fix: start captive portal on AP_START, use esp_timer for service init

Root cause: xTaskCreate from within IP event handler never scheduled the
services_start_task on ESP32-S3. Replaced with esp_timer one-shot callback.

Also moved captive_portal_start() into start_ap_services() so the portal
starts immediately when the AP comes up, not waiting for STA GOT IP.

Added /debug endpoint for runtime diagnostics.
Added captive_portal diagnostic getters.

4 files changed, 81 insertions, 24 deletions

diff --git a/main/captive_portal.c b/main/captive_portal.c
index 6a8c716..9a0a5ff 100644
--- a/main/captive_portal.c
+++ b/main/captive_portal.c
@@ -17,6 +17,8 @@
 #include <stdio.h>
 
 static const char *TAG = "captive_portal";
+static bool s_start_called = false;
+static esp_err_t s_start_result = ESP_OK;
 static httpd_handle_t s_server = NULL;
 static char s_ap_ip_str[16] = "10.0.0.1";
 
@@ -707,16 +709,18 @@ static const httpd_uri_t uri_wifi_status = { .uri = "/wifi/status", .method = HT
 
 esp_err_t captive_portal_start(const char *ap_ip_str)
 {
+    s_start_called = true;
     if (s_server) return ESP_OK;
+    if (!ap_ip_str) return ESP_ERR_INVALID_ARG;
     strncpy(s_ap_ip_str, ap_ip_str, sizeof(s_ap_ip_str) - 1);
 
     httpd_config_t config = HTTPD_DEFAULT_CONFIG();
     config.max_uri_handlers = 20;
 
-    esp_err_t ret = httpd_start(&s_server, &config);
-    if (ret != ESP_OK) {
-        ESP_LOGE(TAG, "Failed to start HTTP server: %s", esp_err_to_name(ret));
-        return ret;
+    s_start_result = httpd_start(&s_server, &config);
+    if (s_start_result != ESP_OK) {
+        ESP_LOGE(TAG, "Failed to start HTTP server on port %d: %s", config.server_port, esp_err_to_name(s_start_result));
+        return s_start_result;
     }
 
     httpd_register_uri_handler(s_server, &uri_portal);
@@ -733,19 +737,23 @@ esp_err_t captive_portal_start(const char *ap_ip_str)
     httpd_register_uri_handler(s_server, &uri_connecttest);
     httpd_register_uri_handler(s_server, &uri_wpad);
     httpd_register_uri_handler(s_server, &uri_setup);
-    ret = httpd_register_uri_handler(s_server, &uri_wifi_scan);
-    ESP_LOGI(TAG, "Registered /wifi/scan: %s", esp_err_to_name(ret));
-    ret = httpd_register_uri_handler(s_server, &uri_wifi_connect);
-    ESP_LOGI(TAG, "Registered /wifi/connect: %s", esp_err_to_name(ret));
-    ret = httpd_register_uri_handler(s_server, &uri_wifi_status);
-    ESP_LOGI(TAG, "Registered /wifi/status: %s", esp_err_to_name(ret));
+    esp_err_t reg_ret;
+    reg_ret = httpd_register_uri_handler(s_server, &uri_wifi_scan);
+    ESP_LOGI(TAG, "Registered /wifi/scan: %s", esp_err_to_name(reg_ret));
+    reg_ret = httpd_register_uri_handler(s_server, &uri_wifi_connect);
+    ESP_LOGI(TAG, "Registered /wifi/connect: %s", esp_err_to_name(reg_ret));
+    reg_ret = httpd_register_uri_handler(s_server, &uri_wifi_status);
+    ESP_LOGI(TAG, "Registered /wifi/status: %s", esp_err_to_name(reg_ret));
 
     httpd_register_err_handler(s_server, HTTPD_404_NOT_FOUND, catchall_err_handler);
 
     ESP_LOGI(TAG, "Captive portal started on port 80");
-    return ESP_OK;
+    return s_start_result;
 }
 
+bool captive_portal_was_start_called(void) { return s_start_called; }
+esp_err_t captive_portal_get_start_result(void) { return s_start_result; }
+
 void captive_portal_stop(void)
 {
     if (s_server) {
diff --git a/main/captive_portal.h b/main/captive_portal.h
index e02a4ce..c3aa923 100644
--- a/main/captive_portal.h
+++ b/main/captive_portal.h
@@ -8,5 +8,7 @@ esp_err_t captive_portal_start(const char *ap_ip_str);
 void captive_portal_stop(void);
 httpd_handle_t captive_portal_get_server(void);
 bool captive_portal_is_setup_available(void);
+bool captive_portal_was_start_called(void);
+esp_err_t captive_portal_get_start_result(void);
 
 #endif
diff --git a/main/tollgate_api.c b/main/tollgate_api.c
index 45cd02f..af91093 100644
--- a/main/tollgate_api.c
+++ b/main/tollgate_api.c
@@ -3,6 +3,7 @@
 #include "config.h"
 #include "identity.h"
 #include "session.h"
+#include "captive_portal.h"
 #include "firewall.h"
 #include "nucula_wallet.h"
 #include "mint_health.h"
@@ -681,6 +682,32 @@ static esp_err_t api_get_mining_stats(httpd_req_t *req)
     return ESP_OK;
 }
 
+extern bool s_start_services_called;
+extern bool s_start_ap_services_called;
+extern bool s_sta_got_ip;
+extern bool s_ap_started;
+
+static esp_err_t api_get_debug(httpd_req_t *req)
+{
+    httpd_handle_t portal = captive_portal_get_server();
+    cJSON *root = cJSON_CreateObject();
+    cJSON_AddBoolToObject(root, "portal_running", portal != NULL);
+    cJSON_AddBoolToObject(root, "portal_start_called", captive_portal_was_start_called());
+    cJSON_AddNumberToObject(root, "portal_start_result", captive_portal_get_start_result());
+    cJSON_AddBoolToObject(root, "start_services_called", s_start_services_called);
+    cJSON_AddBoolToObject(root, "start_ap_services_called", s_start_ap_services_called);
+    cJSON_AddBoolToObject(root, "sta_got_ip", s_sta_got_ip);
+    cJSON_AddBoolToObject(root, "ap_started", s_ap_started);
+    cJSON_AddNumberToObject(root, "free_heap", (double)esp_get_free_heap_size());
+    cJSON_AddNumberToObject(root, "min_free_heap", (double)esp_get_minimum_free_heap_size());
+    char *json = cJSON_PrintUnformatted(root);
+    httpd_resp_set_type(req, "application/json");
+    httpd_resp_sendstr(req, json);
+    cJSON_free(json);
+    cJSON_Delete(root);
+    return ESP_OK;
+}
+
 static const httpd_uri_t uri_discovery = { .uri = "/", .method = HTTP_GET, .handler = api_get_discovery };
 static const httpd_uri_t uri_payment = { .uri = "/", .method = HTTP_POST, .handler = api_post_payment };
 static const httpd_uri_t uri_mints = { .uri = "/mints", .method = HTTP_GET, .handler = api_get_mints };
@@ -731,6 +758,7 @@ static esp_err_t api_get_market(httpd_req_t *req)
 }
 
 static const httpd_uri_t uri_market = { .uri = "/market", .method = HTTP_GET, .handler = api_get_market };
+static const httpd_uri_t uri_debug = { .uri = "/debug", .method = HTTP_GET, .handler = api_get_debug };
 
 esp_err_t tollgate_api_start(void)
 {
@@ -750,6 +778,7 @@ esp_err_t tollgate_api_start(void)
     }
 
     httpd_register_uri_handler(s_api_server, &uri_discovery);
+    httpd_register_uri_handler(s_api_server, &uri_debug);
     httpd_register_uri_handler(s_api_server, &uri_payment);
     httpd_register_uri_handler(s_api_server, &uri_mints);
     httpd_register_uri_handler(s_api_server, &uri_usage);
diff --git a/main/tollgate_main.c b/main/tollgate_main.c
index 6c85b28..23b4a00 100644
--- a/main/tollgate_main.c
+++ b/main/tollgate_main.c
@@ -8,6 +8,7 @@
 #include "esp_system.h"
 #include "nvs_flash.h"
 #include "esp_netif.h"
+#include "esp_timer.h"
 #include "lwip/netif.h"
 #include "lwip/dns.h"
 #include "esp_sntp.h"
@@ -55,14 +56,22 @@ static char s_ap_ip_str[16] = "10.0.0.1";
 static relay_selector_t s_relay_selector;
 static sync_manager_t s_sync_manager;
 
+volatile bool s_start_services_called = false;
+volatile bool s_start_ap_services_called = false;
+volatile bool s_sta_got_ip = false;
+volatile bool s_ap_started = false;
+
 static void start_services(void);
 static void stop_services(void);
 static void start_ap_services(void);
 
 static void start_ap_services(void)
 {
+    s_start_ap_services_called = true;
     if (s_ap_services_running) return;
 
+    const tollgate_config_t *cfg = tollgate_config_get();
+    captive_portal_start(cfg->ap_ip_str);
     tollgate_api_start();
     beacon_price_start();
     market_init();
@@ -120,17 +129,18 @@ static void wifi_event_handler(void *arg, esp_event_base_t event_base,
                  event->mac[0], event->mac[1], event->mac[2],
                  event->mac[3], event->mac[4], event->mac[5]);
     } else if (event_base == WIFI_EVENT && event_id == WIFI_EVENT_AP_START) {
+        s_ap_started = true;
         start_ap_services();
     }
 }
 
-static void services_start_task(void *pvParameters)
+static void services_start_timer_cb(void *arg)
 {
-    vTaskDelay(pdMS_TO_TICKS(3000));
     start_services();
-    vTaskDelete(NULL);
 }
 
+static esp_timer_handle_t s_services_timer;
+
 static void ip_event_handler(void *arg, esp_event_base_t event_base,
                               int32_t event_id, void *event_data)
 {
@@ -138,8 +148,17 @@ static void ip_event_handler(void *arg, esp_event_base_t event_base,
         ip_event_got_ip_t *event = (ip_event_got_ip_t *)event_data;
         ESP_LOGI(TAG, "Got IP:" IPSTR ", GW:" IPSTR, IP2STR(&event->ip_info.ip), IP2STR(&event->ip_info.gw));
         s_retry_count = 0;
+        s_sta_got_ip = true;
         xEventGroupSetBits(s_wifi_event_group, WIFI_CONNECTED_BIT);
 
+        const esp_timer_create_args_t timer_cfg = {
+            .callback = services_start_timer_cb,
+            .name = "svc_start",
+        };
+        ESP_ERROR_CHECK(esp_timer_create(&timer_cfg, &s_services_timer));
+        ESP_ERROR_CHECK(esp_timer_start_once(s_services_timer, 3000000));
+        ESP_LOGI(TAG, "services_start_timer scheduled (3s)");
+
         esp_sntp_stop();
         esp_sntp_setoperatingmode(SNTP_OPMODE_POLL);
         esp_sntp_setservername(0, "pool.ntp.org");
@@ -150,8 +169,6 @@ static void ip_event_handler(void *arg, esp_event_base_t event_base,
         char gw_ip_str[16];
         snprintf(gw_ip_str, sizeof(gw_ip_str), IPSTR, IP2STR(&event->ip_info.gw));
         tollgate_client_on_sta_connected(gw_ip_str);
-
-        xTaskCreate(services_start_task, "svc_start", 32768, NULL, 5, NULL);
     } else if (event_base == IP_EVENT && event_id == IP_EVENT_STA_LOST_IP) {
         ESP_LOGW(TAG, "Lost IP address");
         xEventGroupClearBits(s_wifi_event_group, WIFI_CONNECTED_BIT);
@@ -159,13 +176,6 @@ static void ip_event_handler(void *arg, esp_event_base_t event_base,
     }
 }
 
-static void wallet_init_task(void *pvParameters)
-{
-    const tollgate_config_t *cfg = tollgate_config_get();
-    nucula_wallet_init(cfg->mint_url);
-    vTaskDelete(NULL);
-}
-
 static void publish_wifistr_task(void *pvParameters)
 {
     vTaskDelay(pdMS_TO_TICKS(5000));
@@ -177,12 +187,15 @@ static void publish_wifistr_task(void *pvParameters)
 
 static void start_services(void)
 {
+    ESP_LOGI(TAG, ">>> start_services() called");
     if (s_services_mutex) xSemaphoreTake(s_services_mutex, portMAX_DELAY);
     if (s_services_running) {
         if (s_services_mutex) xSemaphoreGive(s_services_mutex);
         return;
     }
 
+    s_start_services_called = true;
+
     esp_netif_get_ip_info(s_ap_netif, &(esp_netif_ip_info_t){0});
     esp_netif_ip_info_t ap_ip_info;
     esp_netif_get_ip_info(s_ap_netif, &ap_ip_info);
@@ -412,7 +425,12 @@ void app_main(void)
 
     if (tollgate_config_get_wifi(&(wifi_config_t){0}) != ESP_OK) {
         ESP_LOGI(TAG, "No STA network configured, starting services immediately");
-        xTaskCreate(services_start_task, "svc_start", 32768, NULL, 5, NULL);
+        const esp_timer_create_args_t timer_cfg = {
+            .callback = services_start_timer_cb,
+            .name = "svc_start_fallback",
+        };
+        ESP_ERROR_CHECK(esp_timer_create(&timer_cfg, &s_services_timer));
+        ESP_ERROR_CHECK(esp_timer_start_once(s_services_timer, 3000000));
     }
 
     while (1) {