Fixed OTA problems, Clock Alerts and MQTT Logs. V151

vesper/src/OTAManager/OTAManager.cpp

@@ -493,9 +493,57 @@ bool OTAManager::downloadDirectToFlash(const String& url, size_t expectedSize) {
     LOG_INFO("OTA: Checksum validation will be performed by ESP32 bootloader");
     setStatus(Status::INSTALLING);
 
-    // Stream directly to flash
+    // Stream directly to flash with periodic watchdog feeding
     WiFiClient* stream = http.getStreamPtr();
-    size_t written = Update.writeStream(*stream);
+    uint8_t buffer[4096];  // 4KB buffer for efficient transfer
+    size_t written = 0;
+    size_t lastLoggedPercent = 0;
+    unsigned long lastWatchdogReset = millis();
+
+    while (http.connected() && written < (size_t)contentLength) {
+        size_t available = stream->available();
+        if (available) {
+            size_t toRead = min(available, sizeof(buffer));
+            size_t bytesRead = stream->readBytes(buffer, toRead);
+
+            if (bytesRead > 0) {
+                // Write to flash
+                size_t bytesWritten = Update.write(buffer, bytesRead);
+
+                if (bytesWritten != bytesRead) {
+                    LOG_ERROR("OTA: Flash write failed at offset %u (%u/%u bytes written)",
+                             written, bytesWritten, bytesRead);
+                    http.end();
+
+                    // Resume systems
+                    if (_timeKeeper) _timeKeeper->resumeClockUpdates();
+                    if (_telemetry) _telemetry->resume();
+
+                    setStatus(Status::FAILED, ErrorCode::WRITE_FAILED);
+                    return false;
+                }
+
+                written += bytesWritten;
+
+                // Log progress every 20%
+                size_t currentPercent = (written * 100) / contentLength;
+                if (currentPercent >= lastLoggedPercent + 20) {
+                    LOG_INFO("OTA: Flash write progress: %u%% (%u/%u bytes)",
+                             currentPercent, written, contentLength);
+                    lastLoggedPercent = currentPercent;
+                }
+            }
+        }
+
+        // Feed watchdog every 500ms to prevent timeout
+        if (millis() - lastWatchdogReset > 500) {
+            esp_task_wdt_reset();
+            lastWatchdogReset = millis();
+        }
+
+        // Small yield to prevent tight loop
+        yield();
+    }
 
     http.end();
 
@@ -1038,7 +1086,7 @@ bool OTAManager::performManualUpdate(const String& channel) {
 // CUSTOM FIRMWARE UPDATE
 // ════════════════════════════════════════════════════════════════════════════
 
-bool OTAManager::performCustomUpdate(const String& firmwareUrl, const String& checksum, size_t fileSize) {
+bool OTAManager::performCustomUpdate(const String& firmwareUrl, const String& checksum, size_t fileSize, uint16_t version) {
     if (_status != Status::IDLE) {
         LOG_WARNING("OTA update already in progress");
         return false;
@@ -1059,12 +1107,25 @@ bool OTAManager::performCustomUpdate(const String& firmwareUrl, const String& ch
         LOG_INFO("   Checksum: %s (NOTE: ESP32 will validate after flash)", checksum.c_str());
     }
 
+    if (version > 0) {
+        LOG_INFO("   Target Version: %u", version);
+    }
+
     setStatus(Status::DOWNLOADING);
 
     // Download directly to flash
     bool result = downloadDirectToFlash(firmwareUrl, fileSize);
 
     if (result) {
+        // Update version in config if provided
+        if (version > 0) {
+            _configManager.setFwVersion(String(version));
+            _configManager.saveDeviceConfig();
+            LOG_INFO("✅ Custom firmware version %u saved to NVS", version);
+        } else {
+            LOG_WARNING("⚠️ No version provided - NVS version unchanged");
+        }
+
         LOG_INFO("🚀 Custom firmware installed - device will reboot");
     } else {
         LOG_ERROR("❌ Custom firmware installation failed");