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fix(button): stop phantom NORVI operation-mode switches #181

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Merged
stritti merged 6 commits into from
Aug 16, 2026
Merged

fix(button): stop phantom NORVI operation-mode switches #181

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f76db12
fix(button): calibrate NORVI ADC thresholds and make them configurable
stritti Aug 16, 2026
5cc5a1a
fix(web): apply button thresholds to running handler
stritti Aug 16, 2026
3f32e66
fix(web): validate button threshold inputs
stritti Aug 16, 2026
b45aebe
fix(ci): repair native test build and lint for button thresholds
stritti Aug 16, 2026
3a137e0
fix(web): permit 4096 no-press sentinel in threshold validation
stritti Aug 16, 2026
ef3e379
fix(web): reject no-press thresholds that mask button ranges
stritti Aug 16, 2026
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42 changes: 41 additions & 1 deletion data/web/app.js
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Original file line number Diff line number Diff line change
Expand Up @@ -553,6 +553,13 @@ function validateSettings() {
{ id: 'tempCircThreshold', name: 'Circ. Temp Threshold', min: 0, max: 40, type: 'float' },
{ id: 'tempCircFactor', name: 'Circ. Temp Factor', min: 0, max: 120, type: 'int' },
{ id: 'tempCircMaxRuntime', name: 'Circ. Max Runtime', min: 60, max: 1440, type: 'int' },
{ id: 'btn1Min', name: 'Button 1 Min ADC', min: 0, max: 4095, type: 'int' },
{ id: 'btn1Max', name: 'Button 1 Max ADC', min: 0, max: 4095, type: 'int' },
{ id: 'btn2Min', name: 'Button 2 Min ADC', min: 0, max: 4095, type: 'int' },
{ id: 'btn2Max', name: 'Button 2 Max ADC', min: 0, max: 4095, type: 'int' },
{ id: 'btn3Min', name: 'Button 3 Min ADC', min: 0, max: 4095, type: 'int' },
{ id: 'btn3Max', name: 'Button 3 Max ADC', min: 0, max: 4095, type: 'int' },
{ id: 'btnNoPress', name: 'No-Press Threshold', min: 0, max: 4096, type: 'int' },
];
for (const f of fields) {
const el = document.getElementById(f.id);
Expand All @@ -572,6 +579,25 @@ function validateSettings() {
return false;
}
}
// Button ADC thresholds must form coherent, non-overlapping ranges
const btnVal = (id) => parseInt(document.getElementById(id).value, 10);
const b1Min = btnVal('btn1Min'), b1Max = btnVal('btn1Max');
const b2Min = btnVal('btn2Min'), b2Max = btnVal('btn2Max');
const b3Min = btnVal('btn3Min'), b3Max = btnVal('btn3Max');
if (b1Min >= b1Max || b2Min >= b2Max || b3Min >= b3Max) {
alert('Each button Min must be less than its Max.');
return false;
}
if (b1Max > b2Min || b2Max > b3Min) {
alert('Button ADC ranges must not overlap.');
return false;
}
Comment thread
stritti marked this conversation as resolved.
// No-press threshold must sit above every button range, otherwise
// detectButton() checks THRESH_NO_PRESS first and masks those readings as NONE.
if (btnVal('btnNoPress') <= b3Max) {
alert('No-Press Threshold must be above all button ranges.');
return false;
}
return true;
}

Expand All @@ -589,6 +615,13 @@ async function saveControllerSettings() {
const circFactor = document.getElementById('tempCircFactor').value;
const circMaxRuntime = document.getElementById('tempCircMaxRuntime').value;
const tz = document.getElementById('timezone').value;
const btn1Min = document.getElementById('btn1Min').value;
const btn1Max = document.getElementById('btn1Max').value;
const btn2Min = document.getElementById('btn2Min').value;
const btn2Max = document.getElementById('btn2Max').value;
const btn3Min = document.getElementById('btn3Min').value;
const btn3Max = document.getElementById('btn3Max').value;
const btnNoPress = document.getElementById('btnNoPress').value;
Comment thread
stritti marked this conversation as resolved.

// Validate time fields included alongside pool fields
const green = parseInt(document.getElementById('timeLossGreen').value, 10);
Expand All @@ -608,7 +641,7 @@ async function saveControllerSettings() {
const res = await fetch('/api/config', {
method: 'POST',
headers: { 'Content-Type': 'application/x-www-form-urlencoded' },
body: 'type=settings&mode=' + mode + '&interval=' + interval + '&max_pool=' + maxPool + '&min_solar=' + minSolar + '&hysteresis=' + hysteresis + '&circ_threshold=' + circThreshold + '&circ_factor=' + circFactor + '&circ_max_runtime=' + circMaxRuntime + '&timezone=' + tz + '&green=' + green + '&red=' + red + timerParams() + '&ntp_server=' + ntpServer
body: 'type=settings&mode=' + mode + '&interval=' + interval + '&max_pool=' + maxPool + '&min_solar=' + minSolar + '&hysteresis=' + hysteresis + '&circ_threshold=' + circThreshold + '&circ_factor=' + circFactor + '&circ_max_runtime=' + circMaxRuntime + '&timezone=' + tz + '&green=' + green + '&red=' + red + timerParams() + '&ntp_server=' + ntpServer + '&btn1_min=' + btn1Min + '&btn1_max=' + btn1Max + '&btn2_min=' + btn2Min + '&btn2_max=' + btn2Max + '&btn3_min=' + btn3Min + '&btn3_max=' + btn3Max + '&btn_no_press=' + btnNoPress
});
if (res.status === 200) {
document.getElementById('poolThreshold').textContent = 'max ' + parseFloat(maxPool).toFixed(1) + '°C';
Expand Down Expand Up @@ -729,6 +762,13 @@ async function loadConfig() {
document.getElementById('ntpServer').value = data.ntp.server;
document.getElementById('timeLossGreen').value = data.settings.time_loss_green_hours;
document.getElementById('timeLossRed').value = data.settings.time_loss_red_hours;
document.getElementById('btn1Min').value = data.settings.btn1_min;
document.getElementById('btn1Max').value = data.settings.btn1_max;
document.getElementById('btn2Min').value = data.settings.btn2_min;
document.getElementById('btn2Max').value = data.settings.btn2_max;
document.getElementById('btn3Min').value = data.settings.btn3_min;
document.getElementById('btn3Max').value = data.settings.btn3_max;
document.getElementById('btnNoPress').value = data.settings.btn_no_press;
const pad2 = (n) => n.toString().padStart(2, '0');
document.getElementById('timerStart').value = pad2(data.settings.timer_start_hour) + ':' + pad2(data.settings.timer_start_min);
document.getElementById('timerEnd').value = pad2(data.settings.timer_end_hour) + ':' + pad2(data.settings.timer_end_min);
Expand Down
48 changes: 48 additions & 0 deletions data/web/index.html
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Expand Up @@ -307,6 +307,54 @@ <h2>🌡️ Temperature-Based Circulation</h2>
</div>
</div>

<h2>🔘 Button Thresholds (NORVI)</h2>
<div class="telemetry-grid">
<div class="input-group">
<label for="btn1Min">Button 1 Min ADC</label>
<input type="number" id="btn1Min" min="0" max="4095" step="1" value="3100">
<span class="input-hint">Lower bound of Button 1 range · Measured: ~3275–3456</span>
</div>
<div class="input-group">
<label for="btn1Max">Button 1 Max ADC</label>
<input type="number" id="btn1Max" min="0" max="4095" step="1" value="3520">
<span class="input-hint">Upper bound of Button 1 range</span>
</div>
</div>
<div class="telemetry-grid">
<div class="input-group">
<label for="btn2Min">Button 2 Min ADC</label>
<input type="number" id="btn2Min" min="0" max="4095" step="1" value="3520">
<span class="input-hint">Lower bound of Button 2 range · Measured: ~3579–3765</span>
</div>
<div class="input-group">
<label for="btn2Max">Button 2 Max ADC</label>
<input type="number" id="btn2Max" min="0" max="4095" step="1" value="3880">
<span class="input-hint">Upper bound of Button 2 range</span>
</div>
</div>
<div class="telemetry-grid">
<div class="input-group">
<label for="btn3Min">Button 3 Min ADC</label>
<input type="number" id="btn3Min" min="0" max="4095" step="1" value="3880">
<span class="input-hint">Lower bound of Button 3 range · Measured: ~4095 (full scale)</span>
</div>
<div class="input-group">
<label for="btn3Max">Button 3 Max ADC</label>
<input type="number" id="btn3Max" min="0" max="4095" step="1" value="4095">
<span class="input-hint">Upper bound of Button 3 range</span>
</div>
</div>
<div class="telemetry-grid">
<div class="input-group">
<label for="btnNoPress">No-Press Threshold</label>
<input type="number" id="btnNoPress" min="0" max="4096" step="1" value="4096">
<span class="input-hint">Values above this are ignored · 4096 = no-op (S3 reads full scale)</span>
</div>
<div class="input-group" style="visibility:hidden;">
<div style="height:1px;"></div>
</div>
</div>

<h2>⏱️ Timer Schedule</h2>
<div class="telemetry-grid">
<div class="input-group">
Expand Down
21 changes: 21 additions & 0 deletions src/ConfigManager.cpp
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Expand Up @@ -68,6 +68,13 @@ static constexpr const char *kSetRed = "set_red";
static constexpr const char *kSetCircThresh = "set_circth";
static constexpr const char *kSetCircFactor = "set_circfa";
static constexpr const char *kSetCircMax = "set_circmx";
static constexpr const char *kSetBtn1Min = "set_btn1min";
static constexpr const char *kSetBtn1Max = "set_btn1max";
static constexpr const char *kSetBtn2Min = "set_btn2min";
static constexpr const char *kSetBtn2Max = "set_btn2max";
static constexpr const char *kSetBtn3Min = "set_btn3min";
static constexpr const char *kSetBtn3Max = "set_btn3max";
static constexpr const char *kSetBtnNoPress = "set_btnnop";
static constexpr const char *kAdmPass = "adm_pass";
static constexpr const char *kCfgConfigured = "cfg_configured";

Expand Down Expand Up @@ -108,6 +115,13 @@ bool ConfigManager::load() {
settings_.tempCircThreshold = prefs.getDouble(kSetCircThresh, 24.0);
settings_.tempCircFactor = prefs.getUShort(kSetCircFactor, 30);
settings_.tempCircMaxRuntime = prefs.getUShort(kSetCircMax, 720);
settings_.btn1Min = prefs.getUShort(kSetBtn1Min, 3100);
settings_.btn1Max = prefs.getUShort(kSetBtn1Max, 3520);
settings_.btn2Min = prefs.getUShort(kSetBtn2Min, 3520);
settings_.btn2Max = prefs.getUShort(kSetBtn2Max, 3880);
settings_.btn3Min = prefs.getUShort(kSetBtn3Min, 3880);
settings_.btn3Max = prefs.getUShort(kSetBtn3Max, 4095);
settings_.btnNoPress = prefs.getUShort(kSetBtnNoPress, 4096);

adminPasswordHash_ = prefs.getString(kAdmPass, kDefaultPasswordHash);
configured_ = prefs.getBool(kCfgConfigured, false);
Expand Down Expand Up @@ -147,6 +161,13 @@ bool ConfigManager::save() {
prefs.putDouble(kSetCircThresh, settings_.tempCircThreshold);
prefs.putUShort(kSetCircFactor, settings_.tempCircFactor);
prefs.putUShort(kSetCircMax, settings_.tempCircMaxRuntime);
prefs.putUShort(kSetBtn1Min, settings_.btn1Min);
prefs.putUShort(kSetBtn1Max, settings_.btn1Max);
prefs.putUShort(kSetBtn2Min, settings_.btn2Min);
prefs.putUShort(kSetBtn2Max, settings_.btn2Max);
prefs.putUShort(kSetBtn3Min, settings_.btn3Min);
prefs.putUShort(kSetBtn3Max, settings_.btn3Max);
prefs.putUShort(kSetBtnNoPress, settings_.btnNoPress);

prefs.putString(kAdmPass, adminPasswordHash_);
prefs.putBool(kCfgConfigured, configured_);
Expand Down
9 changes: 8 additions & 1 deletion src/ConfigManager.hpp
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Expand Up @@ -45,7 +45,14 @@ struct ControllerSettings {
String opMode = "auto";
long timeLossGreenHours = 1;
long timeLossRedHours = 24;
int timezoneIndex = 0; ///< Index into TimeClientHelper timezone table
int timezoneIndex = 0; ///< Index into TimeClientHelper timezone table
uint16_t btn1Min = 3100; ///< NORVI button 1 ADC range min
uint16_t btn1Max = 3520; ///< NORVI button 1 ADC range max
uint16_t btn2Min = 3520; ///< NORVI button 2 ADC range min
uint16_t btn2Max = 3880; ///< NORVI button 2 ADC range max
uint16_t btn3Min = 3880; ///< NORVI button 3 ADC range min
uint16_t btn3Max = 4095; ///< NORVI button 3 ADC range max
uint16_t btnNoPress = 4096; ///< NORVI no-press threshold (no-op, > ADC max)
};

/**
Expand Down
28 changes: 27 additions & 1 deletion src/NorviButtonHandler.cpp
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Expand Up @@ -19,6 +19,7 @@

#include <Arduino.h>
#include "Config.hpp"
#include "ConfigManager.hpp"
#include "LogCapture.hpp"

namespace PoolController {
Expand Down Expand Up @@ -51,13 +52,25 @@ NorviButtonHandler::ButtonLongPressCallback NorviButtonHandler::cbButton3Long_ =
uint32_t NorviButtonHandler::pressStartMs_ = 0;
uint32_t NorviButtonHandler::releasePendingMs_ = 0;

// ADC thresholds — defaults are the 2026-08-16 calibrated values; begin()
// overwrites them from ConfigManager (NVS) so they are user-configurable.
uint16_t NorviButtonHandler::THRESH_BTN1_MIN{3100};
uint16_t NorviButtonHandler::THRESH_BTN1_MAX{3520};
uint16_t NorviButtonHandler::THRESH_BTN2_MIN{3520};
uint16_t NorviButtonHandler::THRESH_BTN2_MAX{3880};
uint16_t NorviButtonHandler::THRESH_BTN3_MIN{3880};
uint16_t NorviButtonHandler::THRESH_BTN3_MAX{4095};
uint16_t NorviButtonHandler::THRESH_NO_PRESS{4096};

// ═══════════════════════════════════════════════════════════════════════════

void NorviButtonHandler::begin() {
LOG_INFO("• NorviButtonHandler initializing on ADC GPIO%d...\n", PIN_BUTTON_ADC);

pinMode(PIN_BUTTON_ADC, INPUT);

applySettings();

// Take an initial sample to let the ADC stabilise
analogRead(PIN_BUTTON_ADC);
delay(10);
Expand All @@ -72,6 +85,19 @@ void NorviButtonHandler::begin() {

// ═══════════════════════════════════════════════════════════════════════════

void NorviButtonHandler::applySettings() {
// Load configurable ADC thresholds from NVS (defaults = calibrated values)
THRESH_BTN1_MIN = ConfigManager::getSettings().btn1Min;
THRESH_BTN1_MAX = ConfigManager::getSettings().btn1Max;
THRESH_BTN2_MIN = ConfigManager::getSettings().btn2Min;
THRESH_BTN2_MAX = ConfigManager::getSettings().btn2Max;
THRESH_BTN3_MIN = ConfigManager::getSettings().btn3Min;
THRESH_BTN3_MAX = ConfigManager::getSettings().btn3Max;
THRESH_NO_PRESS = ConfigManager::getSettings().btnNoPress;
}

// ═══════════════════════════════════════════════════════════════════════════

void NorviButtonHandler::loop() {
const uint32_t now = millis();

Expand All @@ -89,7 +115,7 @@ void NorviButtonHandler::loop() {
static uint32_t lastStableTime_ = 0;

// Fast-attack: a genuine press/release changes the button range — even
// when the ADC delta is small (no-press 3800 → S3 3700 = 100). Base the
// when the ADC delta is small (no-press ~2700 → S1 ~3400 = 700). Base the
// re-initialization on button-range transitions so every valid press is
// caught within one sample instead of a full moving-average window. The
// transition also restarts the stability window, so a single-sample glitch
Expand Down
45 changes: 30 additions & 15 deletions src/NorviButtonHandler.hpp
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Expand Up @@ -36,11 +36,11 @@ namespace PoolController {
* ~50 ms intervals, applies hysteresis for noise rejection, and fires
* callbacks on press events.
*
* Default thresholds (12-bit ADC, 0–4095):
* Button 1: 200 – 1200
* Button 2: 1400 – 2500
* Button 3: 2700 – 3700
* No press: > 3800
* Calibrated thresholds (12-bit ADC, 0–4095) from live measurements:
* No press: < 3100 (resting level oscillates ~2610–2990)
* Button 1: 3100 – 3520
* Button 2: 3520 – 3880
* Button 3: 3880 – 4095
*/
class NorviButtonHandler {
public:
Expand All @@ -62,6 +62,13 @@ class NorviButtonHandler {
*/
static void begin();

/**
* @brief Reload ADC thresholds from ConfigManager (NVS).
* Called after settings changes so new thresholds apply to the running
* handler without a reboot.
*/
static void applySettings();

/**
* @brief Sample and debounce buttons.
* Must be called regularly from PoolController::loop().
Expand Down Expand Up @@ -172,16 +179,24 @@ class NorviButtonHandler {
static uint32_t releasePendingMs_;

// ── ADC thresholds (12-bit, 0–4095) ──────────────────────────────────
// These are typical ranges for the NORVI AE01-R resistor ladder.
// Adjust if needed based on serial debug output.

static constexpr uint16_t THRESH_BTN1_MIN{200};
static constexpr uint16_t THRESH_BTN1_MAX{1200};
static constexpr uint16_t THRESH_BTN2_MIN{1400};
static constexpr uint16_t THRESH_BTN2_MAX{2500};
static constexpr uint16_t THRESH_BTN3_MIN{2700};
static constexpr uint16_t THRESH_BTN3_MAX{3700};
static constexpr uint16_t THRESH_NO_PRESS{3800};
// Calibrated from live measurements on the NORVI AE01-R (2026-08-16):
// No press: ~2610–2990 (oscillates; must map to NONE)
// Button 1: ~3275–3456
// Button 2: ~3579–3765
// Button 3: ~4095 (full scale)
// The resistor ladder pulls the ADC pin UP toward VCC on press.
// Boundaries sit at the midpoints between adjacent levels.
// THRESH_NO_PRESS is a no-op (4096 > ADC max) — S3 reads full scale.
// Values are loaded from ConfigManager (NVS) in begin(); the defaults
// below are the calibrated values and can be overridden via the web UI.

static uint16_t THRESH_BTN1_MIN;
static uint16_t THRESH_BTN1_MAX;
static uint16_t THRESH_BTN2_MIN;
static uint16_t THRESH_BTN2_MAX;
static uint16_t THRESH_BTN3_MIN;
static uint16_t THRESH_BTN3_MAX;
static uint16_t THRESH_NO_PRESS;
};

} // namespace PoolController
31 changes: 31 additions & 0 deletions src/WebPortal.cpp
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Expand Up @@ -40,6 +40,10 @@
#include "Version.h"
#include "LogCapture.hpp"

#ifdef NORVI_AE01_R
#include "NorviButtonHandler.hpp"
#endif

namespace PoolController {

// File-scoped state for streaming LittleFS upload (used by handleFsUploadStream)
Expand Down Expand Up @@ -666,6 +670,13 @@ void WebPortal::apiGetConfig() {
settingsObj["timezone"] = ConfigManager::getSettings().timezoneIndex;
settingsObj["time_loss_green_hours"] = ConfigManager::getSettings().timeLossGreenHours;
settingsObj["time_loss_red_hours"] = ConfigManager::getSettings().timeLossRedHours;
settingsObj["btn1_min"] = ConfigManager::getSettings().btn1Min;
settingsObj["btn1_max"] = ConfigManager::getSettings().btn1Max;
settingsObj["btn2_min"] = ConfigManager::getSettings().btn2Min;
settingsObj["btn2_max"] = ConfigManager::getSettings().btn2Max;
settingsObj["btn3_min"] = ConfigManager::getSettings().btn3Min;
settingsObj["btn3_max"] = ConfigManager::getSettings().btn3Max;
settingsObj["btn_no_press"] = ConfigManager::getSettings().btnNoPress;
settingsObj["timer_start_hour"] = operationModeNode.getTimerSetting().timerStartHour;
settingsObj["timer_start_min"] = operationModeNode.getTimerSetting().timerStartMinutes;
settingsObj["timer_end_hour"] = operationModeNode.getTimerSetting().timerEndHour;
Expand Down Expand Up @@ -750,12 +761,32 @@ void WebPortal::apiSaveConfig() {
ConfigManager::getSettings().tempCircFactor = server_.arg("circ_factor").toInt();
if (server_.hasArg("circ_max_runtime"))
ConfigManager::getSettings().tempCircMaxRuntime = server_.arg("circ_max_runtime").toInt();
if (server_.hasArg("btn1_min"))
ConfigManager::getSettings().btn1Min = server_.arg("btn1_min").toInt();
Comment thread
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if (server_.hasArg("btn1_max"))
ConfigManager::getSettings().btn1Max = server_.arg("btn1_max").toInt();
if (server_.hasArg("btn2_min"))
ConfigManager::getSettings().btn2Min = server_.arg("btn2_min").toInt();
if (server_.hasArg("btn2_max"))
ConfigManager::getSettings().btn2Max = server_.arg("btn2_max").toInt();
if (server_.hasArg("btn3_min"))
ConfigManager::getSettings().btn3Min = server_.arg("btn3_min").toInt();
if (server_.hasArg("btn3_max"))
ConfigManager::getSettings().btn3Max = server_.arg("btn3_max").toInt();
if (server_.hasArg("btn_no_press"))
ConfigManager::getSettings().btnNoPress = server_.arg("btn_no_press").toInt();
ConfigManager::getSettings().timezoneIndex = server_.arg("timezone").toInt();
ConfigManager::getSettings().timeLossGreenHours = server_.arg("green").toInt();
ConfigManager::getSettings().timeLossRedHours = server_.arg("red").toInt();

ConfigManager::save();

#ifdef NORVI_AE01_R
// Apply button thresholds to the running handler immediately so the
// new values take effect without a reboot (P2 review fix).
NorviButtonHandler::applySettings();
#endif

// Apply timezone change to running clock immediately (P2)
setTimezoneIndex(ConfigManager::getSettings().timezoneIndex);

Expand Down
1 change: 1 addition & 0 deletions test/native/CMakeLists.txt
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Expand Up @@ -58,6 +58,7 @@ set(SERVICE_SOURCES
${PROJ_ROOT}/src/LocalSettingsMenu.cpp
${PROJ_ROOT}/src/Ky040Decoder.cpp
${PROJ_ROOT}/src/OlimexEncoderHandler.cpp
${PROJ_ROOT}/src/NorviButtonHandler.cpp
)

# Mock sources (compiled once)
Expand Down
7 changes: 7 additions & 0 deletions test/native/mocks/ConfigManager.hpp
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Expand Up @@ -20,6 +20,13 @@ struct Settings {
float tempCircThreshold = 24.0f;
int tempCircFactor = 30;
int tempCircMaxRuntime = 720;
uint16_t btn1Min = 3100;
uint16_t btn1Max = 3520;
uint16_t btn2Min = 3520;
uint16_t btn2Max = 3880;
uint16_t btn3Min = 3880;
uint16_t btn3Max = 4095;
uint16_t btnNoPress = 4096;
};

struct WiFiConfig {
Expand Down
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