Require SD card configuration for both server and client settings (remove fallback defaults)

TankAlarm-092025-Client-Hologram/INSTALLATION.md

@@ -74,28 +74,48 @@ File: TankAlarm092025-Test.ino
 
 ## Software Configuration
 
-### Step 1: Configure the Code
+### Step 1: Configure SD Card (REQUIRED)
+1. **Create SD Card Configuration**:
+   - Copy `tank_config_example.txt` to SD card as `tank_config.txt`
+   - Edit `tank_config.txt` with your specific settings
+
+2. **Critical Settings (REQUIRED)**:
+   ```
+   # Update these values for your setup - ALL SETTINGS REQUIRED
+   SITE_NAME=Your Tank Farm Name
+   TANK_NUMBER=1
+   HOLOGRAM_DEVICE_KEY=your_actual_device_key_here
+   ALARM_PHONE_PRIMARY=+15551234567
+   ALARM_PHONE_SECONDARY=+15559876543
+   DAILY_REPORT_PHONE=+15555551234
+   ```
+
+3. **Tank Physical Configuration**:
+   ```
+   TANK_HEIGHT_INCHES=120
+   HIGH_ALARM_INCHES=100
+   LOW_ALARM_INCHES=12
+   ```
+
+4. **Insert SD Card**: Place configured SD card in device before powering on
+
+**IMPORTANT**: The device will not start without a properly configured `tank_config.txt` file on the SD card. The device will halt with error messages if:
+- SD card is not inserted
+- `tank_config.txt` file is missing
+- HOLOGRAM_DEVICE_KEY is not set
+- ALARM_PHONE_PRIMARY is not set
+
+### Step 2: Hardware Configuration (config.h)
 1. **Copy Configuration Template**:
-   - Copy `config_template.h` to `config.h`
-   - Edit `config.h` with your specific settings
+   - Copy `config_template.h` to `config.h` (only if missing)
+   - This file now only contains hardware-specific constants
 
 2. **Select Tank Level Sensor Type**:
    ```cpp
    // Choose sensor type: DIGITAL_FLOAT, ANALOG_VOLTAGE, or CURRENT_LOOP
    #define SENSOR_TYPE DIGITAL_FLOAT
    ```
 
-3. **Update Configuration Values**:
-   ```cpp
-   // Replace with your actual Hologram.io device key
-   #define HOLOGRAM_DEVICE_KEY "your_device_key_here"
-
-   // Update with your phone numbers (include country code)
-   #define ALARM_PHONE_PRIMARY "+12223334444"
-   #define ALARM_PHONE_SECONDARY "+15556667777"
-   #define DAILY_REPORT_PHONE "+18889990000"
-   ```
-
 4. **Configure Sensor-Specific Settings**:
 
    **For Digital Float Switch (SENSOR_TYPE = DIGITAL_FLOAT)**:
@@ -146,16 +166,16 @@ File: TankAlarm092025-Test.ino
    #define DAILY_REPORT_HOURS 24
    ```
 
-### Step 2: Update Main Code
-1. In `TankAlarm092025-Hologram.ino`, change this line:
+### Step 3: Update Main Code
+1. In `TankAlarm-092025-Client-Hologram.ino`, change this line:
    ```cpp
    // Change from:
    #include "config_template.h"
    // To:
    #include "config.h"
    ```
 
-### Step 3: Upload Code
+### Step 4: Upload Code
 1. Connect MKR NB 1500 to computer via USB
 2. Select correct board: Tools → Board → Arduino MKR NB 1500
 3. Select correct port: Tools → Port → (your port)
@@ -260,10 +280,14 @@ File: TankAlarm092025-Test.ino
 - **Annually**: Clean enclosure, inspect connections
 
 ### Updating Configuration
-1. Connect to computer via USB
-2. Modify config.h as needed
-3. Re-upload sketch
-4. Test new configuration
+**NEW APPROACH - Field Configurable:**
+1. Power off device
+2. Remove SD card from device
+3. Edit `tank_config.txt` on computer
+4. Insert SD card back into device
+5. Power on device - new configuration will be loaded and validated
+
+**CRITICAL**: Device will not start without valid SD card configuration.
 
 ### Data Retrieval
 1. Remove SD card from system

TankAlarm-092025-Client-Hologram/TankAlarm-092025-Client-Hologram.ino

@@ -195,44 +195,44 @@ bool powerFailureRecovery = false;
 #endif
 String logFileName = LOG_FILE_NAME;
 
-// SD Card configuration variables (loaded from SD card config file)
-String siteLocationName = SITE_LOCATION_NAME;
-int tankNumber = TANK_NUMBER;
-float inchesPerUnit = INCHES_PER_UNIT;
-float tankHeightInches = TANK_HEIGHT_INCHES;
-float highAlarmInches = HIGH_ALARM_INCHES;
-float lowAlarmInches = LOW_ALARM_INCHES;
-bool digitalHighAlarm = DIGITAL_HIGH_ALARM;
-bool digitalLowAlarm = DIGITAL_LOW_ALARM;
-float largeDecreaseThreshold = LARGE_DECREASE_THRESHOLD_INCHES;
-int largeDecreaseWaitHours = LARGE_DECREASE_WAIT_HOURS;
-
-// Network and communication configuration (loaded from SD card)
-String hologramDeviceKey = HOLOGRAM_DEVICE_KEY;
-String serverDeviceKey = SERVER_DEVICE_KEY;  // Server's device ID for remote commands
-String alarmPhonePrimary = ALARM_PHONE_PRIMARY;
-String alarmPhoneSecondary = ALARM_PHONE_SECONDARY;
-String dailyReportPhone = DAILY_REPORT_PHONE;
-String hologramAPN = HOLOGRAM_APN;
-
-// Timing configuration (loaded from SD card)
-int sleepIntervalHours = SLEEP_INTERVAL_HOURS;
-int dailyReportHours = DAILY_REPORT_HOURS;
-String dailyReportTime = DAILY_REPORT_TIME;
+// SD Card configuration variables (loaded from SD card config file - REQUIRED)
+String siteLocationName = "Unknown Site";
+int tankNumber = 1;
+float inchesPerUnit = 1.0;
+float tankHeightInches = 120.0;
+float highAlarmInches = 100.0;
+float lowAlarmInches = 12.0;
+bool digitalHighAlarm = true;
+bool digitalLowAlarm = false;
+float largeDecreaseThreshold = 24.0;
+int largeDecreaseWaitHours = 2;
+
+// Network and communication configuration (loaded from SD card - REQUIRED)
+String hologramDeviceKey = "";
+String serverDeviceKey = "";  // Server's device ID for remote commands
+String alarmPhonePrimary = "";
+String alarmPhoneSecondary = "";
+String dailyReportPhone = "";
+String hologramAPN = "hologram";
+
+// Timing configuration (loaded from SD card - REQUIRED)
+int sleepIntervalHours = 1;
+int dailyReportHours = 24;
+String dailyReportTime = "05:00";
 
 // Time synchronization variables
 bool timeIsSynced = false;
 unsigned long lastTimeSyncMillis = 0;
 const unsigned long TIME_SYNC_INTERVAL_MS = 24 * 60 * 60 * 1000; // Sync once per day
 
-// Power management variables
+// Power management variables (loaded from SD card - REQUIRED)
 volatile bool wakeFromCellular = false;  // Flag set when woken by cellular data
 volatile int wakeReason = WAKE_REASON_TIMER;  // Reason for last wake
 unsigned long lastCellularCheck = 0;  // Last time we checked for cellular data
-bool deepSleepMode = DEEP_SLEEP_MODE;  // Whether to use deep sleep mode
-int shortSleepMinutes = SHORT_SLEEP_MINUTES;  // Short sleep duration for frequent checks
-int normalSleepHours = NORMAL_SLEEP_HOURS;    // Normal sleep duration between readings
-bool wakeOnPingEnabled = ENABLE_WAKE_ON_PING; // Wake on ping functionality
+bool deepSleepMode = false;  // Whether to use deep sleep mode
+int shortSleepMinutes = 10;  // Short sleep duration for frequent checks
+int normalSleepHours = 1;    // Normal sleep duration between readings
+bool wakeOnPingEnabled = true; // Wake on ping functionality
 
 // Height calibration system
 #define MAX_CALIBRATION_POINTS 10
@@ -270,16 +270,16 @@ void processSMSCommand(String command, String phoneNumber);
 void sendCalibrationSMS(String phoneNumber);
 float getCurrentSensorReading();
 
-// Network configuration (loaded from SD card)
-int connectionTimeoutMs = CONNECTION_TIMEOUT_MS;
-int smsRetryAttempts = SMS_RETRY_ATTEMPTS;
+// Network configuration (loaded from SD card - REQUIRED)
+int connectionTimeoutMs = 30000;
+int smsRetryAttempts = 3;
 
 // Log file names (loaded from SD card)
-String hourlyLogFile = SD_HOURLY_LOG_FILE;
-String dailyLogFile = SD_DAILY_LOG_FILE;
-String alarmLogFile = SD_ALARM_LOG_FILE;
-String decreaseLogFile = SD_DECREASE_LOG_FILE;
-String reportLogFile = SD_REPORT_LOG_FILE;
+String hourlyLogFile = "hourly_log.txt";
+String dailyLogFile = "daily_log.txt";
+String alarmLogFile = "alarm_log.txt";
+String decreaseLogFile = "decrease_log.txt";
+String reportLogFile = "report_log.txt";
 
 void setup() {
   // Initialize serial communication for debugging
@@ -1008,22 +1008,27 @@ String getCurrentTimestamp() {
 // Load configuration from SD card
 void loadSDCardConfiguration() {
   if (!SD.begin(SD_CARD_CS_PIN)) {
-    logEvent("Failed to initialize SD card for configuration loading");
-    return;
+    Serial.println("CRITICAL ERROR: Failed to initialize SD card for client configuration loading");
+    Serial.println("SD card configuration is REQUIRED for operation");
+    while (true) {
+      // Halt execution - SD card config is required
+      delay(5000);
+      Serial.println("Please insert SD card with tank_config.txt and restart");
+    }
   }
 
   File configFile = SD.open(SD_CONFIG_FILE);
   if (!configFile) {
-#ifdef ENABLE_SERIAL_DEBUG
-    if (ENABLE_SERIAL_DEBUG) Serial.println("Config file not found, using defaults");
-#endif
-    logEvent("Config file not found, using defaults from config.h");
-    return;
+    Serial.println("CRITICAL ERROR: Client config file not found on SD card");
+    Serial.println("tank_config.txt is REQUIRED for operation");
+    while (true) {
+      // Halt execution - SD card config is required
+      delay(5000);
+      Serial.println("Please create tank_config.txt on SD card and restart");
+    }
   }
 
-#ifdef ENABLE_SERIAL_DEBUG
-  if (ENABLE_SERIAL_DEBUG) Serial.println("Loading configuration from SD card...");
-#endif
+  Serial.println("Loading client configuration from SD card...");
 
   while (configFile.available()) {
     String line = configFile.readStringUntil('\n');
@@ -1109,15 +1114,28 @@ void loadSDCardConfiguration() {
 
   configFile.close();
 
-  String configMsg = "Configuration loaded - Site: " + siteLocationName + 
+  // Validate critical configuration
+  if (hologramDeviceKey.length() == 0 || hologramDeviceKey == "your_device_key_here") {
+    Serial.println("CRITICAL ERROR: HOLOGRAM_DEVICE_KEY not configured in tank_config.txt");
+    while (true) {
+      delay(5000);
+      Serial.println("Please set HOLOGRAM_DEVICE_KEY in tank_config.txt and restart");
+    }
+  }
+
+  if (alarmPhonePrimary.length() == 0 || alarmPhonePrimary == "+12223334444") {
+    Serial.println("CRITICAL ERROR: ALARM_PHONE_PRIMARY not configured in tank_config.txt");
+    while (true) {
+      delay(5000);
+      Serial.println("Please set ALARM_PHONE_PRIMARY in tank_config.txt and restart");
+    }
+  }
+
+  String configMsg = "Client configuration loaded successfully - Site: " + siteLocationName + 
                     ", Tank: " + String(tankNumber) + 
                     ", Height: " + String(tankHeightInches) + "in" +
                     ", Daily Report: " + dailyReportTime;
-  logEvent(configMsg);
-
-#ifdef ENABLE_SERIAL_DEBUG
-  if (ENABLE_SERIAL_DEBUG) Serial.println(configMsg);
-#endif
+  Serial.println(configMsg);
 }
 
 // Convert sensor reading to inches

TankAlarm-092025-Client-Hologram/config_template.h

@@ -1,32 +1,18 @@
 //
 // Configuration file for Tank Alarm 092025
-// Copy this file and rename to config.h, then update with your specific values
+// This file now contains only essential compile-time constants
+// Most configuration is now loaded from tank_config.txt on SD card
 //
 
 #ifndef CONFIG_H
 #define CONFIG_H
 
-// Hologram.io Configuration
-#define HOLOGRAM_DEVICE_KEY "your_device_key_here"  // Replace with your actual device key
-#define SERVER_DEVICE_KEY "server_device_key_here"  // Server's Hologram device ID for remote commands
-#define HOLOGRAM_APN "hologram"                     // Hologram.io APN (usually stays "hologram")
-
-// Phone Numbers for Notifications (include country code, e.g., +1 for US)
-#define ALARM_PHONE_PRIMARY "+12223334444"     // Primary emergency contact
-#define ALARM_PHONE_SECONDARY "+15556667777"   // Secondary emergency contact  
-#define DAILY_REPORT_PHONE "+18889990000"      // Daily report recipient
-
-// Timing Configuration (in hours)
-#define SLEEP_INTERVAL_HOURS 1          // How often to check tank level (default: 1 hour)
-#define DAILY_REPORT_HOURS 24           // How often to send daily report (default: 24 hours)
-#define DAILY_REPORT_TIME "05:00"       // Time of day for daily report in HH:MM format (24-hour)
-
-// Pin Configuration (adjust if using different pins)
+// Pin Configuration (hardware specific - cannot be changed at runtime)
 #define TANK_LEVEL_PIN 7               // Tank level sensor input pin
 #define RELAY_CONTROL_PIN 5            // Relay output control pin
 #define SD_CARD_CS_PIN 4               // SD card chip select pin (works for both MKR SD PROTO and MKR ETH shields)
 
-// Tank Level Sensor Configuration
+// Sensor Type Configuration (hardware specific)
 // Sensor Types: DIGITAL_FLOAT, ANALOG_VOLTAGE, CURRENT_LOOP
 #define SENSOR_TYPE DIGITAL_FLOAT      // Type of tank level sensor
 
@@ -35,75 +21,34 @@
 #define SENSOR_DEBOUNCE_MS 100         // Debounce delay for sensor reading
 
 // Analog Voltage Sensor Configuration (SENSOR_TYPE = ANALOG_VOLTAGE)
-// For Dwyer 626 series ratiometric 0.5-4.5V pressure sensors
-// Can use A1-A4 pins on MKR RELAY shield with convenient screw terminals
 #define ANALOG_SENSOR_PIN A1           // Analog input pin for voltage sensor (A1, A2, A3, or A4)
 #define VOLTAGE_MIN 0.5                // Minimum sensor voltage (V)
 #define VOLTAGE_MAX 4.5                // Maximum sensor voltage (V)
 #define TANK_EMPTY_VOLTAGE 0.5         // Voltage when tank is empty (V)
 #define TANK_FULL_VOLTAGE 4.5          // Voltage when tank is full (V)
-// Alarm thresholds are now configured in inches using HIGH_ALARM_INCHES and LOW_ALARM_INCHES
-// See tank configuration section above for inches-based alarm settings
-
-// Multiple Analog Sensor Support (Optional - for multiple tank monitoring)
-// Uncomment and configure additional sensors if needed
-// #define ENABLE_MULTI_ANALOG_SENSORS true
-// #define ANALOG_SENSOR_PIN_2 A2        // Second analog sensor
-// #define ANALOG_SENSOR_PIN_3 A3        // Third analog sensor  
-// #define ANALOG_SENSOR_PIN_4 A4        // Fourth analog sensor
 
 // Current Loop Sensor Configuration (SENSOR_TYPE = CURRENT_LOOP)
-// For 4-20mA sensors using NCD.io 4-channel current loop I2C module
 #define I2C_CURRENT_LOOP_ADDRESS 0x48  // I2C address of NCD.io module
 #define CURRENT_LOOP_CHANNEL 0         // Channel number (0-3) on NCD.io module
 #define CURRENT_MIN 4.0                // Minimum current (mA)
 #define CURRENT_MAX 20.0               // Maximum current (mA)
 #define TANK_EMPTY_CURRENT 4.0         // Current when tank is empty (mA)
 #define TANK_FULL_CURRENT 20.0         // Current when tank is full (mA)
-// Alarm thresholds are now configured in inches using HIGH_ALARM_INCHES and LOW_ALARM_INCHES
-// See tank configuration section above for inches-based alarm settings
-
-// Logging Configuration
-#define LOG_FILE_NAME "tanklog.txt"    // SD card log file name
-#define ENABLE_SERIAL_DEBUG true       // Enable/disable serial output for debugging
 
-// Network Configuration
-#define CONNECTION_TIMEOUT_MS 30000    // Network connection timeout (30 seconds)
-#define SMS_RETRY_ATTEMPTS 3           // Number of retry attempts for SMS sending
+// System Buffer Sizes and Hardware Limits (memory allocation at compile time)
+#define MAX_CALIBRATION_POINTS 10
+#define CALIBRATION_FILE_NAME "calibration.txt"
 
-// Power Management
-#define ENABLE_LOW_POWER_MODE true     // Enable low power sleep modes
+// Network Configuration (timeouts and hardware limits)
 #define WAKE_CHECK_DURATION_MS 5000    // How long to stay awake for each check
-#define SHORT_SLEEP_MINUTES 10         // Short sleep duration for active monitoring (minutes)
-#define NORMAL_SLEEP_HOURS 1           // Normal sleep duration between readings (hours)
-#define ENABLE_WAKE_ON_PING true       // Enable wake-on-ping functionality
-#define DEEP_SLEEP_MODE false          // Use deep sleep mode for maximum power savings
 
-// Tank Configuration for Inches/Feet Measurements
-#define TANK_NUMBER 1                  // Tank number identifier (1-99)
-#define SITE_LOCATION_NAME "Your Site Name"  // Site location name for reports
-#define INCHES_PER_UNIT 1.0            // Inches per sensor unit (calibration factor)
-#define TANK_HEIGHT_INCHES 120         // Total tank height in inches
-
-// Alarm Thresholds in Inches/Feet (for analog/current loop sensors)
-#define HIGH_ALARM_INCHES 100          // High alarm threshold in inches
-#define LOW_ALARM_INCHES 12            // Low alarm threshold in inches
-
-// Digital Float Switch Alarm Configuration (for DIGITAL_FLOAT sensors)
-#define DIGITAL_HIGH_ALARM true        // Enable high alarm for digital float
-#define DIGITAL_LOW_ALARM false        // Enable low alarm for digital float
-
-// Large Decrease Detection
-#define ENABLE_LARGE_DECREASE_DETECTION true  // Enable detection of large decreases
-#define LARGE_DECREASE_THRESHOLD_INCHES 24    // Threshold for large decrease in inches
-#define LARGE_DECREASE_WAIT_HOURS 2           // Hours to wait before logging large decrease
+// Logging Configuration (system limits)
+#define ENABLE_SERIAL_DEBUG true       // Enable/disable serial output for debugging
+#define LOG_FILE_NAME "tanklog.txt"    // SD card log file name
 
 // SD Card Configuration Files
 #define SD_CONFIG_FILE "tank_config.txt"      // SD card configuration file
-#define SD_HOURLY_LOG_FILE "hourly_log.txt"   // Hourly data log file
-#define SD_DAILY_LOG_FILE "daily_log.txt"     // Daily report log file
-#define SD_ALARM_LOG_FILE "alarm_log.txt"     // Alarm event log file
-#define SD_DECREASE_LOG_FILE "decrease_log.txt" // Large decrease log file
-#define SD_REPORT_LOG_FILE "report_log.txt"     // Daily report transmission log file
+
+// No fallback defaults - SD card configuration is required
 
 #endif // CONFIG_H