Fixed OTA problems, Clock Alerts and MQTT Logs. V151

vesper/src/Communication/CommandHandler/CommandHandler.cpp

@@ -1249,6 +1249,8 @@ void CommandHandler::handleCustomUpdateCommand(JsonVariant contents, const Messa
                       contents["checksum"].as<String>() : "";
     size_t fileSize = contents.containsKey("file_size") ?
                       contents["file_size"].as<size_t>() : 0;
+    uint16_t version = contents.containsKey("version") ?
+                       contents["version"].as<uint16_t>() : 0;
 
     // Check if player is active
     if (_player && _player->isCurrentlyPlaying()) {
@@ -1257,10 +1259,11 @@ void CommandHandler::handleCustomUpdateCommand(JsonVariant contents, const Messa
         return;
     }
 
-    LOG_INFO("Custom update: URL=%s, Checksum=%s, Size=%u",
+    LOG_INFO("Custom update: URL=%s, Checksum=%s, Size=%u, Version=%u",
              firmwareUrl.c_str(),
              checksum.isEmpty() ? "none" : checksum.c_str(),
-             fileSize);
+             fileSize,
+             version);
 
     sendSuccessResponse("custom_update",
         "Starting custom OTA update. Device may reboot.", context);
@@ -1269,7 +1272,7 @@ void CommandHandler::handleCustomUpdateCommand(JsonVariant contents, const Messa
     delay(1000);
 
     // Perform the custom update
-    bool result = _otaManager.performCustomUpdate(firmwareUrl, checksum, fileSize);
+    bool result = _otaManager.performCustomUpdate(firmwareUrl, checksum, fileSize, version);
 
     // Note: If update succeeds, device will reboot and this won't be reached
     if (!result) {

vesper/src/ConfigManager/ConfigManager.cpp

@@ -1146,10 +1146,17 @@ String ConfigManager::getAllSettingsAsJson() const {
     time["daylightOffsetSec"] = timeConfig.daylightOffsetSec;
     
     // Bell durations (relay timings)
-    JsonObject bells = doc.createNestedObject("bells");
+    JsonObject bellDurations = doc.createNestedObject("bellDurations");
     for (uint8_t i = 0; i < 16; i++) {
         String key = String("b") + (i + 1);
-        bells[key] = bellConfig.durations[i];
+        bellDurations[key] = bellConfig.durations[i];
+    }
+
+    // Bell outputs (physical output mapping)
+    JsonObject bellOutputs = doc.createNestedObject("bellOutputs");
+    for (uint8_t i = 0; i < 16; i++) {
+        String key = String("b") + (i + 1);
+        bellOutputs[key] = bellConfig.outputs[i];
     }
 
     // Clock configuration

vesper/src/Logging/Logging.cpp

@@ -35,8 +35,6 @@ bool Logging::isLevelEnabled(LogLevel level) {
 }
 
 void Logging::error(const char* format, ...) {
-    if (!isLevelEnabled(ERROR)) return;
-
     va_list args;
     va_start(args, format);
     log(ERROR, "🔴 EROR", format, args);
@@ -44,8 +42,6 @@ void Logging::error(const char* format, ...) {
 }
 
 void Logging::warning(const char* format, ...) {
-    if (!isLevelEnabled(WARNING)) return;
-
     va_list args;
     va_start(args, format);
     log(WARNING, "🟡 WARN", format, args);
@@ -53,8 +49,6 @@ void Logging::warning(const char* format, ...) {
 }
 
 void Logging::info(const char* format, ...) {
-    if (!isLevelEnabled(INFO)) return;
-
     va_list args;
     va_start(args, format);
     log(INFO, "🟢 INFO", format, args);
@@ -62,8 +56,6 @@ void Logging::info(const char* format, ...) {
 }
 
 void Logging::debug(const char* format, ...) {
-    if (!isLevelEnabled(DEBUG)) return;
-
     va_list args;
     va_start(args, format);
     log(DEBUG, "🐞 DEBG", format, args);
@@ -71,8 +63,6 @@ void Logging::debug(const char* format, ...) {
 }
 
 void Logging::verbose(const char* format, ...) {
-    if (!isLevelEnabled(VERBOSE)) return;
-
     va_list args;
     va_start(args, format);
     log(VERBOSE, "🧾 VERB", format, args);
@@ -80,19 +70,33 @@ void Logging::verbose(const char* format, ...) {
 }
 
 void Logging::log(LogLevel level, const char* levelStr, const char* format, va_list args) {
-    // Print the formatted message
+    // Check if ANY output needs this log level
+    bool serialEnabled = (currentLevel >= level);
+    bool mqttEnabled = (mqttLogLevel >= level && mqttPublishCallback);
+    // bool sdEnabled = (sdLogLevel >= level && sdLogCallback);  // Future: SD logging
+
+    // Early exit if no outputs need this message
+    if (!serialEnabled && !mqttEnabled) {
+        return;
+    }
+
+    // Format the message once (only if at least one output needs it)
     char buffer[512];
     vsnprintf(buffer, sizeof(buffer), format, args);
 
-    // Serial output
+    // Serial output (independent check)
+    if (serialEnabled) {
         Serial.printf("[%s]  ", levelStr);
         Serial.print(buffer);
         Serial.println();
+    }
 
-    // MQTT output (if enabled and callback is set)
+    // MQTT output (independent check)
-    if (mqttLogLevel >= level && mqttPublishCallback) {
+    if (mqttEnabled) {
         publishToMqtt(level, levelStr, buffer);
     }
+
+    // Future: SD logging would go here with its own independent check
 }
 
 void Logging::publishToMqtt(LogLevel level, const char* levelStr, const char* message) {

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");

vesper/src/OTAManager/OTAManager.hpp

@@ -83,7 +83,7 @@ public:
     void checkFirmwareUpdateFromSD();  // Check SD for firmware update
     bool performManualUpdate(); // Manual update triggered by app
     bool performManualUpdate(const String& channel); // Manual update from specific channel
-    bool performCustomUpdate(const String& firmwareUrl, const String& checksum = "", size_t fileSize = 0); // Custom firmware update
+    bool performCustomUpdate(const String& firmwareUrl, const String& checksum = "", size_t fileSize = 0, uint16_t version = 0); // Custom firmware update
     
     // Hardware identification
     String getHardwareVariant() const;

vesper/src/Player/Player.cpp

@@ -2,6 +2,7 @@
 #include "../Communication/CommunicationRouter/CommunicationRouter.hpp"
 #include "../BellEngine/BellEngine.hpp"
 #include "../Telemetry/Telemetry.hpp"
+#include "../TimeKeeper/TimeKeeper.hpp"  // 🔥 Include for Timekeeper class definition
 #include "../BuiltInMelodies/BuiltInMelodies.hpp"
 
 // Note: Removed global melody_steps dependency for cleaner architecture
@@ -31,6 +32,7 @@ Player::Player(CommunicationRouter* comm, FileManager* fm)
     , _fileManager(fm)
     , _bellEngine(nullptr)
     , _telemetry(nullptr)
+    , _timekeeper(nullptr)
     , _durationTimerHandle(NULL) {
 }
 
@@ -59,6 +61,7 @@ Player::Player()
     , _fileManager(nullptr)
     , _bellEngine(nullptr)
     , _telemetry(nullptr)
+    , _timekeeper(nullptr)
     , _durationTimerHandle(NULL) {
 }
 
@@ -107,6 +110,12 @@ void Player::play() {
         return;
     }
 
+    // 🔥 CRITICAL: Interrupt any active clock alerts - user playback has priority!
+    if (_timekeeper) {
+        _timekeeper->interruptActiveAlert();
+        LOG_DEBUG("Player: Interrupted any active clock alerts");
+    }
+
     if (_bellEngine) {
         _bellEngine->setMelodyData(_melodySteps);
         _bellEngine->start();

vesper/src/Player/Player.hpp

@@ -133,6 +133,12 @@ public:
      */
     void setTelemetry(Telemetry* telemetry) { _telemetry = telemetry; }
 
+    /**
+     * @brief Set Timekeeper reference for alert coordination
+     * @param timekeeper Pointer to Timekeeper instance
+     */
+    void setTimekeeper(class Timekeeper* timekeeper) { _timekeeper = timekeeper; }
+    
     // ═══════════════════════════════════════════════════════════════════════════════
     // MELODY METADATA - Public access for compatibility
     // ═══════════════════════════════════════════════════════════════════════════════
@@ -249,6 +255,7 @@ private:
     FileManager* _fileManager;                      // 📁 File operations reference
     BellEngine* _bellEngine;                        // 🔥 High-precision timing engine reference
     Telemetry* _telemetry;                          // 📄 Telemetry system reference
+    class Timekeeper* _timekeeper;                  // ⏰ Timekeeper reference for alert coordination
     
     std::vector<uint16_t> _melodySteps;             // 🎵 Melody data owned by Player
     TimerHandle_t _durationTimerHandle = NULL;      // ⏱️ FreeRTOS timer (saves 4KB vs task!)

vesper/src/TimeKeeper/TimeKeeper.cpp

@@ -2,6 +2,7 @@
 #include "../OutputManager/OutputManager.hpp"
 #include "../ConfigManager/ConfigManager.hpp"
 #include "../Networking/Networking.hpp"
+#include "../Player/Player.hpp"  // 🔥 Include for Player class definition
 #include "SD.h"
 #include <time.h>
 
@@ -47,6 +48,19 @@ void Timekeeper::setNetworking(Networking* networking) {
     LOG_INFO("Timekeeper connected to Networking");
 }
 
+void Timekeeper::setPlayer(Player* player) {
+    _player = player;
+    LOG_INFO("Timekeeper connected to Player for playback coordination");
+}
+
+void Timekeeper::interruptActiveAlert() {
+    if (alertInProgress.load()) {
+        LOG_INFO("⚡ ALERT INTERRUPTED by user playback - marking as complete");
+        alertInProgress.store(false);
+        // Alert will stop naturally on next check in fireAlertBell loop
+    }
+}
+
 void Timekeeper::setRelayWriteFunction(void (*func)(int, int)) {
     relayWriteFunc = func;
     LOG_WARNING("Using LEGACY relay function - consider upgrading to OutputManager");
@@ -538,14 +552,34 @@ void Timekeeper::checkClockAlerts() {
         return;
     }
 
+    // 🔥 CRITICAL: Check if Player is busy - if so, SKIP alert completely
+    if (_player && _player->isPlaying) {
+        // Player is active (playing, paused, stopping, etc.) - skip alert entirely
+        // Mark this alert as processed to prevent it from firing when playback ends
+        DateTime now = rtc.now();
+        int currentMinute = now.minute();
+
+        if (currentMinute == 0) {
+            lastHour = now.hour();  // Mark hour as processed
+        } else if (currentMinute == 30) {
+            lastMinute = 30;  // Mark half-hour as processed
+        } else if (currentMinute == 15 || currentMinute == 45) {
+            lastMinute = currentMinute;  // Mark quarter-hour as processed
+        }
+
+        LOG_DEBUG("⏭️ SKIPPING clock alert - Player is busy (playing/paused)");
+        return;
+    }
+
     // Get current time
     DateTime now = rtc.now();
     int currentHour = now.hour();
     int currentMinute = now.minute();
     int currentSecond = now.second();
 
-    // Only trigger alerts on exact seconds (0-2) to avoid multiple triggers
+    // Only trigger alerts in first 30 seconds of the minute
-    if (currentSecond > 2) {
+    // The lastHour/lastMinute tracking prevents duplicate triggers
+    if (currentSecond > 30) {
         return;
     }
 
@@ -625,7 +659,16 @@ void Timekeeper::fireAlertBell(uint8_t bellNumber, int count) {
 
     const auto& clockConfig = _configManager->getClockConfig();
 
+    // Mark alert as in progress
+    alertInProgress.store(true);
+
     for (int i = 0; i < count; i++) {
+        // 🔥 Check for interruption by user playback
+        if (!alertInProgress.load()) {
+            LOG_INFO("⚡ Alert interrupted at ring %d/%d - stopping immediately", i + 1, count);
+            return;
+        }
+
         // Get bell duration from bell configuration
         uint16_t bellDuration = _configManager->getBellDuration(bellNumber);
 
@@ -640,6 +683,9 @@ void Timekeeper::fireAlertBell(uint8_t bellNumber, int count) {
             vTaskDelay(pdMS_TO_TICKS(clockConfig.alertRingInterval));
         }
     }
+
+    // Mark alert as complete
+    alertInProgress.store(false);
 }
 
 void Timekeeper::checkBacklightAutomation() {
@@ -697,14 +743,22 @@ bool Timekeeper::isInSilencePeriod() {
 
     // Check daytime silence period
     if (clockConfig.daytimeSilenceEnabled) {
-        if (isTimeInRange(currentTime, clockConfig.daytimeSilenceOnTime, clockConfig.daytimeSilenceOffTime)) {
+        bool inDaytime = isTimeInRange(currentTime, clockConfig.daytimeSilenceOnTime, clockConfig.daytimeSilenceOffTime);
+        LOG_DEBUG("🔇 Daytime silence check: current=%s, range=%s-%s, inRange=%s",
+                  currentTime.c_str(), clockConfig.daytimeSilenceOnTime.c_str(),
+                  clockConfig.daytimeSilenceOffTime.c_str(), inDaytime ? "YES" : "NO");
+        if (inDaytime) {
             return true;
         }
     }
 
     // Check nighttime silence period
     if (clockConfig.nighttimeSilenceEnabled) {
-        if (isTimeInRange(currentTime, clockConfig.nighttimeSilenceOnTime, clockConfig.nighttimeSilenceOffTime)) {
+        bool inNighttime = isTimeInRange(currentTime, clockConfig.nighttimeSilenceOnTime, clockConfig.nighttimeSilenceOffTime);
+        LOG_DEBUG("🌙 Nighttime silence check: current=%s, range=%s-%s, inRange=%s",
+                  currentTime.c_str(), clockConfig.nighttimeSilenceOnTime.c_str(),
+                  clockConfig.nighttimeSilenceOffTime.c_str(), inNighttime ? "YES" : "NO");
+        if (inNighttime) {
             return true;
         }
     }

vesper/src/TimeKeeper/TimeKeeper.hpp

@@ -28,6 +28,7 @@
 #include <Arduino.h>
 #include <vector>
 #include <algorithm>
+#include <atomic>
 #include <ArduinoJson.h>
 #include <RTClib.h>
 #include "freertos/FreeRTOS.h"
@@ -61,6 +62,7 @@ private:
     // Alert management - new functionality
     int lastHour = -1;      // Track last processed hour to avoid duplicate alerts
     int lastMinute = -1;    // Track last processed minute for quarter/half alerts
+    std::atomic<bool> alertInProgress{false};  // Flag to track if alert is currently playing
 
     // Backlight management - new functionality
     bool backlightState = false;  // Track current backlight state
@@ -69,6 +71,7 @@ private:
     OutputManager* _outputManager = nullptr;
     ConfigManager* _configManager = nullptr;
     Networking* _networking = nullptr;
+    class Player* _player = nullptr;  // Reference to Player for playback status checks
 
     // Legacy function pointer (DEPRECATED - will be removed)
     void (*relayWriteFunc)(int relay, int state) = nullptr;
@@ -84,12 +87,16 @@ public:
     void setOutputManager(OutputManager* outputManager);
     void setConfigManager(ConfigManager* configManager);
     void setNetworking(Networking* networking);
+    void setPlayer(class Player* player);  // Set Player reference for playback coordination
 
     // Clock Updates Pause Functions
     void pauseClockUpdates() { clockUpdatesPaused = true; }
     void resumeClockUpdates() { clockUpdatesPaused = false; }
     bool areClockUpdatesPaused() const { return clockUpdatesPaused; }
 
+    // Alert interruption - called by Player when starting playback
+    void interruptActiveAlert();
+
     // Legacy interface (DEPRECATED - will be removed)
     void setRelayWriteFunction(void (*func)(int, int));
 

vesper/vesper.ino

@@ -64,7 +64,7 @@
  * 👨‍💻 AUTHOR: BellSystems bonamin
  */
 
-#define FW_VERSION "138"
+#define FW_VERSION "151"
 
 
 /*
@@ -77,6 +77,8 @@
  * v1.3  (130) - Added Telemetry Reports to App, Various Playback Fixes
  * v137 - Made OTA and MQTT delays Async
  * v138 - Removed Ethernet, added default WiFi creds (Mikrotik AP) and fixed various Clock issues
+ * v140 - Changed FW Updates to Direct-to-Flash and added manual update functionality with version check
+ * v151 - Fixed Clock Alerts not running properly
  * ═══════════════════════════════════════════════════════════════════════════════
  */
 
@@ -315,6 +317,7 @@ void setup()
 	 timekeeper.setOutputManager(&outputManager);
 	 timekeeper.setConfigManager(&configManager);
 	 timekeeper.setNetworking(&networking);
+	 timekeeper.setPlayer(&player);  // 🔥 Connect for playback coordination
 	 // Clock outputs now configured via ConfigManager/Communication commands
 
 	// Register TimeKeeper with health monitor
@@ -356,6 +359,7 @@ void setup()
 	player.setDependencies(&communication, &fileManager);
 	player.setBellEngine(&bellEngine); // Connect the beast!
 	player.setTelemetry(&telemetry);
+	player.setTimekeeper(&timekeeper);  // 🔥 Connect for alert coordination
 
 	// Register Communication with health monitor
 	healthMonitor.setCommunication(&communication);