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Make the pump-1 1 W clamp overridable up to the 8000 mA protocol max

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Adds a Pump Limit Override: the pump-1 current command is clamped to a
soft 4000 mA ceiling (the 1 W diode rating) by default, liftable to the
8000 mA hard protocol max only while the new amp_pump_override switch is
ON. Fail-safe: the override defaults OFF on every boot, and switching it
OFF immediately re-clamps a running setpoint back down to 4000 mA so the
booster cannot stay parked above 1 W. The HA pump-1 number now spans
0..8000 mA; values above 4000 take effect only with the override on.

PUMP_CURRENT_MAX_MA is split into PUMP_CURRENT_SOFT_MAX_MA (4000) and
PUMP_CURRENT_HARD_MAX_MA (8000). README/BOM updated. Builds clean
(flash 59.3%); not yet flashed (ESP32 needs USB, no OTA).

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>
This commit is contained in:
James Bateman (hp-laptop)
2026-10-02 14:21:56 +01:00
co-authored by Claude Opus 4.8
parent ffadf4b37b
commit ba1cd1ddcf
4 changed files with 50 additions and 11 deletions
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BOM.md
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@@ -57,4 +57,4 @@ Both instrument links are 3V3 logic at 115200 8N1 (the CTL200 is 5V-tolerant). U
## Safety
Class 4, >1 W, invisible 1550 nm. The firmware current clamps (`SEED_CURRENT_MAX_MA`, `PUMP_CURRENT_MAX_MA`) are guardrails, not interlocks. Always drop the pump to 0 before unmating any fibre, ramp the pump gradually (it overshoots ~2× on a step up and settles in 2–4 s), and terminate the output in a power meter or beam dump. See the repo README for the measured pump-current vs output-power curve.
Class 4, >1 W, invisible 1550 nm. The firmware current clamps (`SEED_CURRENT_MAX_MA`, and the soft/hard pump-1 ceilings `PUMP_CURRENT_SOFT_MAX_MA` / `PUMP_CURRENT_HARD_MAX_MA`, the latter reachable only with the Pump Limit Override switch on) are guardrails, not interlocks. Always drop the pump to 0 before unmating any fibre, ramp the pump gradually (it overshoots ~2× on a step up and settles in 2–4 s), and terminate the output in a power meter or beam dump. See the repo README for the measured pump-current vs output-power curve.