Added better error reporting for incorrect configs. Added ConfigAlarm state, which you can't get out off so easily - but you are still able to upload, use files, etc.

Grbl_Esp32/src/Grbl.cpp

@@ -71,12 +71,14 @@ void grbl_init() {
 
         machine_init();  // user supplied function for special initialization
                          // Initialize system state.
+        if (sys.state != State::ConfigAlarm) {
 #ifdef FORCE_INITIALIZATION_ALARM
-        // Force Grbl into an ALARM state upon a power-cycle or hard reset.
+            // Force Grbl into an ALARM state upon a power-cycle or hard reset.
-        sys.state = State::Alarm;
+            sys.state = State::Alarm;
 #else
-        sys.state = State::Idle;
+            sys.state = State::Idle;
 #endif
+        }
         // Check for power-up and set system alarm if homing is enabled to force homing cycle
         // by setting Grbl's alarm state. Alarm locks out all g-code commands, including the
         // startup scripts, but allows access to settings and internal commands. Only a homing
@@ -84,7 +86,7 @@ void grbl_init() {
         // NOTE: The startup script will run after successful completion of the homing cycle, but
         // not after disabling the alarm locks. Prevents motion startup blocks from crashing into
         // things uncontrollably. Very bad.
-        if (config->_homingInitLock && homingAxes()) {
+        if (config->_homingInitLock && homingAxes() && sys.state != State::ConfigAlarm) {
             // If there is an axis with homing configured, enter Alarm state on startup
             sys.state = State::Alarm;
         }
@@ -108,6 +110,7 @@ void grbl_init() {
     } catch (const AssertionFailed& ex) {
         // This means something is terribly broken:
         info_serial("Critical error in run_once: %s", ex.what());
+        sys.state = State::ConfigAlarm;
         sleep(10000);
         throw;
     }

Grbl_Esp32/src/Limits.cpp

@@ -46,7 +46,7 @@ void IRAM_ATTR isr_limit_switches(void* /*unused */) {
     // moves in the planner and serial buffers are all cleared and newly sent blocks will be
     // locked out until a homing cycle or a kill lock command. Allows the user to disable the hard
     // limit setting if their limits are constantly triggering after a reset and move their axes.
-    if (sys.state != State::Alarm && sys.state != State::Homing) {
+    if (sys.state != State::Alarm && sys.state != State::ConfigAlarm && sys.state != State::Homing) {
         if (sys_rt_exec_alarm == ExecAlarm::None) {
 #ifdef ENABLE_SOFTWARE_DEBOUNCE
             // we will start a task that will recheck the switches after a small delay

Grbl_Esp32/src/MachineConfig.cpp

@@ -570,18 +570,22 @@ bool MachineConfig::load(const char* filename) {
         // That way, we can always check if the yaml is there, and if it's not, load the yaml.new.
 
     } catch (const Configuration::ParseException& ex) {
+        sys.state      = State::ConfigAlarm;
         auto startNear = ex.Near();
         auto endNear   = (startNear + 10) > (buffer + filesize) ? (buffer + filesize) : (startNear + 10);
 
         StringRange near(startNear, endNear);
         log_error("Configuration parse error: " << ex.What() << " @ " << ex.LineNumber() << ":" << ex.ColumnNumber() << " near " << near);
     } catch (const AssertionFailed& ex) {
+        sys.state = State::ConfigAlarm;  
         // Get rid of buffer and return
         log_error("Configuration loading failed: " << ex.what());
     } catch (std::exception& ex) {
+        sys.state = State::ConfigAlarm;  
         // Log exception:
         log_error("Configuration validation error: " << ex.what());
     } catch (...) {
+        sys.state = State::ConfigAlarm;  
         // Get rid of buffer and return
         log_error("Unknown error while processing config file");
     }

Grbl_Esp32/src/MachineConfig.h

@@ -321,7 +321,7 @@ public:
 class MachineConfig : public Configuration::Configurable {
 public:
     MachineConfig() = default;
-
+    
     Axes*              _axes        = nullptr;
     SPIBus*            _spi         = nullptr;
     I2SOBus*           _i2so        = nullptr;

Grbl_Esp32/src/NutsBolts.h

@@ -20,8 +20,6 @@
   along with Grbl.  If not, see <http://www.gnu.org/licenses/>.
 */
 
-#include "Config.h"
-
 // #define false 0
 // #define true 1
 

Grbl_Esp32/src/Pin.cpp

@@ -41,7 +41,7 @@
 #endif
 
 Pins::PinDetail* Pin::undefinedPin = new Pins::VoidPinDetail();
-Pins::PinDetail* Pin::errorPin     = new Pins::ErrorPinDetail();
+Pins::PinDetail* Pin::errorPin     = new Pins::ErrorPinDetail("unknown");
 
 bool Pin::parse(StringRange tmp, Pins::PinDetail*& pinImplementation) {
     String str = tmp.str();
@@ -151,7 +151,7 @@ Pin Pin::create(const StringRange& str) {
         pin_error("Setting up pin [%s] failed. Details: %s\r\n", str.str().c_str(), ex.what());
         (void)ex;  // Get rid of compiler warning
 
-        return Pin(pinImplementation);
+        return Pin(new Pins::ErrorPinDetail(str.str()));
     }
 }
 

Grbl_Esp32/src/Pins/ErrorPinDetail.cpp

@@ -19,15 +19,30 @@
 #include "ErrorPinDetail.h"
 #include "../Assert.h"
 
+#ifdef ESP32
+#include "../Report.h"
+#endif
+
 namespace Pins {
-    ErrorPinDetail::ErrorPinDetail() : PinDetail(0) {}
+    ErrorPinDetail::ErrorPinDetail(const String& descr) : PinDetail(0), _description(descr) {}
 
     PinCapabilities ErrorPinDetail::capabilities() const { return PinCapabilities::Error; }
 
+#ifdef ESP32
+    void ErrorPinDetail::write(int high) { info_all("Cannot write to pin %s. The config is incorrect.", _description.c_str()); }
+    int  ErrorPinDetail::read() { info_all("Cannot read from pin %s. The config is incorrect.", _description.c_str()); }
+    void ErrorPinDetail::setAttr(PinAttributes value) {
+        info_all("Cannot set mode on pin %s. The config is incorrect.", _description.c_str());
+    }
+
+#else
     void ErrorPinDetail::write(int high) { Assert(false, "Cannot write to an error pin."); }
     int  ErrorPinDetail::read() { Assert(false, "Cannot read from an error pin."); }
     void ErrorPinDetail::setAttr(PinAttributes value) { /* Fine, this won't get you anywhere. */
     }
+
+#endif
+
     PinAttributes ErrorPinDetail::getAttr() const { return PinAttributes::None; }
 
     String ErrorPinDetail::toString() { return "ERROR_PIN"; }

Grbl_Esp32/src/Pins/ErrorPinDetail.h

@@ -23,8 +23,10 @@
 
 namespace Pins {
     class ErrorPinDetail : public PinDetail {
+        String _description;
+
     public:
-        ErrorPinDetail();
+        ErrorPinDetail(const String& descr);
 
         PinCapabilities capabilities() const override;
 

Grbl_Esp32/src/Protocol.cpp

@@ -87,7 +87,7 @@ Error execute_line(char* line, uint8_t client, WebUI::AuthenticationLevel auth_l
         return system_execute_line(line, client, auth_level);
     }
     // Everything else is gcode. Block if in alarm or jog mode.
-    if (sys.state == State::Alarm || sys.state == State::Jog) {
+    if (sys.state == State::Alarm || sys.state == State::ConfigAlarm || sys.state == State::Jog) {
         return Error::SystemGcLock;
     }
     return gc_execute_line(line, client);
@@ -137,7 +137,9 @@ void protocol_main_loop() {
     // Check for and report alarm state after a reset, error, or an initial power up.
     // NOTE: Sleep mode disables the stepper drivers and position can't be guaranteed.
     // Re-initialize the sleep state as an ALARM mode to ensure user homes or acknowledges.
-    if (sys.state == State::Alarm || sys.state == State::Sleep) {
+    if (sys.state == State::ConfigAlarm) {
+        report_feedback_message(Message::AlarmLock);
+    } else if (sys.state == State::Alarm || sys.state == State::Sleep) {
         report_feedback_message(Message::AlarmLock);
         sys.state = State::Alarm;  // Ensure alarm state is set.
     } else {
@@ -325,6 +327,7 @@ static void protocol_do_motion_cancel() {
     // will handle and clear multiple planner block motions.
     switch (sys.state) {
         case State::Alarm:
+        case State::ConfigAlarm:
         case State::CheckMode:
             return;  // Do not set motionCancel
 
@@ -356,6 +359,7 @@ static void protocol_do_feedhold() {
     rtFeedHold   = false;
     rtCycleStart = false;  // Cancel any pending start
     switch (sys.state) {
+        case State::ConfigAlarm:
         case State::Alarm:
         case State::CheckMode:
         case State::SafetyDoor:
@@ -390,6 +394,8 @@ static void protocol_do_safety_door() {
     rtCycleStart = false;  // Cancel any pending start
     report_feedback_message(Message::SafetyDoorAjar);
     switch (sys.state) {
+        case State::ConfigAlarm:
+            return;
         case State::Alarm:
         case State::CheckMode:
         case State::Sleep:
@@ -443,6 +449,7 @@ static void protocol_do_safety_door() {
 static void protocol_do_sleep() {
     rtSleep = false;
     switch (sys.state) {
+        case State::ConfigAlarm:
         case State::Alarm:
             sys.suspend.bit.retractComplete = true;
             sys.suspend.bit.holdComplete    = true;
@@ -518,6 +525,7 @@ static void protocol_do_cycle_start() {
                 }
             }
             break;
+        case State::ConfigAlarm:
         case State::Alarm:
         case State::CheckMode:
         case State::Sleep:
@@ -552,6 +560,7 @@ static void protocol_do_cycle_stop() {
                 break;
             }
             // Fall through
+        case State::ConfigAlarm:
         case State::Alarm:
         case State::CheckMode:
         case State::Idle:
@@ -686,6 +695,7 @@ void protocol_exec_rt_system() {
 #endif
     // Reload step segment buffer
     switch (sys.state) {
+        case State::ConfigAlarm:
         case State::Alarm:
         case State::CheckMode:
         case State::Idle:

Grbl_Esp32/src/Report.cpp

@@ -858,6 +858,7 @@ char* report_state_text() {
         case State::Homing:
             strcpy(state, "Home");
             break;
+        case State::ConfigAlarm:
         case State::Alarm:
             strcpy(state, "Alarm");
             break;

Grbl_Esp32/src/Report.h

@@ -1,6 +1,10 @@
 #pragma once
 
 #include "Error.h"
+#include "NutsBolts.h"
+#include "Exec.h"
+
+#include <FreeRTOS.h>
 
 /*
   Report.h - Header for system level commands and real-time processes

Grbl_Esp32/src/System.h

@@ -40,6 +40,7 @@ enum class State : uint8_t {
     Jog,         // Jogging mode.
     SafetyDoor,  // Safety door is ajar. Feed holds and de-energizes system.
     Sleep,       // Sleep state.
+    ConfigAlarm, // You can't do anything but fix your config file.
 };
 
 // Step segment generator state flags.

Grbl_Esp32/src/WebUI/WebSettings.cpp

@@ -678,7 +678,7 @@ namespace WebUI {
 
     static Error runSDFile(char* parameter, AuthenticationLevel auth_level) {  // ESP220
         Error err;
-        if (sys.state == State::Alarm) {
+        if (sys.state == State::Alarm || sys.state == State::ConfigAlarm) {
             webPrintln("Alarm");
             return Error::IdleError;
         }