merge: LilyGO T-Relay S3 cargo controller support

This reverts commit ac6b0475ff.

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/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

@@ -213,3 +213,13 @@ Rationale:
 - 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

@@ -4,7 +4,7 @@ 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_PASSWORD = "overland1234";
+static const char *CARGO_WIFI_PASSWORD = "Ward1707";
 
 //static const char *CARGO_WIFI_SSID = "WardAP";
 //static const char *CARGO_WIFI_PASSWORD = "Ward5213";
@@ -14,7 +14,7 @@ static const char *CARGO_API_FAST_STATUS_URL = "http://192.168.4.1/api/v1/status
 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_STATUS_URL = "http://192.168.88.108/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_SLOW_STATUS_URL = "http://192.168.88.108/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_STATUS_URL = "http://192.168.88.181/api/v1/status";
+//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://192.168.88.181/api/v1/status?fields=network,system,config";
+//static const char *CARGO_API_RELAY_SET_URL = "http://192.168.88.181/api/v1/relay/set";

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] = {
-        "relay_1",
-        "Relay 1",
-        "aux",
-        1,
-        RELAY_1_PIN,
-        true,
-        true
-    };
-
-    appConfig.relays[1] = {
-        "relay_2",
-        "Relay 2",
-        "fridge",
-        2,
-        RELAY_2_PIN,
-        true,
-        true
-    };
+    appConfig.relays[0] = defaultRelayConfig(1, "Relay 1", "aux");
+    appConfig.relays[1] = defaultRelayConfig(2, "Relay 2", "fridge");
+    appConfig.relays[2] = defaultRelayConfig(3, "Relay 3", "starlink");
+    appConfig.relays[3] = defaultRelayConfig(4, "Relay 4", "aux");
+    appConfig.relays[4] = defaultRelayConfig(5, "Relay 5", "aux");
+    appConfig.relays[5] = defaultRelayConfig(6, "Relay 6", "aux");
 
     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/config.h

@@ -2,24 +2,25 @@
 
 #define DEVICE_NAME "Overland Controller"
 
-// Relay Outputs
-#define RELAY_1_PIN 16
-#define RELAY_2_PIN 17
+// LilyGO T-Relay S3 6-relay board.
+// Relays are driven through onboard 74HC595 shift register.
+#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
-#define ONEWIRE_PIN 4
+// Compatibility placeholder only. Relays are not direct GPIO outputs.
+#define RELAY_SHIFT_REGISTER_PIN 255
 
-// Ignition Sense
-#define IGNITION_PIN 34
+// GPIO4 is used by the LilyGO relay shift-register OE pin.
+#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

@@ -1,4 +1,5 @@
 #include <WiFi.h>
+#include <esp_heap_caps.h>
 #include <WebServer.h>
 #include <Preferences.h>
 #include <esp_wifi.h>
@@ -638,12 +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>
@@ -1045,12 +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")) $("bmsNameInput").value=bms.name||"";
-  if($("bmsAddressInput")) $("bmsAddressInput").value=bms.address||"";
-  if($("bmsAddressTypeInput")) $("bmsAddressTypeInput").value=bms.address_type||"public";
+  setConfigValue("bmsNameInput", bms.name||"");
+  setConfigValue("bmsAddressInput", bms.address||"");
+  setConfigValue("bmsAddressTypeInput", bms.address_type||"public");
 }
 
 async function saveDeviceConfig(){
@@ -1069,6 +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()||"";
@@ -1198,12 +1242,18 @@ function renderConfigControls(data){
 
   const relayBox=$("relayConfigList");
   if(relayBox){
-    relayBox.innerHTML=relays.map((r,i)=>`
-      <div class="configrow">
-        <label>${r.id}</label>
-        <input id="relayName${i}" value="${r.name||""}" placeholder="Relay name">
-        <label>${r.enabled?"Enabled":"Disabled"}</label>
-      </div>`).join("");
+    const signature=relays.map(r=>r.id).join("|");
+    if(relayBox.dataset.signature!==signature){
+      relayBox.dataset.signature=signature;
+      relayBox.innerHTML=relays.map((r,i)=>`
+        <div class="configrow">
+          <label>${r.id}</label>
+          <input id="relayName${i}" placeholder="Relay name" oninput="markConfigFieldTouched('relayName${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);
@@ -1459,6 +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) {
@@ -1649,7 +1702,6 @@ void sendSimpleJsonError(int status, const char* error, const char* detail) {
 }
 
 
-
 const char OTA_HTML[] PROGMEM = R"rawliteral(
 <!doctype html>
 <html>
@@ -2428,9 +2480,6 @@ int findStatusFieldIndex(const String& field) {
 }
 
 
-
-
-
 void buildStatusDocument(JsonDocument& doc) {
     doc["type"] = MSG_STATUS_RESPONSE;
     doc["timestamp"] = millis();
@@ -3656,7 +3705,6 @@ void handleFactoryResetConfig() {
 }
 
 
-
 void sendWifiConfigJson() {
     DynamicJsonDocument doc(2048);
 
@@ -4067,67 +4115,53 @@ void handleStatus() {
     server.send(200, "application/json", output);
 }
 
+
 void setup() {
     Serial.begin(115200);
-
-#if DASHBOARD_UART_ENABLED
-    DashboardSerial.begin(
-        DASHBOARD_UART_BAUD,
-        SERIAL_8N1,
-        0,
-        0
-    );
-    Serial.println("Legacy dashboard UART enabled");
-#endif
+    delay(2000);
 
     Serial.println();
-    Serial.println("==================================");
-    Serial.println("Overland Controller Booting");
-    Serial.println("==================================");
-
-    oledBegin();
+    Serial.println("Overland Controller LilyGO T-Relay S3 Booting");
 
     loadConfig();
+
     printConfig();
 
     pinMode(IGNITION_PIN, INPUT);
 
     initRelays();
+
     initSensors();
+
     initBms();
 
     loadWifiConfig();
+
     loadApConfig();
 
+    WiFi.persistent(false);
+    WiFi.setSleep(false);
     WiFi.mode(WIFI_AP_STA);
-    startAccessPoint();
-    oledShowSetupPage();
 
-    // Do not block setup on STA WiFi. Start the AP and web server first so the
-    // local Web UI/API remains available even when no saved WiFi networks exist.
-    lastStaReconnectAttempt = millis() - STA_RECONNECT_INTERVAL_MS;
+    startAccessPoint();
+
 
     server.on("/", HTTP_GET, []() {
         server.send_P(200, "text/html", INDEX_HTML);
     });
-    server.on("/ota", HTTP_GET, handleOtaPage);
-    server.on(API_V1("/system/ota"), HTTP_POST, handleOtaUploadDone, handleOtaUploadStream);
 
-    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);
@@ -4136,67 +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 > 5000) {
+    if (millis() - lastSensorUpdate > SENSOR_INTERVAL) {
         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++) {
-        if (appConfig.relays[i].available) {
-            pinMode(appConfig.relays[i].pin, OUTPUT);
-        }
-    }
+    pinMode(LILYGO_T_RELAY_S3_DATA_PIN, OUTPUT);
+    pinMode(LILYGO_T_RELAY_S3_CLOCK_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) {
-            digitalWrite(appConfig.relays[i].pin, relays.state[i]);
+        if (!appConfig.relays[i].available) {
+            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();
 }

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",
-  "output_count": 2
+  "hardware_profile": "lilygo_t_relay_s3_6ch",
+  "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",
-  "output_count": 2
+  "hardware_profile": "lilygo_t_relay_s3_6ch",
+  "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["output_count"] == 2
+    assert payload["hardware_profile"] == "lilygo_t_relay_s3_6ch"
+    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["output_count"] == 2
+    assert payload["hardware_profile"] == "lilygo_t_relay_s3_6ch"
+    assert payload["output_count"] == 6
     assert_keys(payload["relays"][0], [
         "id",
         "name",
@@ -461,7 +475,10 @@ def test_cargo_oled_shows_setup_and_service_pages():
     assert 'oledClear("Relays")' in source
     assert 'oledClear("Network")' in source
     assert 'oledClear("Alarms")' in source
-    assert "oledShowSetupPage();" 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