GUI: live STM32 telemetry + sweep guards + auto-logging + bench-plot

- stm32_link.py: port to the live 114-byte broadcast protocol (magic
  0xAA55AA55, odd parity 8-O-1, 100 Hz publish, repetition-validated,
  no CRC); 39 params incl. adc4_trig_phase/iin_zero_sum, CLEAR_FLAGS,
  30-bit flag table; commands stay CRC-16 framed; Telemetry aliases
  BroadcastData, efficiency uses iout_slow and eff_net subtracts P_sys
- gui_workers.py: STM32Worker reader thread with counter dedup, rate/
  loss counters, 20 s graph history, full-rate telemetry CSV writer
- gui.py: right-side telemetry panel (link state, power + EFF net,
  heatsink/board temps, Vfly group, control, HRTIM, status-flag
  checkboxes, fault registers), Vfly + selectable corr/phase-ofs
  graphs, 20 s rolling window on all plots, dual CSV logging (merged
  stm_* columns + <stem>_telem.csv), logging on by default into
  logs/data_<timestamp>.csv, Plot Eff button
- sweep guards: PSU 20 A input-current gate (conservative estimate +
  measured backstop + I-limit clamp), thermal pause at 57/77 C holding
  the load at 1 A until cooled 5 C below threshold, CC range pinned to
  R2 for the whole run with empirical range-max readback rejection
- plot_eff.py + bench-plot entry point: efficiency vs Vin vs current
  maps from any logged CSV (sweep / data log / telem autodetect), file
  dialog when launched without args
- bench.py: HIOKI FAST response speed, 5 s settle defaults; cli.py
  stm32-read prints the full broadcast; README + .gitignore updates

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>

.gitignore

@@ -6,3 +6,4 @@ build/
 .venv/
 *.csv
 !samples/*.csv
+logs/

README.md

@@ -84,8 +84,42 @@ The GUI provides:
 - HIOKI channel range selectors + degauss buttons
 - Meter format selector (scientific/normal)
 - 2D sweep panel with time estimate
-- Live-updating power, efficiency, voltage, and current plots
-- Console log panel
+- Live-updating power, efficiency, voltage, and current plots plus STM32
+  Vfly and vfly_correction/vfly_ofs_applied plots (selectable) — all graphs
+  show the last 20 seconds
+- STM32 telemetry panel ("Link STM32", COM4 @ 460800 8-O-1): every field of
+  the 100 Hz broadcast (V/I/P + net efficiency, temps, Vfly group, control
+  mode, HRTIM compare registers, status flags, fault registers, param echo),
+  with Ping and Clear Flags buttons; auto-reconnects on serial errors
+- Data logging: instrument rows (with the latest STM32 snapshot merged in as
+  `stm_*` columns) to the chosen CSV, plus the full-rate 100 Hz telemetry
+  stream to `<name>_telem.csv` alongside. Logging is ON by default: every
+  launch auto-starts a log at `logs/data_<timestamp>.csv` (relative to the
+  working directory); use Stop Log / Start Log to switch to a custom path
+- Console log panel (STM32 fault flags are reported here as they latch)
+- PSU capability guard: the HV supply can source at most 20 A
+  (`PSU_MAX_CURRENT_A` in `gui.py`). Sweep steps whose estimated input draw
+  `I_in = P_out / (0.90 * V_in)` exceeds that are rejected (skipped and
+  reported per voltage), regardless of the requested step range; a measured
+  backstop additionally drops any point where the supply actually exceeded
+  the limit and backs the load off. The programmed supply current limit
+  (sweep "I limit" field and manual supply controls) is clamped to 20 A, and
+  manual CC/CP load setpoints are checked against live Vin/Vout readings.
+- Load range pinning: a mid-sweep auto-range transition on the Prodigit
+  momentarily unloads the converter, so at sweep start the CC range is
+  pinned to Range II for the whole run (auto-ranging restored after, with
+  the load off). The reachable maximum of the selected range is verified
+  empirically -- the sweep max is programmed with the load off and read
+  back; if the readback comes back clamped, steps above it are rejected
+  instead of silently clamped, and a sweep that fits nothing aborts up
+  front.
+- Thermal sweep guard (needs the STM32 link): before every sweep step the
+  heatsink/board temperatures are checked against the firmware trip limits
+  (60 C / 80 C). At 57 C / 77 C the sweep pauses, holds the load at 1 A
+  (CC; ~1 A worth of W in CP), and waits until both temps drop 5 C below
+  the pause thresholds, then resumes at the same step -- no points are lost.
+  If the STM32 link is down the sweep still runs, with a console warning
+  that the guard is inactive.
 
 ### 5. Run efficiency sweeps
 
@@ -141,6 +175,32 @@ Produces three PNG files:
 - `*_heatmap.png` -- 2D efficiency surface (voltage x load)
 - `*_loss.png` -- power loss vs load, all voltages overlaid
 
+#### Efficiency vs Vin vs current from any logged CSV
+
+`bench-plot` auto-detects all three CSV formats the tooling produces -- sweep
+CSVs, GUI data logs (`data_*.csv`), and full-rate telemetry logs
+(`*_telem.csv`) -- and draws an operating-point map (x = Vin, y = current,
+color = efficiency) plus efficiency-vs-current curves grouped by Vin bin:
+
+```bash
+uv run bench-plot                    # no args -> file-picker dialog
+uv run bench-plot data_20260703_140000.csv
+uv run bench-plot run1_telem.csv run2_telem.csv --vin-bin 2 --save eff.png
+
+# options: --current iout|iin, --source auto|hioki|instr|stm (data logs),
+#          --min-pout W (default 5), --vin-bin V (default 1), --save PNG
+```
+
+Also reachable via the GUI's "Plot Eff..." button (Logging section, opens the
+same dialog preselecting the last log) and `plot_eff.bat` one level up
+(double-click for the dialog, or drag && drop CSV files onto it).
+
+For GUI data logs the efficiency source defaults to `auto`: HIOKI EFF1 if the
+meter was connected, else supply/load power ratio, else the board's own
+`stm_eff_net_pct`. Telemetry logs always use the board's net efficiency
+(`(P_out - P_sys) / P_in`, iout_slow). Points below `--min-pout` (default
+5 W, same as the GUI display gate) are dropped.
+
 ### 7. Tune converter parameters
 
 The tuning commands combine the testbench instruments (ground truth efficiency from HIOKI) with direct STM32 parameter writes to find optimal settings.
@@ -317,6 +377,8 @@ Names, IDs, types and ranges mirror the firmware (`code64/debug_console/protocol
 | `dither_band_lo` / `dither_band_hi` | uint16 | 716-6442 | Forbidden duty band edges (CMP ticks) |
 | `dither_anear` / `dither_afar` | uint16 | 716-6442 | Out-of-band dither anchors |
 | `dither_dzero` | uint16 | 716-6442 | \|e\| fold center (D=0.5) |
+| `adc4_trig_phase` | uint16 | 3-14313 | HRTIM master CMP3: iout_slow sample instant |
+| `iin_zero_sum` | uint16 | 0-32760 | IIN software zero offset (sum-of-8 counts) |
 
 ## CSV Output Format
 
@@ -335,6 +397,16 @@ Sweep CSV files contain:
 
 Tuning CSV files additionally contain `param_name`, `param_value`, and STM32 telemetry columns (`stm_vin`, `stm_vout`, `stm_iin`, `stm_iout`, `stm_eff`, `stm_vfly`, `stm_etemp`).
 
+GUI data-log CSVs contain the instrument columns plus the latest STM32
+broadcast snapshot per row (`stm_counter` … `stm_age_s`; flag/fault registers
+as hex). While logging, the full-rate 100 Hz telemetry stream is additionally
+written to `<name>_telem.csv` with every broadcast field (one row per fresh
+publish, `pc_time`/`t_mono` timestamps, computed `p_in_W`/`p_out_W`).
+
+Note: STM32-derived `power_out_W`/`efficiency` now use `iout_slow` (the
+PWM-synchronous ADC4 output current) instead of the fast protection-path
+`iout` — tuner numbers shift slightly vs. old logs.
+
 ## Project Structure
 
 ```
@@ -348,7 +420,8 @@ mppt-testbench/
 |   +-- cli.py            unified CLI entry point
 |   +-- gui.py            tkinter GUI with live plots
 |   +-- gui_workers.py    background instrument I/O thread
-|   +-- stm32_link.py     synchronous STM32 debug protocol interface
+|   +-- stm32_link.py     STM32 debug protocol: 114B broadcast RX + CRC-framed TX commands (8-O-1)
+|   +-- plot_eff.py       efficiency vs Vin vs current plots from any logged CSV
 |   +-- tuner.py          automated tuning routines (param sweep, deadtime opt)
 +-- code64/
 |   +-- Core/             STM32G474 firmware (C)
@@ -356,7 +429,7 @@ mppt-testbench/
 |   +-- debug_console/    Textual TUI for live debugging
 |   +-- pyproject.toml    uv-compatible package config
 +-- samples/              shade profile CSV examples
-+-- pyproject.toml        package config, entry points: bench, bench-gui
++-- pyproject.toml        package config, entry points: bench, bench-gui, bench-plot
 ```
 
 ## Dependencies

pyproject.toml

@@ -26,3 +26,4 @@ packages = ["testbench"]
 [project.scripts]
 bench = "testbench.cli:main"
 bench-gui = "testbench.gui:main"
+bench-plot = "testbench.plot_eff:main"

testbench/bench.py

@@ -138,7 +138,7 @@ class MPPTTestbench:
         self.meter.set_current_auto(5, True)
         self.meter.set_voltage_auto(6, True)
         self.meter.set_current_auto(6, True)
-        self.meter.set_response_speed("SLOW")
+        self.meter.set_response_speed("FAST")
         self.meter.set_efficiency(1, "P6", "P5")
 
         # Display: 16-item SELECT view
@@ -300,7 +300,7 @@ class MPPTTestbench:
         v_stop: float,
         v_step: float,
         current_limit: float,
-        settle_time: float = 1.0,
+        settle_time: float = 5.0,
         load_setpoint: float = 0.0,
     ) -> list[SweepPoint]:
         """Sweep supply voltage and record measurements at each point.
@@ -366,7 +366,7 @@ class MPPTTestbench:
         i_start: float,
         i_stop: float,
         i_step: float,
-        settle_time: float = 1.0,
+        settle_time: float = 5.0,
     ) -> list[SweepPoint]:
         """Sweep load current (CC mode) at a fixed supply voltage.
 
@@ -473,7 +473,7 @@ class MPPTTestbench:
     def run_shade_profile(
         self,
         steps: list[dict],
-        settle_time: float = 2.0,
+        settle_time: float = 5.0,
     ) -> list[SweepPoint]:
         """Run a shade / irradiance profile sequence.
 
@@ -629,7 +629,7 @@ class MPPTTestbench:
         l_stop: float,
         l_step: float,
         current_limit: float,
-        settle_time: float = 2.0,
+        settle_time: float = 5.0,
         load_mode: str = "CC",
     ) -> list[SweepPoint]:
         """2D sweep: voltage (outer) × load setpoint (inner).
@@ -770,7 +770,7 @@ class MPPTTestbench:
         self,
         voltage: float,
         current_limit: float,
-        settle_time: float = 2.0,
+        settle_time: float = 5.0,
         samples: int = 5,
         sample_interval: float = 1.0,
     ) -> dict[str, float]:

testbench/cli.py

@@ -572,20 +572,29 @@ def cmd_stm32_read(bench: MPPTTestbench, args: argparse.Namespace) -> None:
                 print(f"  {name:<20s} = {val}")
             print()
 
-        # Read telemetry
+        # Read telemetry (100 Hz broadcast, 20 fresh publishes averaged)
         t = link.read_telemetry_avg(n=20)
         if t:
+            from testbench.stm32_link import flags_to_names
+            modes = ("OFF", "MPPT", "CV", "CC")
+            mode = modes[t.ctrl_mode] if 0 <= t.ctrl_mode < len(modes) else str(t.ctrl_mode)
             print("Telemetry (20-sample avg):")
             print(f"  Vin  = {t.vin_V:8.2f} V")
             print(f"  Vout = {t.vout_V:8.2f} V")
-            print(f"  Iin  = {t.iin_A:8.2f} A")
-            print(f"  Iout = {t.iout_A:8.2f} A")
+            print(f"  Iin  = {t.iin_A:8.2f} A   (avg {t.iin_avg_ma:+d} mA)")
+            print(f"  Iout = {t.iout_slow/1000:8.2f} A   (fast {t.iout_A:.2f} A)")
+            print(f"  Isys = {t.sys_current_ma:8d} mA")
             print(f"  Pin  = {t.power_in_W:8.2f} W")
             print(f"  Pout = {t.power_out_W:8.2f} W")
-            print(f"  EFF  = {t.efficiency:8.1f} %")
+            print(f"  EFF  = {t.efficiency:8.1f} %  (net {t.efficiency_net:.1f} %)")
             print(f"  Vfly = {t.vfly/1000:8.2f} V")
-            print(f"  Temp = {t.etemp:8.1f} °C (FET)")
+            print(f"  Temp = {t.etemp:8.1f} °C (heatsink)")
             print(f"  Tbrd = {t.btemp:8.1f} °C (board)")
+            print(f"  Mode = {mode}")
+            if t.status_flags:
+                print(f"  Flags= 0x{t.status_flags:08X}")
+                for name in flags_to_names(t.status_flags):
+                    print(f"         {name}")
 
 
 def cmd_stm32_write(bench: MPPTTestbench, args: argparse.Namespace) -> None:
@@ -1192,7 +1201,7 @@ examples:
     p_sweep.add_argument("--v-stop", type=float, required=True, help="Stop voltage (V)")
     p_sweep.add_argument("--v-step", type=float, required=True, help="Voltage step (V)")
     p_sweep.add_argument("--current-limit", type=float, required=True, help="Current limit (A)")
-    p_sweep.add_argument("--settle", type=float, default=1.0, help="Settle time per step (s)")
+    p_sweep.add_argument("--settle", type=float, default=5.0, help="Settle time per step (s)")
     p_sweep.add_argument("--load-mode", choices=["CC", "CR", "CV", "CP"], help="Set load mode before sweep")
     p_sweep.add_argument("--load-value", type=float, help="Set load value before sweep")
     p_sweep.add_argument("-o", "--output", help="CSV output file")
@@ -1204,7 +1213,7 @@ examples:
     p_swl.add_argument("--i-start", type=float, required=True, help="Start load current (A)")
     p_swl.add_argument("--i-stop", type=float, required=True, help="Stop load current (A)")
     p_swl.add_argument("--i-step", type=float, required=True, help="Current step (A)")
-    p_swl.add_argument("--settle", type=float, default=1.0, help="Settle time per step (s)")
+    p_swl.add_argument("--settle", type=float, default=5.0, help="Settle time per step (s)")
     p_swl.add_argument("-o", "--output", help="CSV output file")
 
     # efficiency
@@ -1212,7 +1221,7 @@ examples:
     p_eff.add_argument("--voltage", type=float, required=True, help="Supply voltage (V)")
     p_eff.add_argument("--current-limit", type=float, required=True, help="Current limit (A)")
     p_eff.add_argument("--samples", type=int, default=5, help="Number of readings to average")
-    p_eff.add_argument("--settle", type=float, default=2.0, help="Initial settle time (s)")
+    p_eff.add_argument("--settle", type=float, default=5.0, help="Initial settle time (s)")
     p_eff.add_argument("-i", "--interval", type=float, default=1.0, help="Interval between samples")
     p_eff.add_argument("--load-mode", choices=["CC", "CR", "CV", "CP"])
     p_eff.add_argument("--load-value", type=float)
@@ -1227,13 +1236,13 @@ examples:
     p_svi.add_argument("--l-step", type=float, required=True, help="Load step size")
     p_svi.add_argument("--load-mode", choices=["CC", "CP"], default="CC", help="Load mode: CC (current) or CP (power)")
     p_svi.add_argument("--current-limit", type=float, required=True, help="Supply current limit (A)")
-    p_svi.add_argument("--settle", type=float, default=2.0, help="Settle time per step (s)")
+    p_svi.add_argument("--settle", type=float, default=5.0, help="Settle time per step (s)")
     p_svi.add_argument("-o", "--output", help="CSV output file")
 
     # shade-profile
     p_shade = sub.add_parser("shade-profile", help="Run a shade/irradiance profile from CSV")
     p_shade.add_argument("--profile", required=True, help="Profile CSV file (time,voltage,current_limit,...)")
-    p_shade.add_argument("--settle", type=float, default=2.0, help="Settle time per step (s)")
+    p_shade.add_argument("--settle", type=float, default=5.0, help="Settle time per step (s)")
     p_shade.add_argument("-o", "--output", help="CSV output file for results")
 
     # supply (direct control)
@@ -1275,7 +1284,7 @@ examples:
     p_tp.add_argument("--current-limit", type=float, required=True, help="Supply current limit (A)")
     p_tp.add_argument("--load-mode", choices=["CC", "CP"], default="CP", help="Load mode")
     p_tp.add_argument("--load-value", type=float, default=200.0, help="Load setpoint (A or W)")
-    p_tp.add_argument("--settle", type=float, default=3.0, help="Settle time per step (s)")
+    p_tp.add_argument("--settle", type=float, default=5.0, help="Settle time per step (s)")
     p_tp.add_argument("--no-plot", action="store_true", help="Skip plot")
     p_tp.add_argument("-o", "--output", help="CSV output file")
 
@@ -1291,7 +1300,7 @@ examples:
     p_tv.add_argument("--current-limit", type=float, required=True, help="Supply current limit (A)")
     p_tv.add_argument("--load-mode", choices=["CC", "CP"], default="CP", help="Load mode")
     p_tv.add_argument("--load-value", type=float, default=200.0, help="Load setpoint (A or W)")
-    p_tv.add_argument("--settle", type=float, default=3.0, help="Settle time per step (s)")
+    p_tv.add_argument("--settle", type=float, default=5.0, help="Settle time per step (s)")
     p_tv.add_argument("-o", "--output", help="Output prefix for CSVs (default: param name)")
 
     # tune-deadtime
@@ -1303,7 +1312,7 @@ examples:
     p_td.add_argument("--current-limit", type=float, default=20.0, help="Supply current limit (A)")
     p_td.add_argument("--load-mode", choices=["CC", "CP"], default="CP", help="Load mode")
     p_td.add_argument("--load-values", help="Comma-separated load values to test (e.g. 100,300,500)")
-    p_td.add_argument("--settle", type=float, default=3.0, help="Settle time per step (s)")
+    p_td.add_argument("--settle", type=float, default=5.0, help="Settle time per step (s)")
     p_td.add_argument("--apply", action="store_true", help="Apply best deadtimes after sweep")
     p_td.add_argument("-o", "--output", help="CSV output file")
 

testbench/gui_workers.py

@@ -6,11 +6,19 @@ never freezes during instrument queries.
 
 from __future__ import annotations
 
+import csv
 import queue
 import threading
 import time
+from collections import deque
 from enum import Enum, auto
 
+import serial
+
+from testbench.stm32_link import (
+    BroadcastData, BroadcastParser, PARAM_BY_ID, decode_param_bits,
+)
+
 
 class Cmd(Enum):
     """Commands sent from GUI to worker thread."""
@@ -226,3 +234,214 @@ class InstrumentWorker(threading.Thread):
                 })
             except queue.Full:
                 pass
+
+
+# ── STM32 broadcast reader ───────────────────────────────────────────
+
+# All BroadcastData wire fields, in dataclass order (full-rate CSV columns).
+TELEM_CSV_FIELDS = (
+    "counter", "vin", "vout", "iin", "iout", "vfly", "etemp", "btemp",
+    "vfly_integral", "vfly_avg_debug", "cc_output_f", "mppt_iref",
+    "mppt_last_vin", "mppt_last_iin", "p_in", "p_out", "iout_slow",
+    "last_tmp", "VREF", "vfly_correction", "cmp_outer", "cmp_inner",
+    "vfly_ofs_applied", "ctrl_mode", "vfly_active", "status_flags",
+    "fmac_sr", "fault_pc", "cfsr", "param_id", "param_type",
+    "param_value", "pong", "sys_current_ma", "iin_avg_ma",
+)
+_TELEM_HEX_FIELDS = frozenset({"status_flags", "fmac_sr", "fault_pc", "cfsr"})
+
+
+class STM32Worker(threading.Thread):
+    """Daemon thread reading the STM32 broadcast stream.
+
+    The board streams 114-byte frames continuously (100 Hz publishes, each
+    repeated ~3-4x at line rate); this thread validates them, keeps the
+    latest sample plus 20 s graph history, and owns the full-rate telemetry
+    CSV (single writer). Auto-reconnects on serial errors.
+    """
+
+    HISTORY = 2200          # 100 Hz x 20 s + margin
+    CSV_FLUSH_S = 1.0       # never flush per-row at 100 rows/s
+
+    def __init__(self, port: str, baudrate: int = 460800) -> None:
+        super().__init__(daemon=True)
+        self.port = port
+        self.baudrate = baudrate
+        self.connected = False
+        self._stop_event = threading.Event()
+        self._tx_queue: queue.Queue = queue.Queue()
+
+        self._lock = threading.Lock()
+        self.latest: BroadcastData | None = None
+        self.latest_wall: float = 0.0
+        self._last_counter = -1
+        self._t: deque = deque(maxlen=self.HISTORY)      # time.monotonic per fresh publish
+        self._vfly: deque = deque(maxlen=self.HISTORY)   # mV
+        self._corr: deque = deque(maxlen=self.HISTORY)   # vfly_correction, ticks
+        self._ofs: deque = deque(maxlen=self.HISTORY)    # vfly_ofs_applied, ticks
+        self._fresh_count = 0    # validated fresh publishes since last get_rates()
+        self._sent_count = 0     # publishes the board sent (counter deltas)
+        self.params: dict[int, float] = {}
+
+        self._csv_lock = threading.Lock()
+        self._csv_file = None
+        self._csv_writer = None
+        self._csv_last_flush = 0.0
+
+    # ── Thread-safe API for the GUI ──────────────────────────────────
+
+    def get_latest(self) -> tuple[BroadcastData | None, float]:
+        """Latest validated sample and its wall-clock arrival time."""
+        with self._lock:
+            return self.latest, self.latest_wall
+
+    def get_graph_snapshot(self, decimate: int = 4):
+        """(t_mono, vfly_mV, corr, ofs) lists, decimated for display.
+
+        Decimation is anchored at the end so the newest sample always shows.
+        Full rate is still recorded to the CSV.
+        """
+        with self._lock:
+            t, v = list(self._t), list(self._vfly)
+            c, o = list(self._corr), list(self._ofs)
+        if decimate > 1 and t:
+            k = (len(t) - 1) % decimate
+            t, v, c, o = t[k::decimate], v[k::decimate], c[k::decimate], o[k::decimate]
+        return t, v, c, o
+
+    def get_rates(self) -> tuple[int, int]:
+        """(fresh publishes received, publishes sent) since the last call."""
+        with self._lock:
+            f, s = self._fresh_count, self._sent_count
+            self._fresh_count = 0
+            self._sent_count = 0
+        return f, s
+
+    def send_frame(self, data: bytes) -> None:
+        """Queue a pre-built command frame for TX on the worker thread."""
+        self._tx_queue.put(data)
+
+    def start_csv(self, path: str) -> None:
+        """Open the full-rate telemetry CSV (one row per fresh publish)."""
+        with self._csv_lock:
+            self._close_csv_locked()
+            f = open(path, "w", newline="", encoding="utf-8")
+            w = csv.writer(f)
+            w.writerow(("pc_time", "t_mono") + TELEM_CSV_FIELDS + ("p_in_W", "p_out_W"))
+            self._csv_file, self._csv_writer = f, w
+            self._csv_last_flush = time.monotonic()
+
+    def stop_csv(self) -> None:
+        with self._csv_lock:
+            self._close_csv_locked()
+
+    def _close_csv_locked(self) -> None:
+        if self._csv_file is not None:
+            try:
+                self._csv_file.close()
+            except OSError:
+                pass
+        self._csv_file = None
+        self._csv_writer = None
+
+    def stop(self) -> None:
+        """Stop the thread and close the CSV (blocks up to 2 s)."""
+        self._stop_event.set()
+        if self.is_alive():
+            self.join(timeout=2.0)
+        self.stop_csv()
+
+    # ── Worker loop ──────────────────────────────────────────────────
+
+    def run(self) -> None:
+        ser = None
+        parser = None
+        while not self._stop_event.is_set():
+            if ser is None:
+                try:
+                    ser = serial.Serial(
+                        self.port, self.baudrate, timeout=0.05,
+                        bytesize=serial.EIGHTBITS,
+                        parity=serial.PARITY_ODD,
+                        stopbits=serial.STOPBITS_ONE,
+                    )
+                    parser = BroadcastParser()
+                    self.connected = True
+                except (serial.SerialException, OSError):
+                    self.connected = False
+                    self._stop_event.wait(1.0)
+                    continue
+            try:
+                while True:
+                    try:
+                        ser.write(self._tx_queue.get_nowait())
+                    except queue.Empty:
+                        break
+                data = ser.read(4096)
+                if data:
+                    for b in parser.feed(data):
+                        self._on_frame(b)
+            except (serial.SerialException, OSError):
+                self.connected = False
+                try:
+                    ser.close()
+                except Exception:
+                    pass
+                ser = None
+                self._stop_event.wait(1.0)
+        if ser is not None:
+            try:
+                ser.close()
+            except Exception:
+                pass
+        self.connected = False
+        self.stop_csv()
+
+    # NB: name must not collide with threading.Thread instance attributes
+    # (Thread.__init__ sets self._handle on Python 3.13+).
+    def _on_frame(self, b: BroadcastData) -> None:
+        now = time.monotonic()
+        with self._lock:
+            # Flags/pong are valid even at counter == 0 (post-reset window);
+            # telemetry/param fields are only valid once counter > 0.
+            self.latest = b
+            self.latest_wall = time.time()
+            fresh = b.counter > 0 and b.counter != self._last_counter
+            if fresh:
+                if 0 < self._last_counter < b.counter:
+                    self._sent_count += b.counter - self._last_counter
+                else:
+                    self._sent_count += 1   # first valid frame, or a reboot
+                self._fresh_count += 1
+                self._last_counter = b.counter
+                self._t.append(now)
+                self._vfly.append(b.vfly)
+                self._corr.append(b.vfly_correction)
+                self._ofs.append(b.vfly_ofs_applied)
+                if b.param_id in PARAM_BY_ID:
+                    self.params[b.param_id] = decode_param_bits(b.param_type, b.param_value)
+        if fresh:
+            self._csv_row(b, now)
+
+    def _csv_row(self, b: BroadcastData, t_mono: float) -> None:
+        with self._csv_lock:
+            if self._csv_writer is None:
+                return
+            row = [f"{b.timestamp:.3f}", f"{t_mono:.3f}"]
+            for name in TELEM_CSV_FIELDS:
+                v = getattr(b, name)
+                if name in _TELEM_HEX_FIELDS:
+                    row.append(f"0x{v:08X}")
+                elif isinstance(v, float):
+                    row.append(f"{v:.6g}")
+                else:
+                    row.append(v)
+            row.append(f"{b.power_in_W:.4f}")
+            row.append(f"{b.power_out_W:.4f}")
+            try:
+                self._csv_writer.writerow(row)
+                if t_mono - self._csv_last_flush >= self.CSV_FLUSH_S:
+                    self._csv_file.flush()
+                    self._csv_last_flush = t_mono
+            except OSError:
+                self._close_csv_locked()

testbench/plot_eff.py

@@ -0,0 +1,234 @@
+"""Plot efficiency vs input voltage vs current from bench CSV logs.
+
+Auto-detects the three CSV formats produced by the tooling:
+  - GUI data log      (data_*.csv: instrument columns + merged stm_* snapshot)
+  - GUI telemetry log (*_telem.csv: full-rate 100 Hz board broadcast)
+  - CLI sweep         (sweep_vi_*.csv: voltage_set/load_setpoint grid)
+
+Left panel: operating-point scatter (x = Vin, y = current, color = efficiency).
+Right panel: efficiency vs current, one curve per Vin bin.
+
+Usage:
+    bench-plot data_20260703_120000.csv
+    bench-plot run_telem.csv another_telem.csv --current iin --save eff.png
+"""
+
+from __future__ import annotations
+
+import argparse
+import csv
+import math
+import sys
+
+import matplotlib.pyplot as plt
+import numpy as np
+
+MIN_P_IN_W = 0.1     # same gate as the firmware/GUI efficiency calc
+
+
+def _f(row: dict, key: str) -> float:
+    """Float cell value; blank/missing/garbage -> NaN."""
+    v = row.get(key, "")
+    if v is None or v == "":
+        return math.nan
+    try:
+        return float(v)
+    except ValueError:
+        return math.nan
+
+
+def _detect_format(header: list[str]) -> str:
+    cols = set(header)
+    if "stm_eff_net_pct" in cols:
+        return "datalog"
+    if "iout_slow" in cols and "p_in_W" in cols:
+        return "telem"
+    if "voltage_set" in cols and "efficiency" in cols:
+        return "sweep"
+    raise ValueError(f"unrecognized CSV header: {header[:6]}...")
+
+
+def _extract(path: str, source: str) -> tuple[dict, str]:
+    """Read one CSV -> dict of float lists (vin_V, iin_A, iout_A, eff_pct,
+    p_out_W) plus the efficiency-source label actually used."""
+    with open(path, newline="") as fh:
+        reader = csv.DictReader(fh)
+        header = reader.fieldnames or []
+        rows = list(reader)
+    fmt = _detect_format(header)
+
+    out: dict[str, list] = {k: [] for k in ("vin_V", "iin_A", "iout_A", "eff_pct", "p_out_W")}
+
+    if fmt == "sweep":
+        for r in rows:
+            out["vin_V"].append(_f(r, "supply_V"))
+            out["iin_A"].append(_f(r, "supply_I"))
+            out["iout_A"].append(_f(r, "load_I"))
+            out["eff_pct"].append(_f(r, "efficiency"))
+            out["p_out_W"].append(_f(r, "output_power"))
+        return out, "sweep efficiency (HIOKI)"
+
+    if fmt == "telem":
+        # Wire units: vin/vout in mV, currents in mA (iin negative into the
+        # converter); eff net = (P_out - P_sys) / P_in, same as the GUI panel.
+        for r in rows:
+            p_in = _f(r, "p_in_W")
+            p_out = _f(r, "p_out_W")
+            p_sys = _f(r, "vout") * _f(r, "sys_current_ma") / 1e6
+            eff = (p_out - p_sys) / p_in * 100.0 if p_in > MIN_P_IN_W else math.nan
+            out["vin_V"].append(_f(r, "vin") / 1000.0)
+            out["iin_A"].append(-_f(r, "iin") / 1000.0)
+            out["iout_A"].append(_f(r, "iout_slow") / 1000.0)
+            out["eff_pct"].append(eff)
+            out["p_out_W"].append(p_out)
+        return out, "board eff net (iout_slow, -P_sys)"
+
+    # datalog: three consistent (vin, current, eff) triples to choose from
+    if source == "auto":
+        med_eff1 = np.nanmedian([_f(r, "meter_EFF1") for r in rows]) if rows else math.nan
+        med_psup = np.nanmedian([_f(r, "supply_P") for r in rows]) if rows else math.nan
+        if med_eff1 > 1.0:
+            source = "hioki"
+        elif med_psup > MIN_P_IN_W:
+            source = "instr"
+        else:
+            source = "stm"
+
+    for r in rows:
+        if source == "hioki":
+            out["vin_V"].append(_f(r, "meter_U5"))
+            out["iin_A"].append(_f(r, "meter_I5"))
+            out["iout_A"].append(_f(r, "meter_I6"))
+            out["eff_pct"].append(_f(r, "meter_EFF1"))
+            out["p_out_W"].append(_f(r, "meter_P6"))
+        elif source == "instr":
+            p_sup = _f(r, "supply_P")
+            eff = _f(r, "load_P") / p_sup * 100.0 if p_sup > MIN_P_IN_W else math.nan
+            out["vin_V"].append(_f(r, "supply_V"))
+            out["iin_A"].append(_f(r, "supply_I"))
+            out["iout_A"].append(_f(r, "load_I"))
+            out["eff_pct"].append(eff)
+            out["p_out_W"].append(_f(r, "load_P"))
+        else:  # stm
+            out["vin_V"].append(_f(r, "stm_vin_mV") / 1000.0)
+            out["iin_A"].append(-_f(r, "stm_iin_mA") / 1000.0)
+            out["iout_A"].append(_f(r, "stm_iout_slow_mA") / 1000.0)
+            out["eff_pct"].append(_f(r, "stm_eff_net_pct"))
+            out["p_out_W"].append(_f(r, "stm_p_out_W"))
+    labels = {"hioki": "HIOKI EFF1", "instr": "supply/load power",
+              "stm": "board eff net"}
+    return out, labels[source]
+
+
+def main() -> None:
+    ap = argparse.ArgumentParser(
+        description="Plot efficiency vs input voltage vs current from bench CSVs.")
+    ap.add_argument("csv", nargs="*",
+                    help="logged CSV file(s); a file dialog opens if omitted")
+    ap.add_argument("--current", choices=("iout", "iin"), default="iout",
+                    help="current axis: output (default) or input current")
+    ap.add_argument("--source", choices=("auto", "hioki", "instr", "stm"),
+                    default="auto",
+                    help="efficiency source for GUI data logs (default auto: "
+                         "HIOKI if present, else supply/load, else board)")
+    ap.add_argument("--vin-bin", type=float, default=1.0, metavar="V",
+                    help="Vin bin width for the per-voltage curves (default 1.0)")
+    ap.add_argument("--min-pout", type=float, default=5.0, metavar="W",
+                    help="drop points below this output power (default 5.0)")
+    ap.add_argument("--save", metavar="PNG", help="write the figure instead of showing it")
+    ap.add_argument("--title", default=None, help="figure title override")
+    args = ap.parse_args()
+
+    if not args.csv:
+        import tkinter as tk
+        from tkinter import filedialog
+        root = tk.Tk()
+        root.withdraw()
+        args.csv = list(filedialog.askopenfilenames(
+            title="Select logged CSV(s) to plot",
+            filetypes=[("CSV files", "*.csv"), ("All files", "*.*")]))
+        root.destroy()
+        if not args.csv:
+            sys.exit("no file selected")
+
+    data: dict[str, list] = {k: [] for k in ("vin_V", "iin_A", "iout_A", "eff_pct", "p_out_W")}
+    labels = set()
+    for path in args.csv:
+        part, label = _extract(path, args.source)
+        for k in data:
+            data[k].extend(part[k])
+        labels.add(label)
+
+    vin = np.asarray(data["vin_V"])
+    cur = np.asarray(data["iin_A" if args.current == "iin" else "iout_A"])
+    eff = np.asarray(data["eff_pct"])
+    pout = np.asarray(data["p_out_W"])
+
+    keep = (np.isfinite(vin) & np.isfinite(cur) & np.isfinite(eff)
+            & (eff > 0.0) & (eff <= 105.0) & (pout >= args.min_pout))
+    n_total = len(vin)
+    vin, cur, eff = vin[keep], cur[keep], eff[keep]
+    if len(vin) == 0:
+        sys.exit(f"no usable points ({n_total} rows read; all filtered — "
+                 f"check --min-pout / --source)")
+
+    ipk = int(np.argmax(eff))
+    print(f"{len(vin)} points ({n_total - len(vin)} filtered) | "
+          f"Vin {vin.min():.1f}..{vin.max():.1f} V | "
+          f"I {cur.min():.2f}..{cur.max():.2f} A | "
+          f"peak eff {eff[ipk]:.2f} % @ {vin[ipk]:.1f} V, {cur[ipk]:.2f} A")
+
+    cur_name = "Input current (A)" if args.current == "iin" else "Output current (A)"
+    fig, (ax1, ax2) = plt.subplots(1, 2, figsize=(13.5, 5.8))
+    fig.suptitle(args.title or f"Efficiency map — {', '.join(sorted(labels))}")
+
+    # Left: operating-point scatter, color = efficiency
+    vmin = np.percentile(eff, 5)
+    sc = ax1.scatter(vin, cur, c=eff, s=14, cmap="viridis",
+                     vmin=vmin, vmax=eff.max(), rasterized=True)
+    fig.colorbar(sc, ax=ax1, label="Efficiency (%)")
+    ax1.plot(vin[ipk], cur[ipk], "r*", ms=14, mec="k",
+             label=f"peak {eff[ipk]:.2f} %")
+    ax1.set_xlabel("Input voltage (V)")
+    ax1.set_ylabel(cur_name)
+    ax1.legend(loc="best", fontsize=8)
+    ax1.grid(alpha=0.3)
+
+    # Right: efficiency vs current, one mean curve per Vin bin
+    w = args.vin_bin
+    centers = np.unique(np.round(vin / w) * w)
+    cmap = plt.cm.plasma(np.linspace(0.0, 0.9, len(centers)))
+    for color, c0 in zip(cmap, centers):
+        m = np.abs(vin - c0) <= w / 2
+        if m.sum() < 2:
+            ax2.plot(cur[m], eff[m], "o", color=color, ms=4,
+                     label=f"{c0:g} V")
+            continue
+        edges = np.linspace(cur[m].min(), cur[m].max() + 1e-9, 41)
+        idx = np.digitize(cur[m], edges)
+        xs, ys = [], []
+        for b in np.unique(idx):
+            bm = idx == b
+            xs.append(cur[m][bm].mean())
+            ys.append(eff[m][bm].mean())
+        ax2.plot(xs, ys, "-o", color=color, ms=3, lw=1.2, label=f"{c0:g} V")
+    ax2.set_xlabel(cur_name)
+    ax2.set_ylabel("Efficiency (%)")
+    ax2.grid(alpha=0.3)
+    if len(centers) <= 14:
+        ax2.legend(title="Vin bin", fontsize=8, ncols=1 + len(centers) // 8)
+    else:
+        norm = plt.Normalize(centers.min(), centers.max())
+        fig.colorbar(plt.cm.ScalarMappable(norm=norm, cmap="plasma"),
+                     ax=ax2, label="Vin bin (V)")
+
+    fig.tight_layout()
+    if args.save:
+        fig.savefig(args.save, dpi=140)
+        print(f"saved: {args.save}")
+    else:
+        plt.show()
+
+
+if __name__ == "__main__":
+    main()

testbench/stm32_link.py

@@ -1,17 +1,20 @@
 """Synchronous serial link to the STM32 debug protocol.
 
-Provides blocking read/write of telemetry and parameters, suitable
-for automated tuning scripts (not a TUI).  Mirrors the binary protocol
-from code64/debug_console/protocol.py (kept in sync with the firmware's
-debug_protocol.h — CRC-16, 78-byte telemetry, current parameter map).
+STM32 -> PC is a continuous 114-byte binary broadcast (magic-delimited,
+repetition-validated, UART odd parity, ~100 Hz publish rate, each publish
+repeated ~3-4x at line rate).  PC -> STM32 commands remain CRC-16 framed.
+Mirrors code64/debug_console/protocol.py (kept in sync with the firmware's
+debug_protocol.h).
 """
 
 from __future__ import annotations
 
+import dataclasses
 import struct
 import time
+from collections import deque
 from dataclasses import dataclass, field
-from typing import Optional
+from typing import Iterator, Optional
 
 import serial
 
@@ -19,13 +22,13 @@ import serial
 
 SYNC_BYTE = 0xAA
 
-CMD_TELEMETRY = 0x01
+CMD_TELEMETRY = 0x01         # legacy; STM32->PC framed telemetry no longer sent
 CMD_PARAM_WRITE = 0x02
-CMD_PARAM_WRITE_ACK = 0x03
-CMD_PARAM_READ_ALL = 0x04
-CMD_PARAM_VALUE = 0x05
+CMD_PARAM_WRITE_ACK = 0x03   # legacy; acks now come via the broadcast round-robin
+CMD_PARAM_READ_ALL = 0x04    # restarts the broadcast param round-robin cursor
+CMD_PARAM_VALUE = 0x05       # legacy; STM32->PC framed replies no longer sent
 CMD_PING = 0x10
-CMD_PONG = 0x11
+CMD_PONG = 0x11              # legacy; pong now increments a broadcast field
 CMD_SHUTDOWN = 0x12          # turn off converter
 CMD_RESET = 0x13             # system reset
 CMD_TEST_50 = 0x14           # 50% duty test mode
@@ -33,7 +36,8 @@ CMD_RELAY_ON = 0x15          # latch input relay closed (bench test)
 CMD_RELAY_OFF = 0x16         # latch input relay open  (bench test)
 CMD_HOLD_CONVERTER = 0x17    # toggle "hold converter off" (boot guard + disarm trips)
 CMD_TOGGLE_PRECHARGE = 0x18  # toggle the precharge FET (bench test)
-CMD_ERROR_MSG = 0xE0
+CMD_CLEAR_FLAGS = 0x19       # clear latched status flags
+CMD_ERROR_MSG = 0xE0         # legacy; STM32->PC no longer sends framed text
 
 PTYPE_FLOAT = 0
 PTYPE_UINT16 = 1
@@ -57,36 +61,116 @@ def crc16(data: bytes) -> int:
     return crc
 
 
-# ── Telemetry ────────────────────────────────────────────────────────
+# ── STM32 -> PC broadcast ────────────────────────────────────────────
+# A single fixed 114-byte struct streamed continuously (circular DMA). No framing
+# length, no CRC. Frames are delimited by the 4-byte magic. Integrity = REPETITION
+# (each `counter` value is re-sent back-to-back, so a corrupt/torn copy differs
+# from its neighbours) + UART odd parity. See debug_protocol.h BroadcastFrame.
+
+BCAST_MAGIC = 0xAA55AA55
+BROADCAST_FMT = "<II16fhHhHHhBBIIIIBBhIHH"   # 114 bytes; h after param_type = iin_avg_ma, trailing H = sys_current_ma
+BROADCAST_SIZE = struct.calcsize(BROADCAST_FMT)
+MAGIC_BYTES = struct.pack("<I", BCAST_MAGIC)
+
+# status_flags bit -> human label (matches the firmware FLAG_* defines)
+FLAG_NAMES = {
+    0:  "STARTUP: waiting (Vfly guard)",
+    1:  "PRECHARGE TIMEOUT",
+    2:  "GUARD: VIN_MAX",
+    3:  "GUARD: VIN<VOUT+5V",
+    4:  "GUARD: IIN",
+    5:  "GUARD: IOUT",
+    6:  "GUARD: VFLY",
+    7:  "GUARD: ETEMP",
+    8:  "GUARD: BTEMP",
+    9:  "LIMIT: VOUT_MAX",
+    10: "LIMIT: VIN_SHUTOFF",
+    11: "LIMIT: IIN reverse-feed",
+    12: "LIMIT: IIN_MIN",
+    13: "LIMIT: IOUT_MAX",
+    14: "LIMIT: IOUT_MIN",
+    15: "LIMIT: VFLY_MAX",
+    16: "LIMIT: VIN<VOUT+5V",
+    17: "FMAC OVF",
+    18: "FMAC UNF",
+    19: "FMAC SAT",
+    20: "TEMP: ETEMP",
+    21: "TEMP: BTEMP",
+    22: "HARDFAULT",
+    23: "OCP: VOUT comparator",
+    24: "OCP: IIN comparator",
+    25: "OCP: ILOAD comparator",
+    26: "Clock Security System",
+    27: "Error_Handler reached",
+    28: "OUTPUTS ENABLED (converter went active)",
+    29: "TURNOFF: current-decay timeout (not COMP4)",
+}
+# flags that are informational / transient (yellow), the rest are faults (red):
+# STARTUP_WAITING (bit 0) + all GUARD_* (bits 2..8) + OUTPUTS ENABLED (bit 28)
+FLAG_INFO_MASK = (1 << 0) | sum(1 << b for b in range(2, 9)) | (1 << 28)
+
+
+def flags_to_names(flags: int) -> list:
+    return [name for bit, name in FLAG_NAMES.items() if flags & (1 << bit)]
+
+
+def decode_param_bits(param_type: int, raw: int) -> float:
+    """Interpret a raw 32-bit param_value from the broadcast per its type."""
+    if param_type == PTYPE_FLOAT:
+        return struct.unpack("<f", struct.pack("<I", raw & 0xFFFFFFFF))[0]
+    if param_type == PTYPE_UINT16:
+        return float(raw & 0xFFFF)
+    if param_type == PTYPE_UINT8:
+        return float(raw & 0xFF)
+    if param_type in (PTYPE_INT32, PTYPE_INT16):
+        return float(struct.unpack("<i", struct.pack("<I", raw & 0xFFFFFFFF))[0])
+    return float(raw)
+
 
 @dataclass
-class Telemetry:
-    """Decoded telemetry packet from the STM32 (78-byte payload)."""
+class BroadcastData:
+    """One decoded broadcast frame — everything the board publishes."""
+    counter: int = 0
     vin: float = 0.0       # mV
     vout: float = 0.0      # mV
     iin: float = 0.0       # mA (negative = into converter)
-    iout: float = 0.0      # mA
+    iout: float = 0.0      # mA (fast ADC5; protection only — use iout_slow for power)
     vfly: float = 0.0      # mV
-    etemp: float = 0.0     # °C (FET / external)
+    etemp: float = 0.0     # °C (heatsink / external)
     btemp: float = 0.0     # °C (board)
-    last_tmp: int = 0
-    VREF: int = 0
-    vfly_correction: int = 0
-    cmp_outer: int = 0     # HRTIM Timer F CMP1xR (outer pair, T1/T4)
     vfly_integral: float = 0.0
     vfly_avg_debug: float = 0.0
     cc_output_f: float = 0.0
     mppt_iref: float = 0.0
     mppt_last_vin: float = 0.0
     mppt_last_iin: float = 0.0
-    p_in: float = 0.0
-    p_out: float = 0.0
-    iout_slow: float = 0.0
-    seq: int = 0
-    cmp_inner: int = 0        # HRTIM Timer E CMP1xR (inner pair, T2/T3)
+    p_in: float = 0.0      # board-computed
+    p_out: float = 0.0     # board-computed
+    iout_slow: float = 0.0  # mA (ADC4, PWM-synchronous avg-point)
+    last_tmp: int = 0
+    VREF: int = 0
+    vfly_correction: int = 0
+    cmp_outer: int = 0     # HRTIM Timer F CMP1xR (outer pair, T1/T4)
+    cmp_inner: int = 0     # HRTIM Timer E CMP1xR (inner pair, T2/T3)
     vfly_ofs_applied: int = 0  # master-phase offset last written, signed ticks
+    ctrl_mode: int = 0     # 0=OFF 1=MPPT 2=CV 3=CC
+    vfly_active: int = 0
+    status_flags: int = 0
+    fmac_sr: int = 0
+    fault_pc: int = 0
+    cfsr: int = 0
+    param_id: int = 0      # broadcast param round-robin
+    param_type: int = 0
+    param_value: int = 0   # raw bits; interpret via decode_param_bits(param_type, ...)
+    pong: int = 0          # increments when the MCU processes CMD_PING
+    sys_current_ma: int = 0   # Vout-rail housekeeping current, mA
+    iin_avg_ma: int = 0       # 8-sample boxcar of iin, mA (the IIN_MAX trip quantity)
     timestamp: float = field(default_factory=time.time)
 
+    @property
+    def seq(self) -> int:       # back-compat for code that used t.seq
+        return self.counter & 0xFFFF
+
     @property
     def vin_V(self) -> float:
         return self.vin / 1000.0
@@ -103,39 +187,91 @@ class Telemetry:
     def iout_A(self) -> float:
         return self.iout / 1000.0
 
+    @property
+    def vfly_V(self) -> float:
+        return self.vfly / 1000.0
+
     @property
     def power_in_W(self) -> float:
         return self.vin * (-self.iin) / 1e6
 
     @property
     def power_out_W(self) -> float:
-        return self.vout * self.iout / 1e6
+        # iout_slow is the accurate output current (fast iout is protection-only)
+        return self.vout * self.iout_slow / 1e6
+
+    @property
+    def power_sys_W(self) -> float:
+        return self.vout * self.sys_current_ma / 1e6
 
     @property
     def efficiency(self) -> float:
+        """Gross efficiency P_out/P_in (%)."""
         p_in = self.power_in_W
         return (self.power_out_W / p_in * 100.0) if p_in > 0.1 else 0.0
 
-
-_TELEM_FMT = "<7f hHhH 6f 3f BxH h"  # 78 bytes
-_TELEM_SIZE = struct.calcsize(_TELEM_FMT)
+    @property
+    def efficiency_net(self) -> float:
+        """Net efficiency (P_out - P_sys)/P_in (%) — self-supply subtracted."""
+        p_in = self.power_in_W
+        if p_in <= 0.1:
+            return 0.0
+        return (self.power_out_W - self.power_sys_W) / p_in * 100.0
 
 
-def _decode_telemetry(payload: bytes) -> Optional[Telemetry]:
-    if len(payload) < _TELEM_SIZE:
-        return None
-    v = struct.unpack(_TELEM_FMT, payload[:_TELEM_SIZE])
-    return Telemetry(
-        vin=v[0], vout=v[1], iin=v[2], iout=v[3], vfly=v[4], etemp=v[5], btemp=v[6],
-        last_tmp=v[7], VREF=v[8], vfly_correction=v[9], cmp_outer=v[10],
-        vfly_integral=v[11], vfly_avg_debug=v[12],
-        cc_output_f=v[13], mppt_iref=v[14],
-        mppt_last_vin=v[15], mppt_last_iin=v[16],
-        p_in=v[17], p_out=v[18], iout_slow=v[19],
-        seq=v[20], cmp_inner=v[21], vfly_ofs_applied=v[22],
+# Back-compat alias: tuner/cli were written against the old Telemetry class.
+Telemetry = BroadcastData
+
+
+def decode_broadcast(frame: bytes) -> BroadcastData:
+    v = struct.unpack(BROADCAST_FMT, frame)
+    return BroadcastData(
+        counter=v[1],
+        vin=v[2], vout=v[3], iin=v[4], iout=v[5], vfly=v[6], etemp=v[7], btemp=v[8],
+        vfly_integral=v[9], vfly_avg_debug=v[10], cc_output_f=v[11],
+        mppt_iref=v[12], mppt_last_vin=v[13], mppt_last_iin=v[14],
+        p_in=v[15], p_out=v[16], iout_slow=v[17],
+        last_tmp=v[18], VREF=v[19], vfly_correction=v[20],
+        cmp_outer=v[21], cmp_inner=v[22], vfly_ofs_applied=v[23],
+        ctrl_mode=v[24], vfly_active=v[25],
+        status_flags=v[26], fmac_sr=v[27], fault_pc=v[28], cfsr=v[29],
+        param_id=v[30], param_type=v[31], param_value=v[33], pong=v[34],
+        sys_current_ma=v[35], iin_avg_ma=v[32],
     )
 
 
+class BroadcastParser:
+    """Parse the continuous 114-byte broadcast stream. Resync on the 4-byte magic;
+    validate a frame by REPETITION -- accept only when two consecutive byte-identical
+    copies arrive (a corrupt/torn copy differs from its neighbours -> discarded). No
+    CRC. Re-sends of the same `counter` are normal; dedup on counter downstream."""
+
+    def __init__(self):
+        self.buf = bytearray()
+        self._prev = None   # previous raw frame awaiting a matching repeat
+
+    def feed(self, data: bytes):
+        self.buf += data
+        while True:
+            i = self.buf.find(MAGIC_BYTES)
+            if i < 0:
+                # no magic yet; keep only a trailing partial-magic (3 bytes)
+                if len(self.buf) > 3:
+                    del self.buf[:-3]
+                return
+            if i > 0:
+                del self.buf[:i]           # drop junk / dropped-byte shift before magic
+            if len(self.buf) < BROADCAST_SIZE:
+                return                     # wait for a full frame
+            frame = bytes(self.buf[:BROADCAST_SIZE])
+            del self.buf[:BROADCAST_SIZE]
+            if frame == self._prev:
+                self._prev = None          # two identical copies -> accept, need a fresh pair next
+                yield decode_broadcast(frame)
+            else:
+                self._prev = frame         # first sighting / differs -> hold, wait for the repeat
+
+
 # ── Parameter definitions ────────────────────────────────────────────
 
 @dataclass
@@ -196,22 +332,25 @@ PARAMS = [
     ParamDef(0x73, "dither_anear",     PTYPE_UINT16, "Dither", 716, 6442, ".0f"),
     ParamDef(0x74, "dither_afar",      PTYPE_UINT16, "Dither", 716, 6442, ".0f"),
     ParamDef(0x75, "dither_dzero",     PTYPE_UINT16, "Dither", 716, 6442, ".0f"),
+    # ADC calibration
+    ParamDef(0x79, "adc4_trig_phase",  PTYPE_UINT16, "ADC", 3, 14313, ".0f"),  # HRTIM master CMP3: iout_slow sample instant
+    ParamDef(0x7A, "iin_zero_sum",     PTYPE_UINT16, "ADC", 0, 32760, ".0f"),  # IIN software zero offset, sum-of-8 counts
 ]
 
 PARAM_BY_ID: dict[int, ParamDef] = {p.id: p for p in PARAMS}
 PARAM_BY_NAME: dict[str, ParamDef] = {p.name: p for p in PARAMS}
 
 
-# ── Frame building ───────────────────────────────────────────────────
+# ── Frame building (PC -> STM32 commands, CRC-16 framed) ─────────────
 
-def _build_frame(cmd: int, payload: bytes = b"") -> bytes:
+def build_frame(cmd: int, payload: bytes = b"") -> bytes:
     header = bytes([SYNC_BYTE, cmd, len(payload)])
     frame = header + payload
     crc = crc16(frame)
     return frame + bytes([(crc >> 8) & 0xFF, crc & 0xFF])  # big-endian: hi, lo
 
 
-def _build_param_write(param_id: int, ptype: int, value) -> bytes:
+def build_param_write(param_id: int, ptype: int, value) -> bytes:
     if ptype == PTYPE_FLOAT:
         val_bytes = struct.pack("<f", float(value))
     elif ptype == PTYPE_UINT16:
@@ -225,90 +364,57 @@ def _build_param_write(param_id: int, ptype: int, value) -> bytes:
     else:
         val_bytes = struct.pack("<I", int(value))
     payload = struct.pack("<BBxx", param_id, ptype) + val_bytes
-    return _build_frame(CMD_PARAM_WRITE, payload)
+    return build_frame(CMD_PARAM_WRITE, payload)
 
 
-def _decode_param_value(payload: bytes) -> Optional[tuple[int, float]]:
-    if len(payload) < 8:
-        return None
-    param_id, ptype = payload[0], payload[1]
-    vb = payload[4:8]
-    if ptype == PTYPE_FLOAT:
-        value = struct.unpack("<f", vb)[0]
-    elif ptype == PTYPE_UINT16:
-        value = float(struct.unpack("<H", vb[:2])[0])
-    elif ptype == PTYPE_UINT8:
-        value = float(vb[0])
-    elif ptype == PTYPE_INT32:
-        value = float(struct.unpack("<i", vb)[0])
-    elif ptype == PTYPE_INT16:
-        value = float(struct.unpack("<i", vb)[0])  # sign-extended 32-bit wire
-    else:
-        value = float(struct.unpack("<I", vb)[0])
-    return (param_id, value)
+def build_ping() -> bytes:
+    return build_frame(CMD_PING)
 
 
-# ── Frame parser state machine ───────────────────────────────────────
+def build_shutdown() -> bytes:
+    return build_frame(CMD_SHUTDOWN)
 
-class _FrameParser:
-    WAIT_SYNC = 0
-    WAIT_CMD = 1
-    WAIT_LEN = 2
-    WAIT_PAYLOAD = 3
-    WAIT_CRC_HI = 4
-    WAIT_CRC_LO = 5
 
-    def __init__(self):
-        self.state = self.WAIT_SYNC
-        self.cmd = 0
-        self.length = 0
-        self.buf = bytearray()
-        self.payload = bytearray()
-        self.idx = 0
-        self.crc_hi = 0
+def build_reset() -> bytes:
+    return build_frame(CMD_RESET)
 
-    def feed(self, data: bytes):
-        for b in data:
-            if self.state == self.WAIT_SYNC:
-                if b == SYNC_BYTE:
-                    self.buf = bytearray([b])
-                    self.state = self.WAIT_CMD
-            elif self.state == self.WAIT_CMD:
-                self.cmd = b
-                self.buf.append(b)
-                self.state = self.WAIT_LEN
-            elif self.state == self.WAIT_LEN:
-                self.length = b
-                self.buf.append(b)
-                self.payload = bytearray()
-                self.idx = 0
-                if b == 0:
-                    self.state = self.WAIT_CRC_HI
-                elif b > 128:
-                    self.state = self.WAIT_SYNC
-                else:
-                    self.state = self.WAIT_PAYLOAD
-            elif self.state == self.WAIT_PAYLOAD:
-                self.payload.append(b)
-                self.buf.append(b)
-                self.idx += 1
-                if self.idx >= self.length:
-                    self.state = self.WAIT_CRC_HI
-            elif self.state == self.WAIT_CRC_HI:
-                self.crc_hi = b
-                self.state = self.WAIT_CRC_LO
-            elif self.state == self.WAIT_CRC_LO:
-                received = (self.crc_hi << 8) | b
-                expected = crc16(bytes(self.buf))
-                self.state = self.WAIT_SYNC
-                if received == expected:
-                    yield (self.cmd, bytes(self.payload))
+
+def build_test_50() -> bytes:
+    return build_frame(CMD_TEST_50)
+
+
+def build_relay_on() -> bytes:
+    return build_frame(CMD_RELAY_ON)
+
+
+def build_relay_off() -> bytes:
+    return build_frame(CMD_RELAY_OFF)
+
+
+def build_hold_converter() -> bytes:
+    return build_frame(CMD_HOLD_CONVERTER)
+
+
+def build_toggle_precharge() -> bytes:
+    return build_frame(CMD_TOGGLE_PRECHARGE)
+
+
+def build_param_read_all() -> bytes:
+    return build_frame(CMD_PARAM_READ_ALL)
+
+
+def build_clear_flags() -> bytes:
+    return build_frame(CMD_CLEAR_FLAGS)
 
 
 # ── STM32Link — synchronous serial interface ─────────────────────────
 
 class STM32Link:
-    """Blocking serial link to STM32 debug protocol.
+    """Blocking serial link to the STM32 debug protocol.
+
+    Telemetry and parameter echoes arrive via the continuous broadcast;
+    commands go out CRC-16 framed.  The port MUST be opened with odd
+    parity (8-O-1) or the broadcast never validates.
 
     Usage::
 
@@ -321,9 +427,17 @@ class STM32Link:
     """
 
     def __init__(self, port: str, baudrate: int = 460800, timeout: float = 2.0):
-        self.ser = serial.Serial(port, baudrate, timeout=timeout)
-        self._parser = _FrameParser()
-        self._param_cache: dict[int, float] = {}
+        self.timeout = timeout
+        self.ser = serial.Serial(
+            port, baudrate, timeout=0.1,
+            bytesize=serial.EIGHTBITS,
+            parity=serial.PARITY_ODD,
+            stopbits=serial.STOPBITS_ONE,
+        )
+        self._parser = BroadcastParser()
+        self._params: dict[int, float] = {}
+        self._pending: deque = deque()   # decoded frames not yet consumed
+        self._last_counter = -1
 
     def close(self):
         if self.ser and self.ser.is_open:
@@ -340,92 +454,95 @@ class STM32Link:
     def _send(self, frame: bytes):
         self.ser.write(frame)
 
-    def _recv_frames(self, timeout: float = 1.0) -> list[tuple[int, bytes]]:
-        """Read available data and return decoded frames."""
-        frames = []
-        deadline = time.monotonic() + timeout
-        while time.monotonic() < deadline:
-            data = self.ser.read(self.ser.in_waiting or 1)
-            if data:
-                for cmd, payload in self._parser.feed(data):
-                    frames.append((cmd, payload))
-            if frames:
-                # Drain any remaining data
-                time.sleep(0.02)
-                data = self.ser.read(self.ser.in_waiting)
-                if data:
-                    for cmd, payload in self._parser.feed(data):
-                        frames.append((cmd, payload))
-                break
-        return frames
+    def _drain_serial(self) -> None:
+        """Read one serial chunk and queue ALL decoded frames.
 
-    def _wait_for(self, target_cmd: int, timeout: float = 2.0) -> Optional[bytes]:
-        """Wait for a specific command response, processing others."""
-        deadline = time.monotonic() + timeout
-        while time.monotonic() < deadline:
-            remaining = deadline - time.monotonic()
-            if remaining <= 0:
-                break
-            data = self.ser.read(self.ser.in_waiting or 1)
-            if data:
-                for cmd, payload in self._parser.feed(data):
-                    if cmd == target_cmd:
-                        return payload
-                    # Cache param values seen in passing
-                    if cmd in (CMD_PARAM_VALUE, CMD_PARAM_WRITE_ACK):
-                        result = _decode_param_value(payload)
-                        if result:
-                            self._param_cache[result[0]] = result[1]
-                    # Cache telemetry too
-                    if cmd == CMD_TELEMETRY:
-                        self._last_telemetry = _decode_telemetry(payload)
-        return None
+        Param round-robin echoes are stashed into self._params in passing
+        (only once counter > 0 — fields are stale during the post-reset window).
+        """
+        data = self.ser.read(4096)
+        if not data:
+            return
+        for b in self._parser.feed(data):
+            if b.counter > 0 and b.param_id in PARAM_BY_ID:
+                self._params[b.param_id] = decode_param_bits(b.param_type, b.param_value)
+            self._pending.append(b)
+
+    def _pump(self, deadline: float) -> Iterator[BroadcastData]:
+        """Yield validated frames until deadline.
+
+        Frames are staged through self._pending so nothing is lost when a
+        caller stops iterating early (generator abandoned mid-chunk).
+        """
+        while True:
+            while self._pending:
+                yield self._pending.popleft()
+            if time.monotonic() >= deadline:
+                return
+            self._drain_serial()
 
     # ── Commands ─────────────────────────────────────────────────────
 
     def ping(self, timeout: float = 2.0) -> bool:
-        """Send PING, return True if PONG received."""
-        self._send(_build_frame(CMD_PING))
-        return self._wait_for(CMD_PONG, timeout) is not None
+        """Send PING, return True when the broadcast pong counter increments."""
+        baseline: Optional[int] = None
+        for b in self._pump(time.monotonic() + min(0.7, timeout)):
+            baseline = b.pong   # pong is valid even at counter == 0
+            break
+        if baseline is None:
+            return False        # no broadcast at all -> not connected
+        self._send(build_ping())
+        for b in self._pump(time.monotonic() + timeout):
+            if b.pong != baseline:
+                return True
+        return False
 
     def shutdown(self):
         """Command the converter off."""
-        self._send(_build_frame(CMD_SHUTDOWN))
+        self._send(build_shutdown())
 
     def reset(self):
         """Command a system reset."""
-        self._send(_build_frame(CMD_RESET))
+        self._send(build_reset())
 
     def test_50(self):
         """Enter 50% duty test mode."""
-        self._send(_build_frame(CMD_TEST_50))
+        self._send(build_test_50())
 
     def relay_on(self):
         """Latch the input relay closed (bench test)."""
-        self._send(_build_frame(CMD_RELAY_ON))
+        self._send(build_relay_on())
 
     def relay_off(self):
         """Latch the input relay open (bench test)."""
-        self._send(_build_frame(CMD_RELAY_OFF))
+        self._send(build_relay_off())
 
     def hold_converter(self):
         """Toggle 'hold converter off' (boot guard + disarm trips)."""
-        self._send(_build_frame(CMD_HOLD_CONVERTER))
+        self._send(build_hold_converter())
 
     def toggle_precharge(self):
         """Toggle the precharge FET (bench test)."""
-        self._send(_build_frame(CMD_TOGGLE_PRECHARGE))
+        self._send(build_toggle_precharge())
 
-    def read_telemetry(self, timeout: float = 2.0) -> Optional[Telemetry]:
-        """Wait for next telemetry packet."""
-        payload = self._wait_for(CMD_TELEMETRY, timeout)
-        if payload:
-            return _decode_telemetry(payload)
+    def clear_flags(self):
+        """Clear latched status flags."""
+        self._send(build_clear_flags())
+
+    # ── Telemetry ────────────────────────────────────────────────────
+
+    def read_telemetry(self, timeout: float = 2.0) -> Optional[BroadcastData]:
+        """Return the next FRESH publish (counter-deduped — repeats skipped)."""
+        for b in self._pump(time.monotonic() + timeout):
+            if b.counter > 0 and b.counter != self._last_counter:
+                self._last_counter = b.counter
+                return b
         return None
 
-    def read_telemetry_avg(self, n: int = 10, timeout: float = 5.0) -> Optional[Telemetry]:
-        """Read n telemetry packets and return the average."""
-        samples: list[Telemetry] = []
+    def read_telemetry_avg(self, n: int = 10, timeout: float = 5.0) -> Optional[BroadcastData]:
+        """Average n fresh publishes (~n/100 s). Float fields are averaged;
+        int/flag fields come from the last sample."""
+        samples: list[BroadcastData] = []
         deadline = time.monotonic() + timeout
         while len(samples) < n and time.monotonic() < deadline:
             t = self.read_telemetry(timeout=deadline - time.monotonic())
@@ -433,43 +550,38 @@ class STM32Link:
                 samples.append(t)
         if not samples:
             return None
-        # Average all analog float fields
-        avg = Telemetry()
+        avg = dataclasses.replace(samples[-1])
         for attr in ("vin", "vout", "iin", "iout", "vfly", "etemp", "btemp",
-                      "vfly_integral", "vfly_avg_debug", "cc_output_f",
-                      "mppt_iref", "mppt_last_vin", "mppt_last_iin",
-                      "p_in", "p_out", "iout_slow"):
+                     "vfly_integral", "vfly_avg_debug", "cc_output_f",
+                     "mppt_iref", "mppt_last_vin", "mppt_last_iin",
+                     "p_in", "p_out", "iout_slow"):
             setattr(avg, attr, sum(getattr(s, attr) for s in samples) / len(samples))
-        avg.seq = samples[-1].seq
         return avg
 
-    def request_all_params(self):
-        """Request all parameter values from the STM32."""
-        self._send(_build_frame(CMD_PARAM_READ_ALL))
+    # ── Parameters ───────────────────────────────────────────────────
 
-    def read_all_params(self, timeout: float = 3.0) -> dict[str, float]:
-        """Request and collect all parameter values."""
-        self._param_cache.clear()
+    def request_all_params(self):
+        """Restart the broadcast param round-robin from the first param."""
+        self._send(build_param_read_all())
+
+    def read_all_params(self, timeout: float = 5.0) -> dict[str, float]:
+        """Collect all parameter values from the broadcast round-robin
+        (one param per publish -> full rotation ~0.4 s at 100 Hz)."""
+        self._params.clear()
         self.request_all_params()
-        deadline = time.monotonic() + timeout
-        while time.monotonic() < deadline:
-            data = self.ser.read(self.ser.in_waiting or 1)
-            if data:
-                for cmd, payload in self._parser.feed(data):
-                    if cmd == CMD_PARAM_VALUE:
-                        result = _decode_param_value(payload)
-                        if result:
-                            self._param_cache[result[0]] = result[1]
-            time.sleep(0.05)
-        # Convert to name->value
+        for _ in self._pump(time.monotonic() + timeout):
+            if len(self._params) >= len(PARAMS):
+                break
         return {
             PARAM_BY_ID[pid].name: val
-            for pid, val in self._param_cache.items()
+            for pid, val in self._params.items()
             if pid in PARAM_BY_ID
         }
 
     def write_param(self, name: str, value: float, wait_ack: bool = True) -> bool:
-        """Write a parameter by name. Returns True if ACK received."""
+        """Write a parameter by name. The write is acknowledged when the
+        broadcast round-robin echoes the new value back (clamped + formatted
+        the way the firmware reports it); retries until it matches."""
         pdef = PARAM_BY_NAME.get(name)
         if not pdef:
             raise ValueError(f"Unknown parameter: {name!r}")
@@ -477,17 +589,22 @@ class STM32Link:
             raise ValueError(
                 f"{name}: {value} out of range [{pdef.min_val}, {pdef.max_val}]"
             )
-        frame = _build_param_write(pdef.id, pdef.ptype, value)
-        self._send(frame)
-        if wait_ack:
-            payload = self._wait_for(CMD_PARAM_WRITE_ACK, timeout=2.0)
-            if payload:
-                result = _decode_param_value(payload)
-                if result:
-                    self._param_cache[result[0]] = result[1]
-                    return True
-            return False
-        return True
+        frame = build_param_write(pdef.id, pdef.ptype, value)
+        if not wait_ack:
+            self._send(frame)
+            return True
+        clamped = max(pdef.min_val, min(pdef.max_val, float(value)))
+        expect = f"{clamped:{pdef.fmt}}"
+        for _ in range(6):
+            self._send(frame)
+            # one full round-robin rotation is ~0.4 s; 0.5 s sees the echo once
+            for b in self._pump(time.monotonic() + 0.5):
+                if b.counter > 0 and b.param_id == pdef.id:
+                    echoed = decode_param_bits(b.param_type, b.param_value)
+                    if f"{echoed:{pdef.fmt}}" == expect:
+                        self._params[pdef.id] = echoed
+                        return True
+        return False
 
     def write_param_by_id(self, param_id: int, value: float) -> bool:
         """Write a parameter by ID."""

testbench/tuner.py

@@ -61,7 +61,7 @@ class Tuner:
         self,
         bench: MPPTTestbench,
         link: STM32Link,
-        settle_time: float = 3.0,
+        settle_time: float = 5.0,
         stm_avg_samples: int = 10,
     ):
         self.bench = bench