Turns the weather dashboard into an actual thermostat. Relays are not
fitted yet -- the GPIOs are driven and can be metered at the UART1-OUT
plug (idle 3.3V, energized 0V, active-low module assumed).
Control loop (main/control/thermostat.c) is pure logic: no ESP-IDF, no
network, no clock of its own. The caller passes a temperature and a
millisecond timestamp, which is what lets the simulator and the test
harness run the identical decision code.
Equipment protections, all verified by tools/thermostat_test.c:
deadband 1.0F stops the burner chattering at the setpoint
minimum on 3 min a shorter call is all ignition wear, no heat
minimum off 5 min back-to-back ignitions are what kill igniters
cycles/hour 5 standard gas default; catches a flapping sensor
boot lockout 60 s a boot loop must not machine-gun the gas valve
That test drives the state machine with synthetic time, so two hours of
furnace behaviour runs in milliseconds. It exits non-zero on failure and
is worth re-running after any edit to thermostat.c -- this switches a gas
valve.
Two deliberate decisions:
- G is never energized during a heat call. The furnace runs its own
blower with a fan-on delay that waits for the heat exchanger and a
fan-off delay that scavenges residual heat; driving G ourselves would
blow cold air at people and throw that heat away. G is manual
circulation only.
- The control loop starts before every early return in app_main. Those
returns are all "no WiFi" or "no HA token", and none of them is a
reason to leave a house unheated.
Relay pins are IO20 heat / IO19 fan on the UART1-OUT plug, measured on
this board since Elecrow documents the GPIO numbers but not the connector
pin order. Heat is on IO20 because it is USB D+, the line carrying the
hardware pull-up -- with an active-low module it fails toward "no heat"
rather than "heat stuck on" if the USB PHY is ever re-enabled. Both pins
were confirmed free of the onboard mic before use.
CONFIG_USJ_ENABLE_USB_SERIAL_JTAG and CONFIG_ESP_PHY_ENABLE_USB are now
off to release them; the console is on UART0 via the CH340 regardless.
UI: the indoor card gains a status dot, mode and fan buttons, and a
setpoint column with finger-sized up/down targets. The reading grid drops
from six cells to four to make room -- wind was the one to cut, since the
station anemometer has been dead since 2026-07-27 and that cell has never
shown a number. Wind now rides on the outdoor cell's sub-line and will
reappear on its own if the sensor is fixed. Sunrise and sunset share a
cell, showing whichever comes next.
Known weakness, documented in README and top of TODO: indoor temperature
comes from Home Assistant over the network, so an HA outage ages the
reading until the 15-minute failsafe forces heat off. A local I2C sensor
removes the failure mode entirely and is the next thing to add. The
setpoint also resets to 68F on reboot, because persisting it means an NVS
write and a flash write while the panel scans faults the bounce-buffer
ISR.
Co-Authored-By: Claude <noreply@anthropic.com>
Keep the HTTP session alive between weather polls (TODO #1). Re-creating the
client each time forced a fresh TLS handshake inside the window where the UI
is frozen. Measured on hardware: the fetch went from ~1.3s to ~80ms, so the
pause is no longer long enough to matter once thermostat controls exist. The
timeout drops from 30s to 10s once a session is warm, since only a cold
handshake needs the longer budget. Any transport error or non-200 tears the
session down so a half-open connection cannot poison every later poll.
The response buffer is now reset per request rather than on
HTTP_EVENT_ON_CONNECTED -- a kept-alive connection does not re-fire that
event, so the buffer would have accumulated across polls.
Indicate stale readings (TODO #2). After two consecutive failures the
temperature dims and the status line shows the age. Age comes from tick
counts, not weather_data_t.last_update: there is no SNTP client here, so
time(NULL) starts at the epoch and any age derived from it is meaningless.
Gate the touch readout behind UI_DEBUG_TOUCH, default off (TODO #3). Kept the
note about LVGL not bubbling events to parents -- it documents a real trap.
Delete main/utils (TODO #4); it had no callers outside itself. Also refreshed
project_structure.txt, which was additionally missing i2c_bus and backlight.
Lay out two 4MB OTA slots (TODO #5) while no devices are fielded, and document
in the README that an OTA download cannot run while the panel is scanning --
the flash write faults the bounce-buffer ISR.
Log the truncation warning once per response instead of once per chunk, and
record the weather task's stack high-water mark (TODO #6): ~2400 bytes spare
of 6144.
Co-Authored-By: Claude <noreply@anthropic.com>
- Clear WIFI_CONNECTED_BIT on disconnect so wifi_is_connected() stops
reporting a link that is gone; the weather task's reconnect path was
dead code without it.
- After the 8 fast retries are spent, retry every 30s via an esp_timer
forever instead of giving up until power cycle. FAIL_BIT now only
unblocks the boot-time wait and is cleared on reconnect.
- Start the weather task even when the boot-time connect times out --
the background retries may still bring WiFi up later. Only an empty
SSID skips it.
- Round temperatures with lroundf(): the old +0.5f-and-truncate rounded
toward zero below 0degF (-10.6 displayed as -10).
- Drop the stale single-framebuffer "Partial-mode flush" comment in
display_rgb.c, fix the README paragraph claiming the bounce buffer is
disabled (it is enabled and load-bearing), and correct the
sdkconfig.defaults header to N16R8/16MB.
Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
mattandClaude