Switch Morse startup to IQ-first and harden timeout handling

routes/morse.py

@@ -354,8 +354,17 @@ def start_morse() -> Response:
 
     can_try_direct_sampling = bool(sdr_device.sdr_type == SDRType.RTL_SDR and freq < 24.0)
     if can_try_direct_sampling:
-        # Keep rtl_fm attempts first (cheap), then switch to IQ capture fallback.
+        # IQ-first strategy: avoid repeated rtl_fm/rtl_sdr handoffs that can
+        # leave the tuner in a bad state on some Linux builds.
         command_attempts: list[dict[str, Any]] = [
+            {
+                'source': 'iq',
+                'direct_sampling_mode': 2,
+            },
+            {
+                'source': 'iq',
+                'direct_sampling_mode': None,
+            },
             {
                 'source': 'rtl_fm',
                 'use_direct_sampling': True,
@@ -370,17 +379,13 @@ def start_morse() -> Response:
                 'add_resample_rate': True,
                 'add_dc_fast': True,
             },
-            {
+        ]
-                'source': 'iq',
+    else:
-                'direct_sampling_mode': 2,
+        command_attempts = [
-            },
             {
                 'source': 'iq',
                 'direct_sampling_mode': None,
             },
-        ]
-    else:
-        command_attempts = [
             {
                 'source': 'rtl_fm',
                 'use_direct_sampling': False,
@@ -388,10 +393,6 @@ def start_morse() -> Response:
                 'add_resample_rate': True,
                 'add_dc_fast': True,
             },
-            {
-                'source': 'iq',
-                'direct_sampling_mode': None,
-            },
         ]
 
     rtl_process: subprocess.Popen | None = None
@@ -571,7 +572,7 @@ def start_morse() -> Response:
                 )
             decoder_thread.start()
 
-            startup_deadline = time.monotonic() + 1.2
+            startup_deadline = time.monotonic() + (2.5 if source == 'iq' else 1.2)
             startup_ok = False
             startup_error = ''
 

static/js/modes/morse.js

@@ -8,7 +8,7 @@ var MorseMode = (function () {
     var SETTINGS_KEY = 'intercept.morse.settings.v3';
     var STATUS_POLL_MS = 5000;
     var LOCAL_STOP_TIMEOUT_MS = 2200;
-    var START_TIMEOUT_MS = 20000;
+    var START_TIMEOUT_MS = 60000;
 
     var state = {
         initialized: false,
@@ -324,12 +324,32 @@ var MorseMode = (function () {
                 if (seq !== state.startSeq) {
                     return { status: 'stale' };
                 }
+                var initialErrorMsg = String(err && err.message ? err.message : err);
+                if (initialErrorMsg === 'Request timed out while waiting for decoder startup') {
+                    return fetch('/morse/status')
+                        .then(function (r) { return parseJsonSafe(r); })
+                        .then(function (statusData) {
+                            var statusError = statusData && (statusData.error || statusData.message);
+                            var resolvedError = statusError ? String(statusError) : initialErrorMsg;
+                            setLifecycle('error');
+                            setStatusText('Start failed');
+                            appendDiagLine('[start] failed: ' + resolvedError);
+                            notifyError('Failed to start Morse decoder: ' + resolvedError);
+                            return { status: 'error', message: resolvedError };
+                        })
+                        .catch(function () {
+                            setLifecycle('error');
+                            setStatusText('Start failed');
+                            appendDiagLine('[start] failed: ' + initialErrorMsg);
+                            notifyError('Failed to start Morse decoder: ' + initialErrorMsg);
+                            return { status: 'error', message: initialErrorMsg };
+                        });
+                }
                 setLifecycle('error');
-                var errorMsg = String(err && err.message ? err.message : err);
                 setStatusText('Start failed');
-                appendDiagLine('[start] failed: ' + errorMsg);
+                appendDiagLine('[start] failed: ' + initialErrorMsg);
-                notifyError('Failed to start Morse decoder: ' + errorMsg);
+                notifyError('Failed to start Morse decoder: ' + initialErrorMsg);
-                return { status: 'error', message: errorMsg };
+                return { status: 'error', message: initialErrorMsg };
             });
     }
 

tests/test_morse.py

@@ -266,6 +266,13 @@ class TestMorseLifecycleRoutes:
             def build_fm_demod_command(self, **kwargs):
                 return ['rtl_fm', '-f', '14060000']
 
+            def build_iq_capture_command(self, **kwargs):
+                cmd = ['rtl_sdr', '-f', '14060000', '-s', '250000']
+                if kwargs.get('gain') is not None:
+                    cmd.extend(['-g', str(kwargs['gain'])])
+                cmd.append('-')
+                return cmd
+
         monkeypatch.setattr(morse_routes.SDRFactory, 'create_default_device', staticmethod(lambda sdr_type, index: DummyDevice()))
         monkeypatch.setattr(morse_routes.SDRFactory, 'get_builder', staticmethod(lambda sdr_type: DummyBuilder()))
         monkeypatch.setattr(morse_routes.time, 'sleep', lambda _secs: None)
@@ -337,6 +344,10 @@ class TestMorseLifecycleRoutes:
                 cmd.append('-')
                 return cmd
 
+            def build_iq_capture_command(self, **kwargs):
+                cmd = ['rtl_sdr', '-f', '14.0593M', '-s', '250000', '-']
+                return cmd
+
         monkeypatch.setattr(morse_routes.SDRFactory, 'create_default_device', staticmethod(lambda sdr_type, index: DummyDevice()))
         monkeypatch.setattr(morse_routes.SDRFactory, 'get_builder', staticmethod(lambda sdr_type: DummyBuilder()))
 
@@ -378,13 +389,11 @@ class TestMorseLifecycleRoutes:
         assert start_resp.status_code == 200
         assert start_resp.get_json()['status'] == 'started'
         assert len(popen_cmds) >= 2
-        assert '-E' in popen_cmds[0] and 'direct2' in popen_cmds[0]
+        assert popen_cmds[0][0] == 'rtl_sdr'
-        assert '-r' in popen_cmds[0]
+        assert '-D' in popen_cmds[0]
-        assert '-A' in popen_cmds[0]
+        assert '2' in popen_cmds[0]
-        assert '-E' in popen_cmds[1] and 'direct2' not in popen_cmds[1]
+        assert popen_cmds[1][0] == 'rtl_sdr'
-        assert '-r' in popen_cmds[1]
+        assert '-D' not in popen_cmds[1]
-        assert '-A' in popen_cmds[1]
-        assert 'dc' in popen_cmds[1]
 
         stop_resp = client.post('/morse/stop')
         assert stop_resp.status_code == 200