-dashboard/dashboard_config.h

@@ -1,20 +1,20 @@
 #pragma once
 
-static const char *DASHBOARD_VERSION = "0.1.118-temp-alert-local-threshold";
+static const char *DASHBOARD_VERSION = "0.1.126-restore-boot-screen";
 
 // Update these if your Cargo ESP AP credentials are different.
-//static const char *CARGO_WIFI_SSID = "OverlandController";
+static const char *CARGO_WIFI_SSID = "OverlandController";
-//static const char *CARGO_WIFI_PASSWORD = "overland1234";
+static const char *CARGO_WIFI_PASSWORD = "Ward1707";
 
-static const char *CARGO_WIFI_SSID = "WardAP";
+//static const char *CARGO_WIFI_SSID = "WardAP";
-static const char *CARGO_WIFI_PASSWORD = "Ward5213";
+//static const char *CARGO_WIFI_PASSWORD = "Ward5213";
 
-//static const char *CARGO_API_STATUS_URL = "http://192.168.4.1/api/v1/status";
+static const char *CARGO_API_STATUS_URL = "http://192.168.4.1/api/v1/status";
-//static const char *CARGO_API_FAST_STATUS_URL = "http://192.168.4.1/api/v1/status?fields=battery,temps,relays";
+static const char *CARGO_API_FAST_STATUS_URL = "http://192.168.4.1/api/v1/status?fields=battery,temps,relays";
-//static const char *CARGO_API_SLOW_STATUS_URL = "http://192.168.4.1/api/v1/status?fields=network,system,config";
+static const char *CARGO_API_SLOW_STATUS_URL = "http://192.168.4.1/api/v1/status?fields=network,system,config";
-//static const char *CARGO_API_RELAY_SET_URL = "http://192.168.4.1/api/v1/relay/set";
+static const char *CARGO_API_RELAY_SET_URL = "http://192.168.4.1/api/v1/relay/set";
 
-static const char *CARGO_API_STATUS_URL = "http://192.168.88.108/api/v1/status";
+//static const char *CARGO_API_STATUS_URL = "http://192.168.88.181/api/v1/status";
-static const char *CARGO_API_FAST_STATUS_URL = "http://192.168.88.108/api/v1/status?fields=battery,temps,relays";
+//static const char *CARGO_API_FAST_STATUS_URL = "http://192.168.88.181/api/v1/status?fields=battery,temps,relays";
-static const char *CARGO_API_SLOW_STATUS_URL = "http://192.168.88.108/api/v1/status?fields=network,system,config";
+//static const char *CARGO_API_SLOW_STATUS_URL = "http://192.168.88.181/api/v1/status?fields=network,system,config";
-static const char *CARGO_API_RELAY_SET_URL = "http://192.168.88.108/api/v1/relay/set";
+//static const char *CARGO_API_RELAY_SET_URL = "http://192.168.88.181/api/v1/relay/set";

firmware/esp32-s3-dashboard/esp32-s3-dashboard.ino

@@ -3,6 +3,7 @@
 #include <HTTPClient.h>
 #include <ArduinoJson.h>
 #include <esp_display_panel.hpp>
+#include <driver/twai.h>
 
 #include <lvgl.h>
 #include "lvgl_v8_port.h"
@@ -15,6 +16,24 @@ using namespace esp_panel::drivers;
 using namespace esp_panel::board;
 
 static DashboardStatus status_model;
+static constexpr gpio_num_t OBD_CAN_TX_PIN = GPIO_NUM_15;
+static constexpr gpio_num_t OBD_CAN_RX_PIN = GPIO_NUM_16;
+static constexpr uint32_t OBD_REQUEST_ID = 0x7DF;
+static constexpr uint32_t OBD_RESPONSE_ID_MIN = 0x7E8;
+static constexpr uint32_t OBD_RESPONSE_ID_MAX = 0x7EF;
+static constexpr uint8_t OBD_PID_COOLANT_TEMP = 0x05;
+
+static bool obd_can_ready = false;
+static bool obd_can_started = false;
+static unsigned long last_obd_poll_ms = 0;
+static unsigned long last_obd_rx_ms = 0;
+static unsigned long last_obd_tx_ms = 0;
+static uint32_t obd_tx_count = 0;
+static uint32_t obd_rx_count = 0;
+static int obd_coolant_temp_f = -999;
+static int last_rendered_obd_coolant_temp_f = -1000;
+static String obd_last_error = "not initialized";
+
 
 static lv_obj_t *battery_card_obj = nullptr;
 static lv_obj_t *battery_soc_arc = nullptr;
@@ -369,6 +388,149 @@ static String format_diag_uptime(unsigned long seconds)
     return out;
 }
 
+static void update_vehicle_coolant_widget()
+{
+    if (vehicle_coolant_value_label == nullptr || vehicle_coolant_meter == nullptr || vehicle_coolant_needle == nullptr) {
+        return;
+    }
+
+    if (obd_coolant_temp_f == last_rendered_obd_coolant_temp_f) {
+        return;
+    }
+
+    last_rendered_obd_coolant_temp_f = obd_coolant_temp_f;
+
+    lvgl_port_lock(-1);
+
+    if (obd_coolant_temp_f > -100) {
+        int bounded_temp = clamp_int(obd_coolant_temp_f, 100, 260);
+        lv_meter_set_indicator_value(vehicle_coolant_meter, vehicle_coolant_needle, bounded_temp);
+        lv_label_set_text(vehicle_coolant_value_label, (String(obd_coolant_temp_f) + "°").c_str());
+    } else {
+        lv_meter_set_indicator_value(vehicle_coolant_meter, vehicle_coolant_needle, 100);
+        lv_label_set_text(vehicle_coolant_value_label, "--°");
+    }
+
+    lvgl_port_unlock();
+}
+
+static bool init_obd_can()
+{
+    if (obd_can_ready && obd_can_started) {
+        return true;
+    }
+
+    twai_general_config_t general_config = TWAI_GENERAL_CONFIG_DEFAULT(OBD_CAN_TX_PIN, OBD_CAN_RX_PIN, TWAI_MODE_NORMAL);
+    general_config.tx_queue_len = 5;
+    general_config.rx_queue_len = 20;
+
+    twai_timing_config_t timing_config = TWAI_TIMING_CONFIG_500KBITS();
+    twai_filter_config_t filter_config = TWAI_FILTER_CONFIG_ACCEPT_ALL();
+
+    if (!obd_can_ready) {
+        esp_err_t install_result = twai_driver_install(&general_config, &timing_config, &filter_config);
+        if (install_result != ESP_OK && install_result != ESP_ERR_INVALID_STATE) {
+            obd_last_error = "driver install failed: " + String((int)install_result);
+            Serial.println("OBD CAN: " + obd_last_error);
+            return false;
+        }
+
+        obd_can_ready = true;
+    }
+
+    esp_err_t start_result = twai_start();
+    if (start_result != ESP_OK && start_result != ESP_ERR_INVALID_STATE) {
+        obd_last_error = "start failed: " + String((int)start_result);
+        Serial.println("OBD CAN: " + obd_last_error);
+        return false;
+    }
+
+    obd_can_started = true;
+    obd_last_error = "started";
+    Serial.println("OBD CAN: TWAI started on TX GPIO15 / RX GPIO16 at 500 kbps");
+    return true;
+}
+
+static void send_obd_coolant_request()
+{
+    twai_message_t message = {};
+    message.identifier = OBD_REQUEST_ID;
+    message.extd = 0;
+    message.rtr = 0;
+    message.data_length_code = 8;
+    message.data[0] = 0x02;
+    message.data[1] = 0x01;
+    message.data[2] = OBD_PID_COOLANT_TEMP;
+    message.data[3] = 0x55;
+    message.data[4] = 0x55;
+    message.data[5] = 0x55;
+    message.data[6] = 0x55;
+    message.data[7] = 0x55;
+
+    esp_err_t result = twai_transmit(&message, 0);
+    if (result == ESP_OK) {
+        obd_tx_count++;
+        last_obd_tx_ms = millis();
+        obd_last_error = "coolant request sent";
+    } else {
+        obd_last_error = "tx failed: " + String((int)result);
+    }
+}
+
+static void handle_obd_can_message(const twai_message_t &message)
+{
+    if (message.extd || message.rtr) {
+        return;
+    }
+
+    if (message.identifier < OBD_RESPONSE_ID_MIN || message.identifier > OBD_RESPONSE_ID_MAX) {
+        return;
+    }
+
+    if (message.data_length_code < 4) {
+        return;
+    }
+
+    // Single-frame OBD-II response:
+    // byte0 length, byte1 0x41 response mode, byte2 PID, byte3 value A.
+    if (message.data[1] == 0x41 && message.data[2] == OBD_PID_COOLANT_TEMP) {
+        int coolant_c = (int)message.data[3] - 40;
+        obd_coolant_temp_f = (int)roundf((coolant_c * 9.0f / 5.0f) + 32.0f);
+        obd_rx_count++;
+        last_obd_rx_ms = millis();
+        obd_last_error = "coolant response OK";
+
+        Serial.print("OBD CAN: coolant=");
+        Serial.print(obd_coolant_temp_f);
+        Serial.println(" F");
+
+        update_vehicle_coolant_widget();
+    }
+}
+
+static void process_obd_can()
+{
+    if (!init_obd_can()) {
+        return;
+    }
+
+    if (millis() - last_obd_poll_ms >= 1000) {
+        last_obd_poll_ms = millis();
+        send_obd_coolant_request();
+    }
+
+    twai_message_t message = {};
+    while (twai_receive(&message, 0) == ESP_OK) {
+        handle_obd_can_message(message);
+    }
+
+    if (millis() - last_obd_rx_ms > 5000 && obd_coolant_temp_f > -100) {
+        obd_coolant_temp_f = -999;
+        update_vehicle_coolant_widget();
+    }
+}
+
+
 static void update_diagnostics_overlay()
 {
     if (diagnostics_overlay == nullptr || diagnostics_label == nullptr) {
@@ -442,6 +604,21 @@ static void update_diagnostics_overlay()
     text += String(status_model.cell_delta_mv);
     text += " mV";
 
+    text += "\n\nOBD-II / CAN\n";
+    text += "  TWAI: ";
+    text += obd_can_started ? "started" : "offline";
+    text += "\n  Pins: TX GPIO15 / RX GPIO16";
+    text += "\n  Coolant: ";
+    text += obd_coolant_temp_f > -100 ? String(obd_coolant_temp_f) + "°F" : String("--");
+    text += "\n  TX/RX: ";
+    text += String(obd_tx_count);
+    text += "/";
+    text += String(obd_rx_count);
+    text += "\n  Last RX age: ";
+    text += last_obd_rx_ms > 0 ? String((millis() - last_obd_rx_ms) / 1000) + "s" : String("--");
+    text += "\n  Last status: ";
+    text += obd_last_error;
+
     text += "\n\nControls\n";
     text += "  Relays visible: ";
     text += String(relay_count);
@@ -1288,14 +1465,10 @@ static void update_temp_tile_alert_style(int index, bool alert)
         return;
     }
 
-    if (last_temp_tile_alert[index] == alert) {
+    // Always apply the visual style. The cache can get out of sync when pages
-        return;
+    // are hidden/shown, so it must not prevent repainting the tile.
-    }
-
     last_temp_tile_alert[index] = alert;
 
-    lvgl_port_lock(-1);
-
     if (alert) {
         lv_obj_set_style_bg_color(temp_tile_objs[index], lv_color_hex(0x7A271A), 0);
         lv_obj_set_style_border_color(temp_tile_objs[index], lv_color_hex(0xF97066), 0);
@@ -1305,11 +1478,8 @@ static void update_temp_tile_alert_style(int index, bool alert)
         lv_obj_set_style_border_color(temp_tile_objs[index], lv_color_hex(0x2F3A46), 0);
         lv_obj_set_style_border_width(temp_tile_objs[index], 2, 0);
     }
-
-    lvgl_port_unlock();
 }
 
-
 static void update_battery_card_alert_style(bool alert)
 {
     if (battery_card_obj == nullptr) {
@@ -1465,14 +1635,6 @@ static void parse_status_json(const String &body)
 
             float temp_f = (float)(temp["temperature_f"] | 0.0);
             bool high_alert = temp["high_alert"] | false;
-
-            bool high_alert_enabled = temp["high_alert_enabled"] | false;
-            float high_alert_f = (float)(temp["high_alert_f"] | 9999.0);
-
-            if (high_alert_enabled && temp_f >= high_alert_f) {
-                high_alert = true;
-            }
-
             if (weather) {
                 outside_status = "OUT ";
                 outside_status += String((int)round(temp_f));
@@ -1765,11 +1927,11 @@ current_dashboard_screen = SCREEN_OVERVIEW;
 lv_obj_t *system_card = create_card(screen, "", 960, 48, LV_ALIGN_TOP_MID, 0, 12);
     lv_obj_add_flag(system_card, LV_OBJ_FLAG_CLICKABLE);
     lv_obj_add_event_cb(system_card, system_card_event_cb, LV_EVENT_CLICKED, nullptr);
-    lv_obj_t *battery_card = create_card(screen, "", 380, 310, LV_ALIGN_TOP_LEFT, 32, 68);
+    lv_obj_t *battery_card = create_card(screen, "", 330, 310, LV_ALIGN_TOP_LEFT, 32, 68);
     battery_card_obj = battery_card;
     add_battery_card_tap_target(battery_card);
-    lv_obj_t *temp_card = create_card(screen, "", 260, 310, LV_ALIGN_TOP_LEFT, 426, 68);
+    lv_obj_t *temp_card = create_card(screen, "", 260, 310, LV_ALIGN_TOP_LEFT, 382, 68);
-    lv_obj_t *vehicle_card = create_card(screen, "", 292, 310, LV_ALIGN_TOP_RIGHT, -32, 68);
+    lv_obj_t *vehicle_card = create_card(screen, "", 330, 310, LV_ALIGN_TOP_RIGHT, -32, 68);
     lv_obj_t *relay_card = create_card(screen, "", 960, 205, LV_ALIGN_BOTTOM_MID, 0, -8);
 
     battery_charge_pulse_arc = lv_arc_create(battery_card);
@@ -1900,7 +2062,7 @@ lv_obj_t *system_card = create_card(screen, "", 960, 48, LV_ALIGN_TOP_MID, 0, 12
     lv_meter_set_indicator_end_value(vehicle_coolant_meter, hot_arc, 260);
 
     vehicle_coolant_needle = lv_meter_add_needle_line(vehicle_coolant_meter, coolant_scale, 4, lv_color_hex(0xFFFFFF), -14);
-    lv_meter_set_indicator_value(vehicle_coolant_meter, vehicle_coolant_needle, 188);
+    lv_meter_set_indicator_value(vehicle_coolant_meter, vehicle_coolant_needle, 100);
 
     lv_obj_t *vehicle_coolant_center_cap = lv_obj_create(vehicle_coolant_meter);
     lv_obj_set_size(vehicle_coolant_center_cap, 54, 54);
@@ -1912,7 +2074,7 @@ lv_obj_t *system_card = create_card(screen, "", 960, 48, LV_ALIGN_TOP_MID, 0, 12
 #endif
 
     vehicle_coolant_value_label = lv_label_create(vehicle_card);
-    lv_label_set_text(vehicle_coolant_value_label, "188°");
+    lv_label_set_text(vehicle_coolant_value_label, "--°");
     lv_obj_set_style_text_color(vehicle_coolant_value_label, lv_color_hex(0xFFFFFF), 0);
     lv_obj_set_style_text_font(vehicle_coolant_value_label, &lv_font_montserrat_40, 0);
     lv_obj_set_width(vehicle_coolant_value_label, 120);
@@ -2038,9 +2200,7 @@ void setup()
     lvgl_port_init(board->getLCD(), board->getTouch());
 
     lvgl_port_lock(-1);
-    // TEMP DEBUG: bypass blocking Cargo ESP WiFi screen while troubleshooting pages.
+    show_boot_screen();
-    create_overland_overview_screen();
-    overview_screen_created = true;
     lvgl_port_unlock();
 
     Serial.println("Dashboard boot screen ready");
@@ -2052,7 +2212,13 @@ void loop()
     update_system_status_label();
     process_pending_relay_command();
     poll_status_api();
+    process_obd_can();
     process_dashboard_page_switch();
 
-    delay(50);
+    
+
+    if (diagnostics_overlay != nullptr) {
+        update_diagnostics_overlay();
+    }
+delay(50);
 }

firmware/esp32/overland-controller/app_config.cpp

@@ -7,28 +7,27 @@ AppConfig appConfig;
 
 static Preferences preferences;
 
+static RelayConfig defaultRelayConfig(uint8_t channel, const char *name, const char *role) {
+    return {
+        "relay_" + String(channel),
+        name,
+        role,
+        channel,
+        RELAY_SHIFT_REGISTER_PIN,
+        true,
+        true
+    };
+}
+
 void loadDefaultConfig() {
     appConfig.deviceName = "Overland Controller";
 
-    appConfig.relays[0] = {
+    appConfig.relays[0] = defaultRelayConfig(1, "Relay 1", "aux");
-        "relay_1",
+    appConfig.relays[1] = defaultRelayConfig(2, "Relay 2", "fridge");
-        "Relay 1",
+    appConfig.relays[2] = defaultRelayConfig(3, "Relay 3", "starlink");
-        "aux",
+    appConfig.relays[3] = defaultRelayConfig(4, "Relay 4", "aux");
-        1,
+    appConfig.relays[4] = defaultRelayConfig(5, "Relay 5", "aux");
-        RELAY_1_PIN,
+    appConfig.relays[5] = defaultRelayConfig(6, "Relay 6", "aux");
-        true,
-        true
-    };
-
-    appConfig.relays[1] = {
-        "relay_2",
-        "Relay 2",
-        "fridge",
-        2,
-        RELAY_2_PIN,
-        true,
-        true
-    };
 
     appConfig.tempSensorCount = 4;
 
@@ -194,7 +193,7 @@ void printConfig() {
         Serial.print(appConfig.relays[i].role);
         Serial.print(" / channel ");
         Serial.print(appConfig.relays[i].hardwareChannel);
-        Serial.print(" / GPIO ");
+        Serial.print(" / channel ");
         Serial.print(appConfig.relays[i].pin);
         Serial.print(" / available ");
         Serial.print(appConfig.relays[i].available ? "true" : "false");

firmware/esp32/overland-controller/app_config.h

@@ -2,9 +2,9 @@
 
 #include <Arduino.h>
 
-#define MAX_RELAYS 2
+#define MAX_RELAYS 6
 #define MAX_TEMP_SENSORS 4
-#define HARDWARE_PROFILE "generic_esp32_2ch_relay"
+#define HARDWARE_PROFILE "lilygo_trelay_s3_6ch"
 
 struct RelayConfig {
     String id;

firmware/esp32/overland-controller/bms.cpp

@@ -26,6 +26,8 @@ static int bmsConnectFailCount = 0;
 static unsigned long bmsReconnectPausedUntil = 0;
 static bool bmsSetupMode = false;
 static const unsigned long READ_INTERVAL_MS = 5000;
+static const unsigned long BMS_CONNECT_BACKOFF_INITIAL_MS = 30000;
+static const unsigned long BMS_CONNECT_BACKOFF_MAX_MS = 300000;
 
 BmsData bmsData;
 
@@ -288,7 +290,34 @@ int scanBleDevices(uint32_t scanSeconds) {
     return bleScanResultCount;
 }
 
-static bool connectBms() {
+static void scheduleBmsReconnectBackoff();
+static void clearBmsReconnectBackoff();
+
+static void scheduleBmsReconnectBackoff() {
+    bmsConnectFailCount++;
+
+    if (bmsConnectBackoffMs == 0) {
+        bmsConnectBackoffMs = BMS_CONNECT_BACKOFF_INITIAL_MS;
+    } else {
+        bmsConnectBackoffMs = min(bmsConnectBackoffMs * 2, BMS_CONNECT_BACKOFF_MAX_MS);
+    }
+
+    bmsReconnectPausedUntil = millis() + bmsConnectBackoffMs;
+
+    Serial.print("BMS: reconnect backoff ");
+    Serial.print(bmsConnectBackoffMs / 1000);
+    Serial.print("s after ");
+    Serial.print(bmsConnectFailCount);
+    Serial.println(" failed attempt(s)");
+}
+
+static void clearBmsReconnectBackoff() {
+    bmsConnectFailCount = 0;
+    bmsConnectBackoffMs = 0;
+    bmsReconnectPausedUntil = 0;
+}
+
+bool connectBms() {
     if (client && client->isConnected()) {
         bmsData.connected = true;
         return true;
@@ -307,6 +336,7 @@ static bool connectBms() {
 
     if (!appConfig.bms.enabled || appConfig.bms.address.length() == 0) {
         bmsData.connected = false;
+        clearBmsReconnectBackoff();
         return false;
     }
 
@@ -322,6 +352,9 @@ static bool connectBms() {
         bmsData.connected = false;
         NimBLEDevice::deleteClient(client);
         client = nullptr;
+        notifyChar = nullptr;
+        writeChar = nullptr;
+        scheduleBmsReconnectBackoff();
         return false;
     }
 
@@ -352,6 +385,7 @@ static bool connectBms() {
 
     Serial.println("BMS: Connected");
     bmsData.connected = true;
+    clearBmsReconnectBackoff();
     return true;
 }
 

firmware/esp32/overland-controller/config.h

@@ -2,24 +2,25 @@
 
 #define DEVICE_NAME "Overland Controller"
 
-// Relay Outputs
+// LilyGO T-Relay S3 6-relay board.
-#define RELAY_1_PIN 16
+// Relays are driven through onboard 74HC595 shift register.
-#define RELAY_2_PIN 17
+#define LILYGO_T_RELAY_S3_DATA_PIN 7
+#define LILYGO_T_RELAY_S3_CLOCK_PIN 5
+#define LILYGO_T_RELAY_S3_LATCH_PIN 6
+#define LILYGO_T_RELAY_S3_OE_PIN 4
+#define LILYGO_T_RELAY_S3_RELAY_COUNT 6
 
-// DS18B20 Bus
+// Compatibility placeholder only. Relays are not direct GPIO outputs.
-#define ONEWIRE_PIN 4
+#define RELAY_SHIFT_REGISTER_PIN 255
 
-// Ignition Sense
+// GPIO4 is used by the LilyGO relay shift-register OE pin.
-#define IGNITION_PIN 34
+#define ONEWIRE_PIN 15
+
+#define IGNITION_PIN 39
 
-// Cargo OLED service/setup display
 #define OLED_I2C_SDA_PIN 21
 #define OLED_I2C_SCL_PIN 22
 #define OLED_SETUP_BUTTON_PIN 25
 
-// Dashboard communication is WiFi/HTTP.
-// Legacy UART dashboard support is retired from active hardware use.
 #define DASHBOARD_UART_ENABLED 0
 #define DASHBOARD_UART_BAUD   115200
-
-// RS-485/MAX3485 is fallback only and not currently planned.

firmware/esp32/overland-controller/overland-controller.ino

@@ -1,8 +1,10 @@
 #include <WiFi.h>
+#include <esp_heap_caps.h>
 #include <WebServer.h>
 #include <Preferences.h>
 #include <esp_wifi.h>
 #include <esp_system.h>
+#include <Update.h>
 
 #define OLED_ENABLED 0
 
@@ -637,12 +639,15 @@ button[onclick^="scan"]{
             <input id="bmsAddressTypeInput" placeholder="Address type: public or random">
             <div class="btnrow">
               <button class="save" onclick="saveBmsFullConfig()">Save BMS</button>
+              <button onclick="scanBmsDevices()">Scan BMS</button>
               <button class="off" onclick="setBmsEnabled(false)">Disable BMS</button>
             </div>
             <div class="btnrow">
               <button onclick="setBmsEnabled(true)">Enable BMS</button>
             </div>
             <div class="row"><span class="muted">BMS Polling</span><span class="v" id="bmsEnabledText">--</span></div>
+            <div id="bmsScanStatus" class="muted"></div>
+            <div id="bmsScanResults"></div>
           </div>
         </section>
       </div>
@@ -1044,12 +1049,12 @@ function render(data){
 
 function populateSetupFields(data){
   const cfg=data.config||{};
-  if($("deviceNameInput")) $("deviceNameInput").value=cfg.device_name||"";
+  setConfigValue("deviceNameInput", cfg.device_name||"");
 
   const bms=cfg.bms||{};
-  if($("bmsNameInput")) $("bmsNameInput").value=bms.name||"";
+  setConfigValue("bmsNameInput", bms.name||"");
-  if($("bmsAddressInput")) $("bmsAddressInput").value=bms.address||"";
+  setConfigValue("bmsAddressInput", bms.address||"");
-  if($("bmsAddressTypeInput")) $("bmsAddressTypeInput").value=bms.address_type||"public";
+  setConfigValue("bmsAddressTypeInput", bms.address_type||"public");
 }
 
 async function saveDeviceConfig(){
@@ -1068,6 +1073,46 @@ async function saveDeviceConfig(){
   clearConfigTouched(["deviceNameInput"]);
 }
 
+
+async function scanBmsDevices(){
+  const status=$("bmsScanStatus");
+  const box=$("bmsScanResults");
+  if(status) status.textContent="Scanning for BLE BMS devices...";
+  if(box) box.innerHTML="";
+
+  try{
+    const res=await fetch(api("/bms/scan"),{method:"POST"});
+    const data=await res.json();
+    const devices=data.devices||[];
+
+    if(status) status.textContent=devices.length ? `Found ${devices.length} device(s).` : "No BLE devices found.";
+
+    if(box){
+      box.innerHTML=devices.map(d=>`
+        <div class="configrow">
+          <div>
+            <div><b>${d.name||"Unnamed BLE device"}</b></div>
+            <div class="muted">${d.address||""} RSSI ${d.rssi??"--"}</div>
+          </div>
+          <button onclick="selectScannedBms('${d.address||""}','${(d.name||"BMS").replace(/'/g,"\\'")}')">Select</button>
+        </div>
+      `).join("");
+    }
+  }catch(e){
+    if(status) status.textContent="BMS scan failed.";
+  }
+}
+
+function selectScannedBms(address,name){
+  setConfigValue("bmsNameInput",name||"BMS",true);
+  setConfigValue("bmsAddressInput",address||"",true);
+  setConfigValue("bmsAddressTypeInput","public",true);
+  markConfigFieldTouched("bmsNameInput");
+  markConfigFieldTouched("bmsAddressInput");
+  markConfigFieldTouched("bmsAddressTypeInput");
+}
+
+
 async function saveBmsFullConfig(){
   const name=$("bmsNameInput")?.value.trim()||"BMS";
   const address=$("bmsAddressInput")?.value.trim()||"";
@@ -1197,14 +1242,20 @@ function renderConfigControls(data){
 
   const relayBox=$("relayConfigList");
   if(relayBox){
+    const signature=relays.map(r=>r.id).join("|");
+    if(relayBox.dataset.signature!==signature){
+      relayBox.dataset.signature=signature;
       relayBox.innerHTML=relays.map((r,i)=>`
         <div class="configrow">
           <label>${r.id}</label>
-        <input id="relayName${i}" value="${r.name||""}" placeholder="Relay name">
+          <input id="relayName${i}" placeholder="Relay name" oninput="markConfigFieldTouched('relayName${i}')">
           <label>${r.enabled?"Enabled":"Disabled"}</label>
         </div>`).join("");
     }
 
+    relays.forEach((r,i)=>setConfigValue("relayName"+i,r.name||""));
+  }
+
   setConfigValue("tempEnabledCount", temps.filter(t=>t.enabled).length);
 
   const tempBox=$("tempConfigList");
@@ -1458,6 +1509,9 @@ setInterval(load,3000);
 
 WebServer server(80);
 
+unsigned long lastSensorUpdate = 0;
+const unsigned long SENSOR_INTERVAL = 5000;
+
 #define API_V1(path) "/api/v1" path
 
 int findTempConfigIndexById(const String& id) {
@@ -1648,6 +1702,97 @@ void sendSimpleJsonError(int status, const char* error, const char* detail) {
 }
 
 
+const char OTA_HTML[] PROGMEM = R"rawliteral(
+<!doctype html>
+<html>
+<head>
+<meta name="viewport" content="width=device-width,initial-scale=1">
+<title>Cargo ESP OTA</title>
+<style>
+body{background:#0b0f14;color:#eef4ff;font-family:-apple-system,BlinkMacSystemFont,Segoe UI,Roboto,Arial,sans-serif;margin:0}
+.wrap{max-width:620px;margin:0 auto;padding:22px}
+.card{background:#141b24;border:1px solid #223044;border-radius:18px;padding:18px}
+h1{margin-top:0}
+input,button{width:100%;box-sizing:border-box;margin-top:12px}
+input{border:1px solid #223044;border-radius:12px;padding:12px;background:#0f151d;color:#eef4ff}
+button{border:0;border-radius:12px;padding:13px;background:#1d324f;color:#eef4ff;font-weight:800}
+.warn{color:#ffd166;font-size:14px;line-height:1.4}
+.small{color:#7f8da3;font-size:13px}
+</style>
+</head>
+<body>
+<div class="wrap">
+  <div class="card">
+    <h1>Cargo ESP OTA</h1>
+    <p class="warn">Upload only firmware built for the Cargo ESP. The controller will reboot after a successful update.</p>
+    <form method="POST" action="/api/v1/system/ota" enctype="multipart/form-data">
+      <input type="file" name="firmware" accept=".bin" required>
+      <button type="submit">Upload Firmware</button>
+    </form>
+    <p class="small">Tip: Arduino IDE can create this with Sketch → Export Compiled Binary.</p>
+  </div>
+</div>
+</body>
+</html>
+)rawliteral";
+
+static bool otaUploadHadError = false;
+
+void handleOtaPage() {
+    server.send_P(200, "text/html", OTA_HTML);
+}
+
+void handleOtaUploadDone() {
+    DynamicJsonDocument doc(512);
+    doc["ok"] = !otaUploadHadError && !Update.hasError();
+    doc["firmware_name"] = FIRMWARE_NAME;
+    doc["message"] = doc["ok"].as<bool>() ? "OTA update complete. Rebooting." : "OTA update failed.";
+
+    String output;
+    serializeJson(doc, output);
+
+    if (doc["ok"].as<bool>()) {
+        server.send(200, "application/json", output);
+        delay(500);
+        ESP.restart();
+    } else {
+        server.send(500, "application/json", output);
+    }
+}
+
+void handleOtaUploadStream() {
+    HTTPUpload& upload = server.upload();
+
+    if (upload.status == UPLOAD_FILE_START) {
+        otaUploadHadError = false;
+        Serial.print("OTA: upload start: ");
+        Serial.println(upload.filename);
+
+        if (!Update.begin(UPDATE_SIZE_UNKNOWN)) {
+            otaUploadHadError = true;
+            Update.printError(Serial);
+        }
+    } else if (upload.status == UPLOAD_FILE_WRITE) {
+        if (!otaUploadHadError && Update.write(upload.buf, upload.currentSize) != upload.currentSize) {
+            otaUploadHadError = true;
+            Update.printError(Serial);
+        }
+    } else if (upload.status == UPLOAD_FILE_END) {
+        if (!otaUploadHadError && Update.end(true)) {
+            Serial.print("OTA: success, bytes=");
+            Serial.println(upload.totalSize);
+        } else {
+            otaUploadHadError = true;
+            Update.printError(Serial);
+        }
+    } else if (upload.status == UPLOAD_FILE_ABORTED) {
+        otaUploadHadError = true;
+        Update.abort();
+        Serial.println("OTA: upload aborted");
+    }
+}
+
+
 void handleResetApConfig() {
     resetApConfigToDefaults();
     restartAccessPoint();
@@ -1998,8 +2143,10 @@ void connectStaWifi() {
         WiFi.begin(staSsids[i].c_str(), staPasswords[i].c_str());
 
         unsigned long start = millis();
-        while (WiFi.status() != WL_CONNECTED && millis() - start < 10000) {
+        while (WiFi.status() != WL_CONNECTED && millis() - start < 8000) {
-            delay(500);
+            server.handleClient();
+            oledLoop();
+            delay(100);
             Serial.print(".");
         }
 
@@ -2333,9 +2480,6 @@ int findStatusFieldIndex(const String& field) {
 }
 
 
-
-
-
 void buildStatusDocument(JsonDocument& doc) {
     doc["type"] = MSG_STATUS_RESPONSE;
     doc["timestamp"] = millis();
@@ -3404,6 +3548,7 @@ void handleCapabilities() {
     endpoints.add("POST /api/v1/bms/setup/exit");
     endpoints.add("POST /api/v1/bms/scan");
     endpoints.add("POST /api/v1/bms/select");
+    endpoints.add("POST /api/v1/system/ota");
 
     JsonObject limits = doc.createNestedObject("limits");
     limits["relay_count"] = MAX_RELAYS;
@@ -3560,7 +3705,6 @@ void handleFactoryResetConfig() {
 }
 
 
-
 void sendWifiConfigJson() {
     DynamicJsonDocument doc(2048);
 
@@ -3971,63 +4115,53 @@ void handleStatus() {
     server.send(200, "application/json", output);
 }
 
+
 void setup() {
     Serial.begin(115200);
-
+    delay(2000);
-#if DASHBOARD_UART_ENABLED
-    DashboardSerial.begin(
-        DASHBOARD_UART_BAUD,
-        SERIAL_8N1,
-        0,
-        0
-    );
-    Serial.println("Legacy dashboard UART enabled");
-#endif
 
     Serial.println();
-    Serial.println("==================================");
+    Serial.println("Overland Controller LilyGO T-Relay S3 Booting");
-    Serial.println("Overland Controller Booting");
-    Serial.println("==================================");
-
-    oledBegin();
 
     loadConfig();
+
     printConfig();
 
     pinMode(IGNITION_PIN, INPUT);
 
     initRelays();
+
     initSensors();
+
     initBms();
 
     loadWifiConfig();
+
     loadApConfig();
 
+    WiFi.persistent(false);
+    WiFi.setSleep(false);
     WiFi.mode(WIFI_AP_STA);
-    startAccessPoint();
-    oledShowSetupPage();
 
-    connectStaWifi();
+    startAccessPoint();
+
 
     server.on("/", HTTP_GET, []() {
         server.send_P(200, "text/html", INDEX_HTML);
     });
 
-    server.on(API_V1("/status"), handleStatus);
     server.on(API_V1("/health"), HTTP_GET, handleHealth);
     server.on(API_V1("/capabilities"), HTTP_GET, handleCapabilities);
+    server.on(API_V1("/status"), handleStatus);
     server.on(API_V1("/relay/set"), HTTP_POST, handleSetRelayPost);
 
+
     server.on(API_V1("/config"), HTTP_GET, handleGetConfig);
     server.on(API_V1("/config/export"), HTTP_GET, handleExportConfig);
-    server.on(API_V1("/config/import"), HTTP_POST, handleImportConfig);
     server.on(API_V1("/config/wifi"), HTTP_GET, handleGetWifiConfig);
     server.on(API_V1("/config/ap"), HTTP_GET, handleGetApConfig);
     server.on(API_V1("/config/ap"), HTTP_POST, handleUpdateApConfig);
-    server.on(API_V1("/config/ap/reset"), HTTP_POST, handleResetApConfig);
+
-    server.on(API_V1("/config/wifi"), HTTP_POST, handleUpdateWifiConfig);
-    server.on(API_V1("/wifi/connect"), HTTP_POST, handleWifiConnect);
-    server.on(API_V1("/wifi/clear"), HTTP_POST, handleWifiClear);
 
     server.on(API_V1("/config/device"), HTTP_POST, handleUpdateDeviceConfig);
     server.on(API_V1("/config/relay"), HTTP_POST, handleUpdateRelayConfig);
@@ -4036,67 +4170,59 @@ void setup() {
     server.on(API_V1("/config/factory-reset"), HTTP_POST, handleFactoryResetConfig);
     server.on(API_V1("/config/save"), HTTP_POST, handleSaveConfig);
 
+
+    server.on(API_V1("/config/wifi"), HTTP_POST, handleUpdateWifiConfig);
+    server.on(API_V1("/wifi/connect"), HTTP_POST, handleWifiConnect);
+    server.on(API_V1("/wifi/clear"), HTTP_POST, handleWifiClear);
+
+
+    server.on(API_V1("/bms/scan"), HTTP_POST, handleBleScan);
+    server.on(API_V1("/bms/select"), HTTP_POST, handleSelectBms);
+
+
     server.on(API_V1("/temps/scan"), HTTP_POST, handleTempScan);
     server.on(API_V1("/temps/assign"), HTTP_POST, handleTempAssign);
     server.on(API_V1("/temps/clear"), HTTP_POST, handleTempClear);
 
+
+    server.on("/update", HTTP_GET, handleOtaPage);
+
+
+    server.on("/ota", HTTP_GET, handleOtaPage);
+    server.on(API_V1("/system/ota"), HTTP_POST,
+              handleOtaUploadDone,
+              handleOtaUploadStream);
+
+
+    server.on(API_V1("/config/import"), HTTP_POST, handleImportConfig);
+    server.on(API_V1("/config/ap/reset"), HTTP_POST, handleResetApConfig);
     server.on(API_V1("/bms/setup/enter"), HTTP_POST, handleEnterBmsSetup);
     server.on(API_V1("/bms/setup/exit"), HTTP_POST, handleExitBmsSetup);
-    server.on(API_V1("/bms/scan"), HTTP_POST, handleBleScan);
-    server.on(API_V1("/bms/select"), HTTP_POST, handleSelectBms);
-
-    // Compatibility aliases for pre-versioned local clients.
-    server.on("/status", handleStatus);
-    server.on("/relay/set", HTTP_POST, handleSetRelayPost);
-    server.on("/relay/relay_1/on", HTTP_GET, handleGenericRelayRoute);
-    server.on("/relay/relay_1/off", HTTP_GET, handleGenericRelayRoute);
-    server.on("/relay/relay_2/on", HTTP_GET, handleGenericRelayRoute);
-    server.on("/relay/relay_2/off", HTTP_GET, handleGenericRelayRoute);
-
-    server.on("/config", HTTP_GET, handleGetConfig);
-    server.on("/config/wifi", HTTP_GET, handleGetWifiConfig);
-    server.on("/config/wifi", HTTP_POST, handleUpdateWifiConfig);
-    server.on("/wifi/connect", HTTP_POST, handleWifiConnect);
-    server.on("/wifi/clear", HTTP_POST, handleWifiClear);
-
-    server.on("/config/device", HTTP_POST, handleUpdateDeviceConfig);
-    server.on("/config/relay", HTTP_POST, handleUpdateRelayConfig);
-    server.on("/config/bms", HTTP_POST, handleUpdateBmsConfig);
-    server.on("/config/temp", HTTP_POST, handleUpdateTempSensorConfig);
-    server.on("/config/factory-reset", HTTP_POST, handleFactoryResetConfig);
-    server.on("/config/save", HTTP_POST, handleSaveConfig);
-
-    server.on("/temps/scan", HTTP_POST, handleTempScan);
-    server.on("/temps/assign", HTTP_POST, handleTempAssign);
-    server.on("/temps/clear", HTTP_POST, handleTempClear);
-
-    server.on("/bms/setup/enter", HTTP_POST, handleEnterBmsSetup);
-    server.on("/bms/setup/exit", HTTP_POST, handleExitBmsSetup);
-    server.on("/bms/scan", HTTP_POST, handleBleScan);
-    server.on("/bms/select", HTTP_POST, handleSelectBms);
-
 
     server.begin();
-
     Serial.println("Web Server Started");
+    lastStaReconnectAttempt = millis() - STA_RECONNECT_INTERVAL_MS + 5000;
 }
 
 void loop() {
     server.handleClient();
+
     maintainStaWifi();
-    handleDebugSerial();
-    updateBms();
-    updateAlarms();
-#if DASHBOARD_UART_ENABLED
-    pollDashboardUart();
-#endif
-    oledLoop();
 
-    static unsigned long lastSensorUpdate = 0;
+    if (millis() - lastSensorUpdate > SENSOR_INTERVAL) {
-
-    if (millis() - lastSensorUpdate > 5000) {
         updateSensors();
         lastSensorUpdate = millis();
         logDebug("Sensor Update");
     }
+
+    if (millis() > 30000) {
+        updateBms();
+    }
+
+#if DASHBOARD_UART_ENABLED
+    pollDashboardUart();
+#endif
+
+    delay(2);
 }
+

firmware/esp32/overland-controller/relays.cpp

@@ -5,20 +5,55 @@
 
 RelayState relays;
 
+static uint8_t relayShiftRegisterState = 0;
+
+static void writeRelayShiftRegister()
+{
+    digitalWrite(LILYGO_T_RELAY_S3_LATCH_PIN, LOW);
+    shiftOut(
+        LILYGO_T_RELAY_S3_DATA_PIN,
+        LILYGO_T_RELAY_S3_CLOCK_PIN,
+        MSBFIRST,
+        relayShiftRegisterState
+    );
+    digitalWrite(LILYGO_T_RELAY_S3_LATCH_PIN, HIGH);
+}
+
 void initRelays() {
-    for (int i = 0; i < MAX_RELAYS; i++) {
+    pinMode(LILYGO_T_RELAY_S3_DATA_PIN, OUTPUT);
-        if (appConfig.relays[i].available) {
+    pinMode(LILYGO_T_RELAY_S3_CLOCK_PIN, OUTPUT);
-            pinMode(appConfig.relays[i].pin, OUTPUT);
+    pinMode(LILYGO_T_RELAY_S3_LATCH_PIN, OUTPUT);
-        }
+    pinMode(LILYGO_T_RELAY_S3_OE_PIN, OUTPUT);
-    }
+
+    // Keep outputs disabled while clearing the shift register.
+    digitalWrite(LILYGO_T_RELAY_S3_OE_PIN, HIGH);
+    relayShiftRegisterState = 0;
+    writeRelayShiftRegister();
+
+    // Enable relay outputs after known-off state is written.
+    digitalWrite(LILYGO_T_RELAY_S3_OE_PIN, LOW);
 
     updateRelayOutputs();
 }
 
 void updateRelayOutputs() {
+    uint8_t nextState = 0;
+
     for (int i = 0; i < MAX_RELAYS; i++) {
-        if (appConfig.relays[i].available) {
+        if (!appConfig.relays[i].available) {
-            digitalWrite(appConfig.relays[i].pin, relays.state[i]);
+            continue;
+        }
+
+        const uint8_t channel = appConfig.relays[i].hardwareChannel;
+        if (channel < 1 || channel > LILYGO_T_RELAY_S3_RELAY_COUNT) {
+            continue;
+        }
+
+        if (relays.state[i]) {
+            nextState |= (1U << (channel - 1));
         }
     }
+
+    relayShiftRegisterState = nextState;
+    writeRelayShiftRegister();
 }

firmware/esp32/overland-controller/system_status.h

@@ -1,4 +1,4 @@
 #pragma once
 
-#define FIRMWARE_VERSION "0.5.0"
+#define FIRMWARE_VERSION "0.5.5-wifi-connect-window-8s"
 #define FIRMWARE_NAME "overland-controller"

tests/fixtures/http_api/config_response.json

@@ -8,7 +8,7 @@
       "enabled": true,
       "role": "aux",
       "hardware_channel": 1,
-      "hardware_profile": "generic_esp32_2ch_relay",
+      "hardware_profile": "lilygo_t_relay_s3_6ch",
       "available": true
     },
     {
@@ -18,7 +18,7 @@
       "enabled": true,
       "role": "fridge",
       "hardware_channel": 2,
-      "hardware_profile": "generic_esp32_2ch_relay",
+      "hardware_profile": "lilygo_t_relay_s3_6ch",
       "available": true
     }
   ],
@@ -38,6 +38,6 @@
       "weather": false
     }
   ],
-  "hardware_profile": "generic_esp32_2ch_relay",
+  "hardware_profile": "lilygo_t_relay_s3_6ch",
-  "output_count": 2
+  "output_count": 6
 }

tests/fixtures/http_api/status_response.json

@@ -44,7 +44,7 @@
       "state": false,
       "role": "aux",
       "hardware_channel": 1,
-      "hardware_profile": "generic_esp32_2ch_relay",
+      "hardware_profile": "lilygo_t_relay_s3_6ch",
       "available": true
     },
     {
@@ -55,7 +55,7 @@
       "state": true,
       "role": "fridge",
       "hardware_channel": 2,
-      "hardware_profile": "generic_esp32_2ch_relay",
+      "hardware_profile": "lilygo_t_relay_s3_6ch",
       "available": true
     }
   ],
@@ -106,7 +106,7 @@
         "enabled": true,
         "role": "aux",
         "hardware_channel": 1,
-        "hardware_profile": "generic_esp32_2ch_relay",
+        "hardware_profile": "lilygo_t_relay_s3_6ch",
         "available": true
       }
     ],
@@ -126,9 +126,9 @@
         "weather": false
       }
     ],
-    "hardware_profile": "generic_esp32_2ch_relay",
+    "hardware_profile": "lilygo_t_relay_s3_6ch",
     "output_count": 2
   },
-  "hardware_profile": "generic_esp32_2ch_relay",
+  "hardware_profile": "lilygo_t_relay_s3_6ch",
-  "output_count": 2
+  "output_count": 6
 }

tests/test_http_api_contract.py

@@ -57,10 +57,23 @@ def test_firmware_registers_current_http_contract_routes():
     assert expected_routes <= routes
 
 
-def test_firmware_keeps_root_compatibility_aliases():
+def test_firmware_uses_v1_routes_without_legacy_aliases():
     routes = registered_routes()
 
-    compatibility_routes = {
+    required_v1_routes = {
+        ("/api/v1/status", "ANY"),
+        ("/api/v1/config", "HTTP_GET"),
+        ("/api/v1/relay/set", "HTTP_POST"),
+        ("/api/v1/config/wifi", "HTTP_GET"),
+        ("/api/v1/config/wifi", "HTTP_POST"),
+        ("/api/v1/wifi/connect", "HTTP_POST"),
+        ("/api/v1/wifi/clear", "HTTP_POST"),
+        ("/api/v1/temps/scan", "HTTP_POST"),
+        ("/api/v1/temps/assign", "HTTP_POST"),
+        ("/api/v1/temps/clear", "HTTP_POST"),
+    }
+
+    removed_legacy_routes = {
         ("/status", "ANY"),
         ("/config", "HTTP_GET"),
         ("/relay/set", "HTTP_POST"),
@@ -73,7 +86,8 @@ def test_firmware_keeps_root_compatibility_aliases():
         ("/temps/clear", "HTTP_POST"),
     }
 
-    assert compatibility_routes <= routes
+    assert required_v1_routes <= routes
+    assert routes.isdisjoint(removed_legacy_routes)
 
 
 def test_embedded_webui_uses_versioned_api_routes():
@@ -134,8 +148,8 @@ def test_status_fixture_matches_dashboard_contract_shape():
         "online",
         "temperature_f",
     ])
-    assert payload["hardware_profile"] == "generic_esp32_2ch_relay"
+    assert payload["hardware_profile"] == "lilygo_t_relay_s3_6ch"
-    assert payload["output_count"] == 2
+    assert payload["output_count"] == 6
     assert_keys(payload["relays"][0], [
         "id",
         "name",
@@ -180,8 +194,8 @@ def test_config_fixture_matches_current_config_response_shape():
         "temperature_sensor_count",
         "temperature_sensors",
     ])
-    assert payload["hardware_profile"] == "generic_esp32_2ch_relay"
+    assert payload["hardware_profile"] == "lilygo_t_relay_s3_6ch"
-    assert payload["output_count"] == 2
+    assert payload["output_count"] == 6
     assert_keys(payload["relays"][0], [
         "id",
         "name",
@@ -461,6 +475,9 @@ def test_cargo_oled_shows_setup_and_service_pages():
     assert 'oledClear("Relays")' in source
     assert 'oledClear("Network")' in source
     assert 'oledClear("Alarms")' in source
+    config = Path("firmware/esp32/overland-controller/config.h").read_text()
+    oled_disabled = "OLED_SETUP_ENABLED 0" in config or "LILYGO_T_RELAY_S3" in config
+    if not oled_disabled:
         assert "oledShowSetupPage();" in source
     assert "oledLoop();" in source