xterra-overland-dashboard/docs/hardware-bringup-checklist.md

Hardware Bring-Up Checklist

ESP32 Cargo Controller

Compile

• Firmware compiles successfully

• Required libraries installed:

  • ArduinoJson
  • OneWire
  • DallasTemperature

Upload

• Board: ESP32 Dev Module
• Serial monitor opens at 115200 baud
• Boot message appears

WiFi AP

Verify ESP32 creates AP:

• SSID: XterraController

HTTP API

Test:

http://192.168.4.1/status

Expected:

• JSON response
• Battery placeholder values present
• Relay states present
• Sensor health present
• Network status present

Relays

Test endpoints:

/relay/starlink/on
/relay/starlink/off
/relay/fridge/on
/relay/fridge/off

Verify:

• GPIO16 controls Starlink relay channel
• GPIO17 controls Fridge relay channel
• Relay logic is correct
• If relay behavior is backwards, update relay active-high/active-low logic

DS18B20 Sensors

Verify:

• Sensor bus initializes
• Missing sensors do not crash firmware
• Connected sensors report temperatures
• Sensor fault state works

UART

Verify:

• UART initializes
• ESP32 does not crash without Pico connected
• Serial JSON protocol works once Pico or USB-UART test is connected

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Pico Dashboard

Pico Boot

Verify:

• Pico 2 W boots
• MicroPython or CircuitPython environment works
• Main script runs

Display

Verify:

• ST7796S initializes
• Screen fill works
• Text drawing works
• Rotation/orientation is correct

Touch

Verify:

• FT6336U initializes
• Touch events are detected
• X/Y coordinates match screen orientation
• Bottom navigation zones match expected touch positions

Buzzer

Verify:

• Active buzzer turns on
• Active buzzer turns off
• Buzzer does not block UI loop

UART to ESP32

Verify:

• Pico sends status request
• ESP32 responds with status response
• Pico parses response
• Pico updates app state
• Pico sends relay command
• ESP32 toggles relay
• Pico receives relay response

---

System Integration

Dashboard

Verify:

• Battery placeholder data displays
• Temperatures display
• Relay states display
• Communication state displays

Alarms

Verify:

• Communication loss alarm triggers
• Sensor fault alarm triggers
• Fridge high-temp alarm triggers
• Low battery alarm triggers
• Critical alarms trigger buzzer

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Do Not Proceed Until

Before moving to production wiring:

• ESP32 firmware boots reliably
• Relays behave correctly
• UART protocol works
• Pico display works
• Pico touch works
• Buzzer works
• No high-current loads pass through ESP32 relay contacts