BIG FIXES: External thermostat start denied if internal thermostat too high

Pump priming from web page only worked once - was because prime command was never released from heater.

src/Afterburner.cpp

@@ -202,7 +202,7 @@ CSecuritySetup SecurityMenu;
 
 TaskHandle_t handleWatchdogTask;
 TaskHandle_t handleBlueWireTask;
-extern TaskHandle_t handleSSLTask;
+extern TaskHandle_t handleWebServerTask;
 
 // these variables will persist over a soft reboot.
 __NOINIT_ATTR float persistentRunTime;
@@ -647,7 +647,7 @@ bool checkTemperatureSensors()
       DebugPort.printf("  Arduino: %d\r\n", uxTaskGetStackHighWaterMark(NULL));
       DebugPort.printf("  BlueWire: %d\r\n", uxTaskGetStackHighWaterMark(handleBlueWireTask));
       DebugPort.printf("  Watchdog: %d\r\n", uxTaskGetStackHighWaterMark(handleWatchdogTask));
-      DebugPort.printf("  SSL loop: %d\r\n", uxTaskGetStackHighWaterMark(handleSSLTask));
+      DebugPort.printf("  SSL loop: %d\r\n", uxTaskGetStackHighWaterMark(handleWebServerTask));
     }
 
     TempSensor.readSensors();

src/Protocol/BlueWireTask.cpp

@@ -53,6 +53,7 @@ CProtocol HeaterFrame2;              // data packet received from heater in resp
 // CSmartError SmartError;
 CProtocolPackage reportHeaterData;
 CProtocolPackage primaryHeaterData;
+char dbgMsg[BLUEWIRE_MSGQUEUESIZE];
 
 static bool bHasOEMController = false;
 static bool bHasOEMLCDController = false;
@@ -142,9 +143,8 @@ void BlueWireTask(void*) {
         if(RxTimeElapsed >= moderator) {
           moderator += 10;  
           if(bReportRecyleEvents) {
-            char msg[32];
-            sprintf(msg, "%ldms - ", RxTimeElapsed);
-            pushDebugMsg(msg);
+            sprintf(dbgMsg, "%ldms - ", RxTimeElapsed);
+            pushDebugMsg(dbgMsg);
           }
           if(CommState.is(CommStates::OEMCtrlRx)) {
             bHasOEMController = false;
@@ -208,9 +208,8 @@ void BlueWireTask(void*) {
         if(BlueWireRxData.available() && (RxTimeElapsed > (RX_DATA_TIMOUT+10))) {  
 
           if(bReportOEMresync) {
-            char msg[64];
-            sprintf(msg, "Re-sync'd with OEM Controller. %ldms Idle time.\r\n", RxTimeElapsed);
-            pushDebugMsg(msg);
+            sprintf(dbgMsg, "Re-sync'd with OEM Controller. %ldms Idle time.\r\n", RxTimeElapsed);
+            pushDebugMsg(dbgMsg);
           }
 
           bHasHtrData = false;
@@ -395,12 +394,11 @@ bool validateFrame(const CProtocol& frame, const char* name)
 {
   if(!frame.verifyCRC(pushDebugMsg)) {
     // Bad CRC - restart blue wire Serial port
-    char msg[128];
-    sprintf(msg, "\007Bad CRC detected for %s frame - restarting blue wire's serial port\r\n", name);
-    pushDebugMsg(msg);
-    msg[0] = 0;  // empty string
-    DebugReportFrame("BAD CRC:", frame, "\r\n", msg);
-    pushDebugMsg(msg);
+    sprintf(dbgMsg, "\007Bad CRC detected for %s frame - restarting blue wire's serial port\r\n", name);
+    pushDebugMsg(dbgMsg);
+    dbgMsg[0] = 0;  // empty string
+    DebugReportFrame("BAD CRC:", frame, "\r\n", dbgMsg);
+    pushDebugMsg(dbgMsg);
 #ifdef REBOOT_BLUEWIRE
     initBlueWireSerial();
 #endif
@@ -415,7 +413,7 @@ void DebugReportFrame(const char* hdr, const CProtocol& Frame, const char* ftr,
 {
   strcat(msg, hdr);                     // header
   for(int i=0; i<24; i++) {
-    char str[16];
+    char str[8];
     sprintf(str, " %02X", Frame.Data[i]);  // build 2 dig hex values
     strcat(msg, str);                   // and print     
   }
@@ -478,7 +476,7 @@ const char* getBlueWireStatStr()
 
 void reqPumpPrime(bool on)
 {
-  DefaultBTCParams.setPump_Prime(on);
+  TxManage.reqPrime(on);
 }
 
 

src/Protocol/Protocol.cpp

@@ -431,20 +431,21 @@ CProtocolPackage::setRefTime()
   _timeStamp.setRefTime();
 }*/
 
+char dbgFrameMsg[192];
+
 void  
 CProtocolPackage::reportFrames(bool isOEM, std::function<void(const char*)> pushMsg)
 {
-  char msg[192];
-  msg[0] = 0;
-  _timeStamp.report(msg);   // absolute time
+  dbgFrameMsg[0] = 0;
+  _timeStamp.report(dbgFrameMsg);   // absolute time
   if(isOEM) {
-    DebugReportFrame("OEM:", Controller, TERMINATE_OEM_LINE ? "\r\n" : "   ", msg);
+    DebugReportFrame("OEM:", Controller, TERMINATE_OEM_LINE ? "\r\n" : "   ", dbgFrameMsg);
   }
   else {
-    DebugReportFrame("BTC:", Controller, TERMINATE_BTC_LINE ? "\r\n" : "   ", msg);
+    DebugReportFrame("BTC:", Controller, TERMINATE_BTC_LINE ? "\r\n" : "   ", dbgFrameMsg);
   }
-  DebugReportFrame("HTR:", Heater, "\r\n", msg);
-  pushMsg(msg);
+  DebugReportFrame("HTR:", Heater, "\r\n", dbgFrameMsg);
+  pushMsg(dbgFrameMsg);
 }
 
 int   

src/Protocol/SmartError.cpp

@@ -36,6 +36,7 @@ void
 CSmartError::reset()
 {
   _prevRunState = 0;
+  _prevPumpHz = 0;
   _Error = 0;
   _bInhibit = false;
 }
@@ -61,14 +62,15 @@ CSmartError::monitor(const CProtocol& heaterFrame)
 {
   if(heaterFrame.verifyCRC(NULL)) {  // check but don't report dodgy frames to debug
     // only accept valid heater frames!
-    monitor(heaterFrame.getRunState());
+    _monitor(heaterFrame.getRunState());
+    _monitorPriming(heaterFrame.getRunState(), heaterFrame.getPump_Actual());
   }
 }
 
 // test the new run state value, comparing to previous
 // detect abnormal transitions
 void 
-CSmartError::monitor(uint8_t newRunState)
+CSmartError::_monitor(uint8_t newRunState)
 {
   // check if moving away from heater Idle state (S0)
   // especially useful if an OEM controller exists
@@ -209,3 +211,15 @@ CSmartError::checkfuelUsage(bool throwfault)
   }
   return retval;
 }
+
+void
+CSmartError::_monitorPriming(uint8_t runState, uint8_t pumpHz)
+{
+  if(runState == 0 && pumpHz == 0 && _prevPumpHz != 0) {
+    TxManage.reqPrime(false);     // cancel pump priming request upon heater auto stopping priming
+  }
+  if(runState != 0) {
+    TxManage.reqPrime(false);     // ALWAYS cancel pump priming request upon heater running
+  }
+  _prevPumpHz = pumpHz;
+}

src/Protocol/SmartError.h

@@ -23,14 +23,16 @@
 
 class CSmartError {
   uint8_t _prevRunState;
+  uint8_t _prevPumpHz;
   uint8_t _Error;
   bool _bInhibit;
+  void _monitorPriming(uint8_t runState, uint8_t pumpHz);
+  void _monitor(uint8_t runstate);
 public: 
   CSmartError();
   void reset();
   void inhibit(bool reseterror=false);
   void monitor(const CProtocol& heaterFrame);
-  void monitor(uint8_t runstate);
   int checkVolts(float volts, float plugI, bool throwfault=true);  // 0 = OK, 1 = within 0.5V of LVC, 2 = under LVC
   int checkfuelUsage(bool throwfault=true);
   uint8_t getError();

src/Protocol/TxManage.cpp

@@ -70,6 +70,7 @@ CTxManage::CTxManage(int TxGatePin, HardwareSerial& serial) :
   _rawCommand = 0;
   m_HWTimer = NULL;
   _callback = NULL;
+  _prime = false;
 }
 
 // static function used for the tx gate termination 
@@ -178,6 +179,8 @@ CTxManage::PrepareFrame(const CProtocol& basisFrame, bool isBTCmaster)
       m_TxFrame.setAltitude(3500);  // default height - yes it is weird, but that's what the simple controllers send!
     }
 
+    m_TxFrame.setPump_Prime(_prime);
+
     float tActual = getTemperatureSensor();
     int8_t s8Temp = (int8_t)(tActual + 0.5);
     m_TxFrame.setTemperature_Actual(s8Temp);  // use current temp, for now
@@ -338,3 +341,8 @@ CTxManage::CheckTx(unsigned long timenow)
   return m_nStartTime == 0;   // returns true when done
 }
 
+void 
+CTxManage::reqPrime(bool on)
+{
+  _prime = on;
+}

src/Protocol/TxManage.h

@@ -28,6 +28,7 @@ class CTxManage
   const int m_nFrontPorch = 0;  
   int m_sysUpdate;
   std::function<void(const char*)> _callback;
+  bool _prime;
 
 public:
   CTxManage(int TxGatePin, HardwareSerial& serial);
@@ -42,6 +43,7 @@ public:
   static void IRAM_ATTR callbackGateTerminate();
   void queueSysUpdate();  // use to implant NV settings into heater
   void setCallback(std::function<void(const char*)> fn) { _callback = fn; };
+  void reqPrime(bool on);
 
 private:
   HardwareSerial& m_BlueWireSerial;

src/Utility/DemandManager.cpp

@@ -123,28 +123,30 @@ CDemandManager::checkStart()
   // create a deny start temperature margin
   int stopDeltaT = 0;
 
-  int cyclicstop = NVstore.getUserSettings().cyclic.Stop;
-  if(cyclicstop) {                // cyclic mode enabled
-    // if cylic mode, raise the margin by the cyclic stop range
-    stopDeltaT = cyclicstop + 1;  // bump up by 1 degree - no point invoking cyclic at 1 deg over!
-  }
-
   // determine temperature error vs desired thermostat value
   float deltaT = getTemperatureSensor() - getDegC();
 
-  if(deltaT > stopDeltaT) {
-    // temperature exceeded the allowed margin
-    if(cyclicstop) {
-      // using cyclic mode - suggest immediate cyclic suspend
+  int cyclicstop = NVstore.getUserSettings().cyclic.Stop;
+  if(cyclicstop) {                // cyclic mode enabled
+    // if cyclic mode, raise the margin by the cyclic stop range
+    stopDeltaT = cyclicstop + 1;  // bump up by 1 degree - no point invoking cyclic at 1 deg over!
+
+    // alows honour cyclic stop threshold - immediate suspend transition
+    if(deltaT > stopDeltaT) {
       return eStartSuspend;
     }
-    else {
-      // only deny start if actually using thermostat mode
+  }
+
+  if(!isExtThermostatMode()) {
+    if(deltaT > stopDeltaT) {
+      // temperature exceeded the allowed margin
+      // only deny start if actually using inbuilt thermostat mode
       if(isThermostat()) {
         return eStartTooWarm;  // too warm - deny start
       }
     }
   }
+
   return eStartOK;  // allow start
 }
 

src/WiFi/BTCWebServer.cpp

@@ -77,9 +77,9 @@ void streamFileCoreSSL(const size_t fileSize, const String & fileName, const Str
 void processWebsocketQueue();
 
 QueueHandle_t webSocketQueue = NULL;
+TaskHandle_t handleWebServerTask;
 #if USE_HTTPS == 1
 SSLCert* pCert;
-TaskHandle_t handleSSLTask;
 HTTPSServer * secureServer;
 #endif
 HTTPServer * insecureServer;
@@ -403,7 +403,7 @@ void initWebServer(void) {
              16384,
              NULL,
              TASK_PRIORITY_SSL_CERT,   // low priority as this blocks BIG time
-             &handleSSLTask);
+             &handleWebServerTask);
 
   while(!xSemaphoreTake(SSLSemaphore, 250)) {
     ScreenManager.showBootWait(1);
@@ -476,12 +476,12 @@ void initWebServer(void) {
   // setup task to handle webserver
   webSocketQueue = xQueueCreate(50, sizeof(char*) );
   xTaskCreate(SSLloopTask,
-             "SSLloopTask",
+             "Web server task",
              8192,
             //  16384,
              NULL,
              TASK_PRIORITY_SSL_LOOP,   // low priority as this potentially blocks BIG time
-             &handleSSLTask);
+             &handleWebServerTask);
 
   DebugPort.println("HTTP task started");
 }