Butterfly EDFA Rack bridge: seed + EDFA over WiFi/MQTT to Home Assistant

ESP32 firmware bridging the 1550 nm MOPA (Koheron CTL200 seed + Agiltron
M511 two-stage EDFA) to MQTT/HA as a single device. Telemetry and control
for both instruments verified end-to-end: MQTT command -> seed lasing ->
booster ramp to 27 dBm (~515 mW) at the documented 2500 mA operating point.

- PlatformIO/Arduino project, project-local venv, Makefile upload flow
- Koheron ASCII driver on UART2; Agiltron binary 0x55AA driver on UART1
- HA discovery (sensors, binary_sensors, switches, numbers); LWT availability
- Static IP, firmware current clamps on seed and booster pump
This commit is contained in:
James Bateman (hp-laptop)
2026-06-19 10:16:50 +01:00
commit 58475386ba
11 changed files with 967 additions and 0 deletions
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.venv/
.pio/
include/secrets.h
*.pyc
__pycache__/
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# Koheron CTL200 -> WiFi/MQTT bridge on ESP32.
#
# All commands run PlatformIO from the project-local venv, so you never need
# `pio` on your PATH. Just `make`, `make upload`, `make monitor`.
VENV := .venv
PIO := $(VENV)/bin/pio
PORT ?= /dev/ttyUSB0
ENV := esp32dev
.PHONY: help build upload monitor flash clean detect erase venv
help: ## Show this help
@grep -E '^[a-zA-Z_-]+:.*?## .*$$' $(MAKEFILE_LIST) \
| awk 'BEGIN{FS=":.*?## "}{printf " \033[36m%-10s\033[0m %s\n", $$1, $$2}'
build: $(PIO) ## Compile firmware
$(PIO) run -e $(ENV)
upload: $(PIO) ## Compile + flash to the ESP32
$(PIO) run -e $(ENV) -t upload --upload-port $(PORT)
monitor: $(PIO) ## Open serial monitor (Ctrl-C to exit)
$(PIO) device monitor --port $(PORT) -b 115200
flash: upload monitor ## Upload then immediately open the monitor
detect: $(PIO) ## Identify the chip on $(PORT)
$(VENV)/bin/python -m esptool --port $(PORT) chip_id
erase: $(PIO) ## Erase entire flash (factory reset)
$(VENV)/bin/python -m esptool --port $(PORT) erase_flash
clean: $(PIO) ## Remove build artifacts
$(PIO) run -e $(ENV) -t clean
# Recreate the venv if it is missing (e.g. fresh checkout).
venv $(PIO):
python3 -m venv $(VENV)
$(VENV)/bin/pip install --upgrade pip
$(VENV)/bin/pip install platformio esptool
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# koheron-esp32-bridge
ESP32 firmware that bridges the **Butterfly EDFA Rack** — a 1550 nm MOPA:
a [Koheron CTL200](https://www.koheron.com/photonics/ctl200-digital-laser-controller/)
driving a DFB seed into an Agiltron M511 EYDFA power amplifier (output up to
~1 W / 30 dBm) — to WiFi/MQTT for monitoring and control from Home Assistant
(broker `192.168.0.102:1883`, anonymous).
The whole rack is presented as a **single HA device** (`butterfly_edfa_rack`).
Topics, mirroring the lab's EDFA→MQTT convention:
```
lab/laser/butterfly_edfa_rack/availability online | offline (LWT)
lab/laser/butterfly_edfa_rack/diag/<key> ESP/network diagnostics
lab/laser/butterfly_edfa_rack/seed/<key> Koheron CTL200 (increment 3)
lab/laser/butterfly_edfa_rack/amp/<key> Agiltron M511 (increment 4)
lab/laser/butterfly_edfa_rack/set/<...> commands (increment 5)
```
HA discovery configs are published under `homeassistant/...`, all sharing one
`device` block so entities group under the single rack device.
## Optical architecture
The rack is a **MOPA** (master-oscillator power-amplifier) at 1550 nm:
```
Koheron CTL200 Agiltron M511 EYDFA (two-stage)
┌──────────────┐ ┌─────────────────────────────────────┐
│ DFB1550LP │ fibre │ pre-amp stage ──► booster stage │ fibre
│ seed diode ├─────────►│ (pump diode A) (pump diode B, ├────────► output
│ + TEC │ │ ~170 mA, ~16 dBm "pump-1") │ (up to ~1 W
└──────────────┘ └─────────────────────────────────────┘ / 30 dBm)
ilaser, lason input PD preamp PD output-1 PD
```
**The M511 has two internal pump diodes**, and the firmware reads both:
- **Pre-amp pump** — runs semi-independently at ~170 mA, lifts the seed to
~16 dBm (`amp/preamp_current_ma`, `amp/preamp_power_dbm`).
- **Booster pump = "pump-1"** — the controllable output stage
(`amp/pump1_current_ma`, set via `set/amp/pump1_current_ma`).
- **"Pump-2"** is a second booster channel that this unit leaves at 0 mA
regardless of settings (per `Lab/Equipment/Lasers/Agiltron EDFA`); we don't
drive it. It is read but not exposed as a control.
Run the booster in **ACC (constant-current)** mode — APC stepping quantises the
output. Below transparency the booster erbium fibre *absorbs* the pre-amp
output, so output stays at the PD floor (−60 dBm) until the pump is high
enough. Measured 2026-06-17 with ~6 mW (7.8 dBm) seed into the EDFA:
| Pump-1 | Output-1 | note |
|-------:|---------:|------|
| 500–900 mA | −60 dBm | below transparency, signal absorbed |
| 1200 mA | 21.0 dBm | booster turns on |
| 1500 mA | 23.3 dBm | |
| 2000 mA | 25.9 dBm | |
| 2500 mA | 27.1 dBm | documented operating point, ~515 mW |
Pump current overshoots ~2× briefly on each step up and settles in 2–4 s, so
**ramp gradually** rather than jumping straight to the setpoint.
> **Safety:** this is a Class 4, ~1 W, invisible 1550 nm source. The firmware
> clamps pump-1 to `PUMP_CURRENT_MAX_MA` (3000 mA) and seed current to
> `SEED_CURRENT_MAX_MA`, but those are not interlocks — treat the output as
> hazardous unless it terminates in a power meter / beam dump / closed system.
## Hardware
- ESP32-D0WD-V3 dev board (WROOM-32 class), CP2102N USB bridge → `/dev/ttyUSB0`,
MAC `b0:cb:d8:8f:ba:10`.
- The ESP32 USB port is used **only** for flashing/console (UART0).
- Two instrument links on separate hardware UARTs:
| ESP32 | Instrument | Protocol |
|----------------|-------------------------------------|----------|
| GPIO17 (TX2) → | Koheron CTL200 RX (terminal block) | ASCII, 115200 8N1, `\r\n`, `>>` prompt |
| GPIO16 (RX2) ← | Koheron CTL200 TX | |
| GPIO26 (TX1) → | Agiltron M511 RX (P2 pin 3) | binary 0x55AA packets, 115200 8N1 |
| GPIO25 (RX1) ← | Agiltron M511 TX (P2 pin 7) | |
| GND | both grounds | |
All links are 3V3 logic (CTL200 is 5V-tolerant). UART1 is remapped off its
default flash-clashing pins.
> **Network:** the firmware pins a static IP `192.168.0.150` (gateway `.1`,
> /24) — see `USE_STATIC_IP` in `include/config.h`. This avoids the clash with
> the BKtel EDFA Pi on `.101` that a DHCP lease originally caused. `.150` is
> outside any device documented in the HA notes; move it if your DHCP pool
> overlaps.
## Toolchain
PlatformIO (Arduino framework), pinned in a project-local `.venv` so nothing
is installed globally.
```bash
make # show targets
make build # compile
make upload # compile + flash (PORT=/dev/ttyUSB0 by default)
make monitor # serial console at 115200
make detect # identify the chip on the port
```
A fresh checkout self-bootstraps the venv on first `make`.
## Configuration
Copy `include/secrets.example.h` → `include/secrets.h` (git-ignored) and fill
in WiFi + MQTT details. Needed from increment 2 onward.
## Increment roadmap
- [x] **1 — toolchain check.** Blink + serial heartbeat; confirms build/upload/monitor.
- [x] **2 — WiFi + MQTT + HA discovery.** Joins WiFi, connects to broker with an
LWT availability topic, publishes diagnostic entities (uptime, RSSI, IP).
- [x] **3 — Seed telemetry (read-only).** UART2 → Koheron `lason`/`ilaser`/`vlaser`/
`rtset`/`rtact`/`itec`/`vtec`/`tboard`/`iphd`/`err`; published under `seed/...`
as HA sensors. Verified live against CTL200 fw v0.21 (echo + value + `>>`
framing, parsed correctly).
- [x] **4 — Amp telemetry (read-only).** UART1 → Agiltron `get_status` (binary
0x55AA, ported from `edfa.py`); publishes module/pre-amp temp, pre-amp &
pump-1 currents, input/pre-amp/output dBm, warnings under `amp/...`.
Verified against the live unit (SN Y4022708, PN EDFA-1C51113331111,
device ID 0x0000006F). `amp/pump_enabled` reads the authoritative
`get_settings` field.
- [x] **5 — control.** `set/...` for seed (`lason`, `ilaser`) and amp (pump
on/off, pump-1 ACC current) as HA switch/number entities, with firmware
current clamps. Verified end-to-end: MQTT command → seed lasing → booster
ramp to 27 dBm. (Future: seed `rtset`/`tecon`, amp APC power, Koheron `save`.)
## MQTT interface
State topics retained under `lab/laser/butterfly_edfa_rack/`:
| Topic suffix | Meaning |
|--------------|---------|
| `availability` | `online` / `offline` (LWT) |
| `diag/{uptime,rssi,ip}` | ESP / network diagnostics |
| `seed/link` | Koheron reachable? |
| `seed/laser_enabled` | seed laser on (1/0) |
| `seed/current_ma`, `seed/voltage_v` | seed drive |
| `seed/rt_setpoint_ohm`, `seed/rt_actual_ohm` | thermistor setpoint / actual |
| `seed/tec_current_a`, `seed/tec_voltage_v`, `seed/board_temp_c` | seed TEC / board |
| `seed/photodiode_ma`, `seed/error` | seed monitor PD, CTL200 error code |
| `amp/link` | Agiltron reachable? |
| `amp/module_temp_c`, `amp/preamp_temp_c` | EDFA temperatures |
| `amp/preamp_current_ma`, `amp/preamp_power_dbm` | pre-amp stage |
| `amp/pump1_current_ma`, `amp/pump1_set_ma` | booster pump actual / setpoint |
| `amp/input_power_dbm`, `amp/output1_power_dbm`, `amp/output2_power_dbm` | optical powers |
| `amp/pump_enabled`, `amp/warnings` | booster state, decoded warnings |
Command topics (publish to `lab/laser/butterfly_edfa_rack/set/`):
| Topic suffix | Payload | Action |
|--------------|---------|--------|
| `seed/laser` | `1` / `0` | Koheron `lason` |
| `seed/current_ma` | mA | Koheron `ilaser` (clamped ≤ `SEED_CURRENT_MAX_MA`) |
| `amp/pump` | `1` / `0` | Agiltron pump on / off |
| `amp/pump1_current_ma` | mA | set ACC mode + pump-1 current (clamped ≤ `PUMP_CURRENT_MAX_MA`) |
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// Compile-time configuration for the Butterfly EDFA Rack bridge.
#pragma once
#include "secrets.h"
// ── MQTT topics ─────────────────────────────────────────────────────
// One HA device, one topic base. Sub-units namespaced under it:
// <base>/availability online | offline (LWT)
// <base>/diag/<key> ESP/network diagnostics
// <base>/seed/<key> Koheron CTL200 (increment 3)
// <base>/amp/<key> Agiltron M511 EYDFA (increment 4)
// <base>/set/<...> command topics (increment 5)
#define TOPIC_BASE "lab/laser/" DEVICE_NAME
#define TOPIC_AVAIL TOPIC_BASE "/availability"
#define DISCOVERY_PREFIX "homeassistant"
#define AVAIL_ONLINE "online"
#define AVAIL_OFFLINE "offline"
#define TOPIC_CMD TOPIC_BASE "/set" // subscribe <base>/set/#
// ── Agiltron M511 identity & safety limits ──────────────────────────
// SN Y4022708 / PN EDFA-1C51113331111 -> device ID 0x0000006F (edfa.py).
// Startup reads SN/PN and logs them so the ID is confirmed before control.
#define AGILTRON_DEV_ID 0x00, 0x00, 0x00, 0x6F
// HA number sliders are capped here. The hardware allows 8000 mA pump, but
// the lab notes report ~2500 mA pump-1 -> ~27 dBm (~515 mW). Keep a margin.
#define SEED_CURRENT_MAX_MA 300 // CTL200 ilmax default is 1000; seed DFB is low-power
#define PUMP_CURRENT_MAX_MA 3000 // firmware clamps amp pump-1 to this
// ── Serial links to the instruments (wired in later increments) ─────
// UART0 stays the USB console. The classic ESP32 has 3 hardware UARTs.
//
// Koheron CTL200 (ASCII, 115200 8N1, "\r\n", ">>" prompt) -> UART2
// ESP32 GPIO17 (TX2) -> CTL200 RX, GPIO16 (RX2) <- CTL200 TX, GND
//
// Agiltron M511 (binary 0x55AA packets, 115200 8N1) -> UART1
// ESP32 GPIO26 (TX1) -> M511 RX(pin3), GPIO25 (RX1) <- M511 TX(pin7), GND
// (UART1 default pins clash with SPI flash on WROOM, so remap to 26/25.)
#define KOHERON_UART_NUM 2
#define KOHERON_TX_PIN 17
#define KOHERON_RX_PIN 16
#define KOHERON_BAUD 115200
#define AGILTRON_UART_NUM 1
#define AGILTRON_TX_PIN 26
#define AGILTRON_RX_PIN 25
#define AGILTRON_BAUD 115200
// ── Static IP ───────────────────────────────────────────────────────
// Pinned to .150 (free as of 2026-06-17) to avoid the DHCP clash with the
// BKtel EDFA Pi on .101. Comment out USE_STATIC_IP to fall back to DHCP.
#define USE_STATIC_IP
#define STATIC_IP_OCTETS 192, 168, 0, 150
#define GATEWAY_OCTETS 192, 168, 0, 1
#define SUBNET_OCTETS 255, 255, 255, 0
#define DNS_OCTETS 192, 168, 0, 1
// ── Timing ──────────────────────────────────────────────────────────
#define PUBLISH_INTERVAL_MS 2000 // telemetry cadence
#define MQTT_RECONNECT_MS 5000
// PubSubClient's default 256-byte buffer is too small for discovery
// payloads that embed the device block; bump it.
#define MQTT_BUFFER_SIZE 1024
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// Copy to secrets.h and fill in. secrets.h is git-ignored.
#pragma once
#define WIFI_SSID "your-ssid"
#define WIFI_PASSWORD "your-password"
#define MQTT_BROKER "192.168.0.102" // HA / mosquitto host
#define MQTT_PORT 1883
// Broker allows anonymous; leave user/pass empty unless that changes.
#define MQTT_USER ""
#define MQTT_PASSWORD ""
// Logical unit slug -> topics live under lab/laser/<DEVICE_NAME>/...
#define DEVICE_NAME "butterfly_edfa_rack"
#define DEVICE_FRIENDLY "Butterfly EDFA Rack"
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; PlatformIO project for the Koheron CTL200 -> WiFi/MQTT bridge on ESP32.
; Board: ESP32-D0WD-V3 (WROOM-32 class) on a CP2102N USB bridge.
[env:esp32dev]
platform = espressif32
board = esp32dev
framework = arduino
; CP2102N enumerates as /dev/ttyUSB0 on this PC. Override at the command line
; with `pio run -t upload --upload-port /dev/ttyXXX` if it moves.
upload_port = /dev/ttyUSB0
monitor_port = /dev/ttyUSB0
; The ESP32's own USB console. The Koheron link is a *separate* hardware UART
; (see src/main.cpp) so the two never collide.
monitor_speed = 115200
upload_speed = 460800
; MQTT client. PubSubClient is small and battle-tested.
lib_deps =
knolleary/PubSubClient@^2.8
; Keep WiFi/MQTT credentials out of source control: see include/secrets.h.
build_flags =
-DCORE_DEBUG_LEVEL=3
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#include "agiltron.h"
uint8_t Agiltron::checksum(const uint8_t *p, size_t n) {
uint32_t s = 0;
for (size_t i = 0; i < n; i++) s += p[i];
return ((0xFF - (s & 0xFF)) + 0x01) & 0xFF;
}
size_t Agiltron::buildPacket(uint8_t *out, uint8_t cmd, const uint8_t *data, uint8_t len) {
size_t i = 0;
out[i++] = 0x55;
out[i++] = 0xAA;
for (int k = 0; k < 4; k++) out[i++] = _devId[k];
out[i++] = cmd;
out[i++] = len;
for (uint8_t k = 0; k < len; k++) out[i++] = data[k];
// checksum covers everything from dev_id onward (i.e. skip the 0x55 0xAA)
out[i] = checksum(out + 2, i - 2);
i++;
return i;
}
size_t Agiltron::transact(uint8_t cmd, const uint8_t *data, uint8_t len,
uint8_t *buf, size_t bufLen, uint32_t timeoutMs) {
uint8_t pkt[64];
size_t n = buildPacket(pkt, cmd, data, len);
while (_ser.available()) _ser.read(); // flush stale
_ser.write(pkt, n);
_ser.flush();
size_t got = 0;
uint32_t start = millis(), lastByte = start;
const uint32_t IDLE_GAP = 30; // binary reply is short and prompt
while (millis() - start < timeoutMs) {
while (_ser.available() && got < bufLen) {
buf[got++] = (uint8_t)_ser.read();
lastByte = millis();
}
if (got && (millis() - lastByte) > IDLE_GAP) break;
delay(2);
}
return got;
}
bool Agiltron::validate(const uint8_t *buf, size_t n, uint8_t expectCmd) {
if (n < 8) return false;
if (buf[0] != 0xAA || buf[1] != 0x55) return false;
if (buf[6] != expectCmd) return false;
return true;
}
AmpStatus Agiltron::getStatus() {
AmpStatus st;
uint8_t r[64];
size_t n = transact(0x2F, nullptr, 0, r, sizeof(r));
if (!validate(r, n, 0x2F) || n < 32) { _linkOk = false; return st; }
_linkOk = true;
st.module_temp_c = u16(r[10], r[11]) / 10.0f;
st.preamp_temp_c = u16(r[12], r[13]) / 10.0f;
st.preamp_current_ma = u16(r[14], r[15]) / 10.0f;
st.tec_current_ma = u16(r[16], r[17]) / 10.0f;
st.pump1_current_ma = u16(r[18], r[19]);
st.pump2_current_ma = u16(r[20], r[21]);
st.input_power_dbm = s16(r[22], r[23]) / 100.0f;
st.preamp_power_dbm = s16(r[24], r[25]) / 100.0f;
st.output1_power_dbm = s16(r[26], r[27]) / 100.0f;
st.output2_power_dbm = s16(r[28], r[29]) / 100.0f;
st.warn_byte = r[31];
st.valid = true;
return st;
}
int Agiltron::getPumpEnabled() {
uint8_t r[64];
size_t n = transact(0x2E, nullptr, 0, r, sizeof(r));
if (!validate(r, n, 0x2E) || n < 10) return -1;
return (u16(r[8], r[9]) == 0) ? 1 : 0; // edfa.py: ==0 means enabled
}
String Agiltron::getSn() {
uint8_t r[64];
size_t n = transact(0x1F, nullptr, 0, r, sizeof(r));
if (!validate(r, n, 0x1F)) return String();
String s;
for (size_t i = 8; i + 1 < n; i++) { // r[8 .. n-2], drop checksum
char c = (char)r[i];
if (c >= 32 && c < 127) s += c;
}
s.trim();
return s;
}
String Agiltron::getPn() {
uint8_t r[64];
size_t n = transact(0x1E, nullptr, 0, r, sizeof(r));
if (!validate(r, n, 0x1E)) return String();
String s;
for (size_t i = 8; i + 1 < n; i++) {
char c = (char)r[i];
if (c >= 32 && c < 127) s += c;
}
s.trim();
return s;
}
bool Agiltron::setPump1Current(int ma) {
if (ma < 0 || ma > MAX_PUMP_CURRENT_MA) return false;
uint8_t d[2] = {(uint8_t)((ma >> 8) & 0xFF), (uint8_t)(ma & 0xFF)};
return cmdAck(0x23, d, 2);
}
bool Agiltron::cmdAck(uint8_t cmd, const uint8_t *data, uint8_t len) {
uint8_t r[64];
size_t n = transact(cmd, data, len, r, sizeof(r));
bool ok = validate(r, n, cmd);
_linkOk = ok || _linkOk;
return ok;
}
String Agiltron::warningsString(uint8_t w) {
String out;
auto add = [&](const char *m) { if (out.length()) out += ", "; out += m; };
// bit set (=1) means warning
if (w & (1 << 7)) add("Overall warning");
if (w & (1 << 3)) add("Pump current");
if (w & (1 << 2)) add("Device temperature");
if (w & (1 << 1)) add("Input LOS");
if (w & (1 << 0)) add("Output LOS");
// bit clear (=0) means warning
if (!(w & (1 << 6))) add("Pump is OFF");
if (!(w & (1 << 5))) add("TEC current");
if (!(w & (1 << 4))) add("Pump temperature");
if (out.length() == 0) out = "none";
return out;
}
void Agiltron::rawProbe(uint8_t cmd, const uint8_t *data, uint8_t len) {
uint8_t r[64];
size_t n = transact(cmd, data, len, r, sizeof(r));
Serial.printf("[agiltron] probe cmd 0x%02x -> %u bytes:\n", cmd, (unsigned)n);
Serial.print(" hex:");
for (size_t i = 0; i < n; i++) Serial.printf(" %02x", r[i]);
Serial.println();
}
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// Agiltron M511 EYDFA driver --- binary 0x55AA packet protocol.
//
// Ported from the lab's edfa.py (Agiltron EDFA/edfa.py). Packet layout:
// 0x55 0xAA | dev_id[4] | cmd | len | data[len] | checksum
// checksum = ((0xFF - (sum(bytes from dev_id..end of data) & 0xFF)) + 1) & 0xFF
// Reply starts 0xAA 0x55, with the command id echoed at byte[6]. 115200 8N1.
//
// Scalings (from edfa.py, corrected against the docs):
// optical power = signed int16 / 100 (dBm)
// pump currents = raw mA
// temps, preamp/TEC currents = / 10
#pragma once
#include <Arduino.h>
struct AmpStatus {
bool valid = false;
float module_temp_c;
float preamp_temp_c;
float preamp_current_ma;
float tec_current_ma;
int pump1_current_ma;
int pump2_current_ma;
float input_power_dbm;
float preamp_power_dbm;
float output1_power_dbm;
float output2_power_dbm;
uint8_t warn_byte;
};
class Agiltron {
public:
static const uint8_t ACC = 0x01; // constant current
static const uint8_t APC = 0x00; // constant power
static const int MAX_PUMP_CURRENT_MA = 8000;
Agiltron(HardwareSerial &serial, int8_t rxPin, int8_t txPin, uint32_t baud,
const uint8_t devId[4])
: _ser(serial), _rx(rxPin), _tx(txPin), _baud(baud) {
memcpy(_devId, devId, 4);
}
void begin() { _ser.begin(_baud, SERIAL_8N1, _rx, _tx); }
bool linkOk() const { return _linkOk; }
// Queries
AmpStatus getStatus();
String getSn();
String getPn();
// Authoritative pump-enable from get_settings (0x2E): byte[8:9]==0 => enabled.
// Returns -1 on no/invalid reply, 0 = disabled, 1 = enabled.
int getPumpEnabled();
// Control (return true if the device ACKed)
bool pumpOn() { return cmdAck(0x20, (const uint8_t[]){0x00,0x00}, 2); }
bool pumpOff() { return cmdAck(0x20, (const uint8_t[]){0x00,0x01}, 2); }
bool setPump1Mode(uint8_t mode) { uint8_t d[2]={0x00,mode}; return cmdAck(0x21,d,2); }
bool setPump1Current(int ma);
// Decode the warning byte into a comma-separated list (matches edfa.py).
static String warningsString(uint8_t warnByte);
// Dump raw reply bytes for a command to the USB console (first-wiring aid).
void rawProbe(uint8_t cmd, const uint8_t *data, uint8_t len);
private:
HardwareSerial &_ser;
int8_t _rx, _tx;
uint32_t _baud;
uint8_t _devId[4];
bool _linkOk = false;
uint8_t checksum(const uint8_t *p, size_t n);
size_t buildPacket(uint8_t *out, uint8_t cmd, const uint8_t *data, uint8_t len);
// Send cmd, read reply into buf (max bufLen). Returns bytes read.
size_t transact(uint8_t cmd, const uint8_t *data, uint8_t len,
uint8_t *buf, size_t bufLen, uint32_t timeoutMs = 300);
bool validate(const uint8_t *buf, size_t n, uint8_t expectCmd);
bool cmdAck(uint8_t cmd, const uint8_t *data, uint8_t len);
static uint16_t u16(uint8_t msb, uint8_t lsb) { return (uint16_t)msb * 256 + lsb; }
static int16_t s16(uint8_t msb, uint8_t lsb) { return (int16_t)((msb << 8) | lsb); }
};
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#include "koheron.h"
// Read everything the device sends until there's an ~80 ms idle gap (end of
// reply) or the overall timeout elapses.
String Koheron::readRaw(uint32_t timeoutMs) {
String buf;
uint32_t start = millis();
uint32_t lastByte = start;
const uint32_t IDLE_GAP = 80;
while (millis() - start < timeoutMs) {
while (_ser.available()) {
buf += (char)_ser.read();
lastByte = millis();
}
if (buf.length() && (millis() - lastByte) > IDLE_GAP) break;
delay(2);
}
return buf;
}
String Koheron::query(const char *cmd, uint32_t timeoutMs) {
while (_ser.available()) _ser.read(); // flush stale input
_ser.print(cmd);
_ser.print("\r\n");
String raw = readRaw(timeoutMs);
if (raw.length() == 0) {
_linkOk = false;
return String();
}
_linkOk = true;
// Split into lines; drop ">>" prompts, the echoed command, and blanks.
// Return the last surviving line (the value).
String value;
int start = 0;
while (start < (int)raw.length()) {
int nl = raw.indexOf('\n', start);
String line = (nl < 0) ? raw.substring(start) : raw.substring(start, nl);
line.replace(">", ""); // strip prompt chars
line.trim(); // drop \r and surrounding whitespace
if (line.length() && line != cmd) value = line;
if (nl < 0) break;
start = nl + 1;
}
return value;
}
void Koheron::rawProbe(const char *cmd, uint32_t timeoutMs) {
while (_ser.available()) _ser.read();
_ser.print(cmd);
_ser.print("\r\n");
String raw = readRaw(timeoutMs);
Serial.printf("[koheron] probe \"%s\" -> %u bytes:\n", cmd, raw.length());
Serial.print(" hex:");
for (size_t i = 0; i < raw.length(); i++) Serial.printf(" %02x", (uint8_t)raw[i]);
Serial.println();
Serial.print(" asc: ");
for (size_t i = 0; i < raw.length(); i++) {
char c = raw[i];
Serial.print((c >= 32 && c < 127) ? c : '.');
}
Serial.println();
Serial.printf(" parsed value: \"%s\"\n", query(cmd, timeoutMs).c_str());
}
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// Koheron CTL200 driver --- ASCII serial protocol.
//
// The CTL200 is a line-oriented terminal: send "<cmd>\r\n", it replies with
// the value (and may echo the command and a ">>" prompt). We strip the echo
// and prompt and return the value. 115200 8N1.
#pragma once
#include <Arduino.h>
class Koheron {
public:
Koheron(HardwareSerial &serial, int8_t rxPin, int8_t txPin, uint32_t baud)
: _ser(serial), _rx(rxPin), _tx(txPin), _baud(baud) {}
void begin() { _ser.begin(_baud, SERIAL_8N1, _rx, _tx); }
// Send a command, return the cleaned value line (echo + ">>" removed).
// Empty string means no/garbled response.
String query(const char *cmd, uint32_t timeoutMs = 250);
// Dump the raw bytes of a reply (hex + ascii) to the USB console, so the
// exact framing (echo? prompt placement?) can be confirmed on first wiring.
void rawProbe(const char *cmd, uint32_t timeoutMs = 500);
bool linkOk() const { return _linkOk; }
private:
HardwareSerial &_ser;
int8_t _rx, _tx;
uint32_t _baud;
bool _linkOk = false;
String readRaw(uint32_t timeoutMs); // read until idle gap or timeout
};
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// Koheron CTL200 + Agiltron M511 -> WiFi/MQTT bridge --- ESP32 firmware.
//
// INCREMENT 3: seed (Koheron CTL200) read-only telemetry on UART2, published
// under lab/laser/butterfly_edfa_rack/seed/... with HA discovery. Builds on
// increment 2 (WiFi + MQTT + diagnostics). Amp (Agiltron) and control come
// in increments 4-5.
//
// On boot the firmware raw-probes the Koheron `version` command and dumps the
// reply (hex+ascii) to the USB console, so the exact framing can be confirmed
// the first time the CTL200 is wired to GPIO16/17. See include/config.h.
#include <Arduino.h>
#include <WiFi.h>
#include <PubSubClient.h>
#include "config.h"
#include "koheron.h"
#include "agiltron.h"
static WiFiClient net;
static PubSubClient mqtt(net);
static Koheron koheron(Serial2, KOHERON_RX_PIN, KOHERON_TX_PIN, KOHERON_BAUD);
static const uint8_t kAmpDevId[4] = {AGILTRON_DEV_ID};
static Agiltron agiltron(Serial1, AGILTRON_RX_PIN, AGILTRON_TX_PIN, AGILTRON_BAUD, kAmpDevId);
// Probe each instrument link once per boot to reveal its framing.
#define KOHERON_RAW_PROBE 1
#define AGILTRON_PROBE 1
// ── HA discovery helpers ────────────────────────────────────────────
static String deviceBlock() {
return String("\"device\":{")
+ "\"identifiers\":[\"" DEVICE_NAME "\"],"
+ "\"name\":\"" DEVICE_FRIENDLY "\","
+ "\"manufacturer\":\"Koheron + Agiltron\","
+ "\"model\":\"CTL200 seed + M511 EYDFA\","
+ "\"sw_version\":\"" __DATE__ " " __TIME__ "\"}";
}
// Common availability + device tail shared by every discovery payload.
static String commonTail(const char *objectId) {
return String("\"availability_topic\":\"" TOPIC_AVAIL "\",")
+ "\"payload_available\":\"" AVAIL_ONLINE "\","
+ "\"payload_not_available\":\"" AVAIL_OFFLINE "\","
+ "\"unique_id\":\"" DEVICE_NAME "_" + objectId + "\","
+ deviceBlock() + "}";
}
static void publishConfig(const char *component, const char *objectId, const String &payload) {
String topic = String(DISCOVERY_PREFIX) + "/" + component + "/" + DEVICE_NAME + "/" + objectId + "/config";
if (!mqtt.publish(topic.c_str(), (const uint8_t *)payload.c_str(), payload.length(), true))
Serial.printf(" ! discovery publish failed: %s (len %u)\n", objectId, payload.length());
}
// A numeric/text sensor. stateSub is the topic suffix under TOPIC_BASE.
static void sensorDiscovery(const char *objectId, const char *name, const char *stateSub,
const char *unit, const char *devClass, const char *icon,
bool diagnostic) {
String p = String("{\"name\":\"") + name + "\","
+ "\"state_topic\":\"" TOPIC_BASE "/" + stateSub + "\",";
if (unit && *unit) p += String("\"unit_of_measurement\":\"") + unit + "\",";
if (devClass && *devClass) p += String("\"device_class\":\"") + devClass + "\",";
if (icon && *icon) p += String("\"icon\":\"") + icon + "\",";
if (diagnostic) p += "\"entity_category\":\"diagnostic\",";
p += commonTail(objectId);
publishConfig("sensor", objectId, p);
}
static void binaryDiscovery(const char *objectId, const char *name, const char *stateSub,
const char *payloadOn, const char *payloadOff,
const char *devClass, bool diagnostic) {
String p = String("{\"name\":\"") + name + "\","
+ "\"state_topic\":\"" TOPIC_BASE "/" + stateSub + "\","
+ "\"payload_on\":\"" + payloadOn + "\","
+ "\"payload_off\":\"" + payloadOff + "\",";
if (devClass && *devClass) p += String("\"device_class\":\"") + devClass + "\",";
if (diagnostic) p += "\"entity_category\":\"diagnostic\",";
p += commonTail(objectId);
publishConfig("binary_sensor", objectId, p);
}
// A switch with state + command topics.
static void switchDiscovery(const char *objectId, const char *name, const char *stateSub,
const char *cmdSub, const char *payloadOn, const char *payloadOff,
const char *icon) {
String p = String("{\"name\":\"") + name + "\","
+ "\"state_topic\":\"" TOPIC_BASE "/" + stateSub + "\","
+ "\"command_topic\":\"" TOPIC_CMD "/" + cmdSub + "\","
+ "\"payload_on\":\"" + payloadOn + "\",\"payload_off\":\"" + payloadOff + "\","
+ "\"state_on\":\"" + payloadOn + "\",\"state_off\":\"" + payloadOff + "\",";
if (icon && *icon) p += String("\"icon\":\"") + icon + "\",";
p += commonTail(objectId);
publishConfig("switch", objectId, p);
}
// A number (slider) with state + command topics.
static void numberDiscovery(const char *objectId, const char *name, const char *stateSub,
const char *cmdSub, float vmin, float vmax, float step,
const char *unit, const char *icon) {
String p = String("{\"name\":\"") + name + "\","
+ "\"state_topic\":\"" TOPIC_BASE "/" + stateSub + "\","
+ "\"command_topic\":\"" TOPIC_CMD "/" + cmdSub + "\","
+ "\"min\":" + String(vmin, 0) + ",\"max\":" + String(vmax, 0)
+ ",\"step\":" + String(step, 0) + ",\"mode\":\"box\",";
if (unit && *unit) p += String("\"unit_of_measurement\":\"") + unit + "\",";
if (icon && *icon) p += String("\"icon\":\"") + icon + "\",";
p += commonTail(objectId);
publishConfig("number", objectId, p);
}
static void publishDiscovery() {
Serial.println("Publishing HA discovery...");
// Diagnostics (ESP / network)
sensorDiscovery("uptime", "Uptime", "diag/uptime", "s", "duration", nullptr, true);
sensorDiscovery("rssi", "WiFi Signal", "diag/rssi", "dBm", "signal_strength", nullptr, true);
sensorDiscovery("ip", "IP Address", "diag/ip", nullptr, nullptr, "mdi:ip-network", true);
// Seed (Koheron CTL200)
binaryDiscovery("seed_link", "Seed Link", "seed/link", AVAIL_ONLINE, AVAIL_OFFLINE, "connectivity", true);
binaryDiscovery("seed_laser_enabled", "Seed Laser Enabled", "seed/laser_enabled", "1", "0", nullptr, false);
sensorDiscovery("seed_current", "Seed Current", "seed/current_ma", "mA", "current", "mdi:current-dc", false);
sensorDiscovery("seed_voltage", "Seed Voltage", "seed/voltage_v", "V", "voltage", nullptr, false);
sensorDiscovery("seed_rt_setpoint", "Seed Thermistor Setpoint", "seed/rt_setpoint_ohm", "Ω", nullptr, "mdi:resistor", false);
sensorDiscovery("seed_rt_actual", "Seed Thermistor", "seed/rt_actual_ohm", "Ω", nullptr, "mdi:resistor", false);
sensorDiscovery("seed_tec_current", "Seed TEC Current", "seed/tec_current_a", "A", "current", nullptr, false);
sensorDiscovery("seed_tec_voltage", "Seed TEC Voltage", "seed/tec_voltage_v", "V", "voltage", nullptr, false);
sensorDiscovery("seed_board_temp", "Seed Board Temperature", "seed/board_temp_c", "°C", "temperature", nullptr, false);
sensorDiscovery("seed_photodiode", "Seed Photodiode Current", "seed/photodiode_ma", "mA", nullptr, "mdi:current-dc", false);
sensorDiscovery("seed_error", "Seed Error Code", "seed/error", nullptr, nullptr, "mdi:alert-circle", true);
// Seed controls
switchDiscovery("seed_laser", "Seed Laser", "seed/laser_enabled", "seed/laser", "1", "0", "mdi:laser-pointer");
numberDiscovery("seed_set_current", "Seed Set Current", "seed/current_ma", "seed/current_ma",
0, SEED_CURRENT_MAX_MA, 1, "mA", "mdi:current-dc");
// Amp (Agiltron M511)
binaryDiscovery("amp_link", "Amp Link", "amp/link", AVAIL_ONLINE, AVAIL_OFFLINE, "connectivity", true);
sensorDiscovery("amp_module_temp", "Amp Module Temperature", "amp/module_temp_c", "°C", "temperature", nullptr, false);
sensorDiscovery("amp_preamp_temp", "Amp Pre-amp Temperature", "amp/preamp_temp_c", "°C", "temperature", nullptr, true);
sensorDiscovery("amp_preamp_current", "Amp Pre-amp Current", "amp/preamp_current_ma", "mA", "current", nullptr, true);
sensorDiscovery("amp_tec_current", "Amp TEC Current", "amp/tec_current_ma", "mA", "current", nullptr, true);
sensorDiscovery("amp_pump1_current", "Amp Pump-1 Current", "amp/pump1_current_ma", "mA", "current", "mdi:current-dc", false);
sensorDiscovery("amp_input_power", "Amp Input Power", "amp/input_power_dbm", "dBm", nullptr, "mdi:arrow-right-bold", false);
sensorDiscovery("amp_preamp_power", "Amp Pre-amp Power", "amp/preamp_power_dbm", "dBm", nullptr, "mdi:arrow-right-bold", true);
sensorDiscovery("amp_output_power", "Output Power", "amp/output1_power_dbm", "dBm", nullptr, "mdi:arrow-left-bold", false);
sensorDiscovery("amp_warnings", "Amp Warnings", "amp/warnings", nullptr, nullptr, "mdi:alert", true);
// Amp controls
switchDiscovery("amp_pump", "Amp Pump", "amp/pump_enabled", "amp/pump", "1", "0", "mdi:flash");
numberDiscovery("amp_set_pump_current", "Amp Pump Current", "amp/pump1_set_ma", "amp/pump1_current_ma",
0, PUMP_CURRENT_MAX_MA, 10, "mA", "mdi:current-dc");
}
// ── State publishing ────────────────────────────────────────────────
static void publishDiag() {
String base = String(TOPIC_BASE) + "/diag/";
mqtt.publish((base + "uptime").c_str(), String(millis() / 1000).c_str(), true);
mqtt.publish((base + "rssi").c_str(), String(WiFi.RSSI()).c_str(), true);
mqtt.publish((base + "ip").c_str(), WiFi.localIP().toString().c_str(), true);
}
// Each seed value is the raw string the CTL200 returns (already numeric text).
struct SeedPoint { const char *cmd; const char *sub; };
static const SeedPoint seedPoints[] = {
{"lason", "seed/laser_enabled"},
{"ilaser", "seed/current_ma"},
{"vlaser", "seed/voltage_v"},
{"rtset", "seed/rt_setpoint_ohm"},
{"rtact", "seed/rt_actual_ohm"},
{"itec", "seed/tec_current_a"},
{"vtec", "seed/tec_voltage_v"},
{"tboard", "seed/board_temp_c"},
{"iphd", "seed/photodiode_ma"},
{"err", "seed/error"},
};
static void publishSeed() {
bool any = false;
for (const auto &pt : seedPoints) {
String v = koheron.query(pt.cmd);
if (v.length()) {
mqtt.publish((String(TOPIC_BASE) + "/" + pt.sub).c_str(), v.c_str(), true);
any = true;
}
mqtt.loop(); // keep MQTT serviced between (potentially slow) UART round-trips
}
mqtt.publish(TOPIC_BASE "/seed/link", any ? AVAIL_ONLINE : AVAIL_OFFLINE, true);
}
static void pub(const char *sub, const String &v) {
mqtt.publish((String(TOPIC_BASE) + "/" + sub).c_str(), v.c_str(), true);
}
static void publishAmp() {
AmpStatus s = agiltron.getStatus();
mqtt.publish(TOPIC_BASE "/amp/link", s.valid ? AVAIL_ONLINE : AVAIL_OFFLINE, true);
if (!s.valid) return;
pub("amp/module_temp_c", String(s.module_temp_c, 1));
pub("amp/preamp_temp_c", String(s.preamp_temp_c, 1));
pub("amp/preamp_current_ma", String(s.preamp_current_ma, 1));
pub("amp/tec_current_ma", String(s.tec_current_ma, 1));
pub("amp/pump1_current_ma", String(s.pump1_current_ma));
pub("amp/input_power_dbm", String(s.input_power_dbm, 2));
pub("amp/preamp_power_dbm", String(s.preamp_power_dbm, 2));
pub("amp/output1_power_dbm", String(s.output1_power_dbm, 2));
pub("amp/output2_power_dbm", String(s.output2_power_dbm, 2));
pub("amp/warnings", Agiltron::warningsString(s.warn_byte));
int pe = agiltron.getPumpEnabled(); // authoritative, from get_settings
if (pe >= 0) pub("amp/pump_enabled", pe ? "1" : "0");
}
// ── Command handling ────────────────────────────────────────────────
static void onMqtt(char *topic, byte *payload, unsigned int len) {
String t(topic), p;
for (unsigned int i = 0; i < len; i++) p += (char)payload[i];
p.trim();
Serial.printf("[cmd] %s = %s\n", topic, p.c_str());
if (t == TOPIC_CMD "/seed/laser") {
bool on = (p == "1" || p.equalsIgnoreCase("on") || p.equalsIgnoreCase(AVAIL_ONLINE));
koheron.query(on ? "lason 1" : "lason 0");
pub("seed/laser_enabled", on ? "1" : "0");
} else if (t == TOPIC_CMD "/seed/current_ma") {
float ma = p.toFloat();
if (ma < 0) ma = 0;
if (ma > SEED_CURRENT_MAX_MA) ma = SEED_CURRENT_MAX_MA; // firmware clamp
koheron.query((String("ilaser ") + String(ma, 1)).c_str());
pub("seed/current_ma", String(ma, 3));
} else if (t == TOPIC_CMD "/amp/pump") {
bool on = (p == "1" || p.equalsIgnoreCase("on") || p.equalsIgnoreCase(AVAIL_ONLINE));
bool ok = on ? agiltron.pumpOn() : agiltron.pumpOff();
Serial.printf("[cmd] amp pump %s -> %s\n", on ? "ON" : "OFF", ok ? "ack" : "NO-ACK");
pub("amp/pump_enabled", on ? "1" : "0");
} else if (t == TOPIC_CMD "/amp/pump1_current_ma") {
int ma = (int)p.toFloat();
if (ma < 0) ma = 0;
if (ma > PUMP_CURRENT_MAX_MA) ma = PUMP_CURRENT_MAX_MA; // firmware clamp
agiltron.setPump1Mode(Agiltron::ACC); // current-control mode (lab note: avoid APC steps)
bool ok = agiltron.setPump1Current(ma);
Serial.printf("[cmd] amp pump1 = %d mA -> %s\n", ma, ok ? "ack" : "NO-ACK");
pub("amp/pump1_set_ma", String(ma));
}
}
// ── Connectivity ────────────────────────────────────────────────────
static void connectWiFi() {
Serial.printf("WiFi: connecting to \"%s\"", WIFI_SSID);
WiFi.mode(WIFI_STA);
WiFi.setHostname(DEVICE_NAME);
#ifdef USE_STATIC_IP
IPAddress ip(STATIC_IP_OCTETS), gw(GATEWAY_OCTETS), sn(SUBNET_OCTETS), dns(DNS_OCTETS);
if (!WiFi.config(ip, gw, sn, dns)) Serial.print(" [static cfg failed]");
#endif
WiFi.begin(WIFI_SSID, WIFI_PASSWORD);
while (WiFi.status() != WL_CONNECTED) { delay(400); Serial.print("."); }
Serial.printf(" ok, IP %s, RSSI %d dBm\n", WiFi.localIP().toString().c_str(), WiFi.RSSI());
}
static bool connectMQTT() {
Serial.printf("MQTT: connecting to %s:%d ... ", MQTT_BROKER, MQTT_PORT);
bool ok = mqtt.connect(DEVICE_NAME, MQTT_USER, MQTT_PASSWORD,
TOPIC_AVAIL, 0, true, AVAIL_OFFLINE);
if (ok) {
Serial.println("ok");
mqtt.publish(TOPIC_AVAIL, AVAIL_ONLINE, true);
mqtt.subscribe(TOPIC_CMD "/#");
publishDiscovery();
publishDiag();
} else {
Serial.printf("failed, rc=%d\n", mqtt.state());
}
return ok;
}
// ── Arduino entry points ────────────────────────────────────────────
void setup() {
Serial.begin(115200);
delay(200);
Serial.println("\n=== Butterfly EDFA Rack bridge — increment 3 (seed telemetry) ===");
Serial.printf("Device: %s (%s)\n", DEVICE_FRIENDLY, DEVICE_NAME);
koheron.begin();
agiltron.begin();
#if KOHERON_RAW_PROBE
Serial.printf("Seed probe on UART%d (RX=%d, TX=%d):\n",
KOHERON_UART_NUM, KOHERON_RX_PIN, KOHERON_TX_PIN);
koheron.rawProbe("version");
if (!koheron.linkOk())
Serial.println(" (no reply — Koheron not wired yet? RX/TX swapped? GND?)");
#endif
#if AGILTRON_PROBE
Serial.printf("Amp probe on UART%d (RX=%d, TX=%d):\n",
AGILTRON_UART_NUM, AGILTRON_RX_PIN, AGILTRON_TX_PIN);
String sn = agiltron.getSn(), pn = agiltron.getPn();
Serial.printf(" SN=\"%s\" PN=\"%s\"\n", sn.c_str(), pn.c_str());
if (sn.length() == 0)
Serial.println(" (no reply — Agiltron not wired? RX/TX swapped? wrong dev ID? GND?)");
#endif
connectWiFi();
mqtt.setServer(MQTT_BROKER, MQTT_PORT);
mqtt.setBufferSize(MQTT_BUFFER_SIZE);
mqtt.setCallback(onMqtt);
connectMQTT();
}
void loop() {
if (WiFi.status() != WL_CONNECTED) connectWiFi();
if (!mqtt.connected()) {
static uint32_t lastTry = 0;
if (millis() - lastTry >= MQTT_RECONNECT_MS) { lastTry = millis(); connectMQTT(); }
} else {
mqtt.loop();
static uint32_t lastPub = 0;
if (millis() - lastPub >= PUBLISH_INTERVAL_MS) {
lastPub = millis();
publishDiag();
publishSeed();
publishAmp();
}
}
}