Hi All,

how can i prevent aWeld() functioning from false triggering.

#include <Arduino.h>
#include <EEPROM.h>
#include <NTC_Thermistor.h>
#include <PinChangeInterrupt.h>
#include <Servo.h>
#include <Wire.h>
#include <hd44780.h>
#include <hd44780ioClass/hd44780_I2Cexp.h>
hd44780_I2Cexp lcd;
Servo myServo;
// Const Variables and pin assinged
const byte ENC_SW = 3;   // Encoder Switch
const byte rdy = 4;      // READY LED
const byte servoPin = 6; // Servo
const int ENC_PinA = 7;  // PIN A of Encoder
const byte bzr = 5;      // Buzzer
const int ENC_PinB = 8;  // PIN B of Encoder
const int buttonPin = 9; // Weld button
const byte cs = 10;      // Contact Sense
const int TRIAC = A1;    // Load
const int shortPress = 1;
const int longPress = 2;
const int longerPress = 3;
const int tgr_dly = 5084;  // delay after zero cross at peak sine - average of 50/60Hz
const int shortTime = 200; // if equal longTime there is no unrecorded press
const int longTime = 500;
const int longerTime = 2000;
const int pause = 450;    // pause value between dual pulses
const int delayTime = 50; // bounce delay for Encoder Switch
// Variables
#define Temp A6  // NTC PIN
#define RR 10000 // Reference Resistance
#define NR 10000 // Nominal Resistance
#define NT 25    // Nominal Temperature
#define B_Val 3435
NTC_Thermistor *thermistor;
byte zCd = 2; // Zero Crossing Detect
//byte weldCont = false;
byte menuSelect = 0;
byte stayInMenu = false;
byte weldExitFlag = true;
byte previousButtonState = HIGH;
byte buttonState = HIGH;
byte prevENC_SWstate = HIGH;
byte ENC_SWstate = HIGH;
byte buttonFlag;
//byte resetFlag = false;
byte manualWeld = 0;
byte testLoop = 1;
byte cs_State = HIGH;
byte prevCS_State;
byte currCS_State;
byte confMenu;
byte rdyState;
byte noCtc;
byte ctc;
byte currCtc;
byte prevCtc;
byte prevWeldFlag;
int ENC_PinAState = LOW;
int ENC_PinALastState = LOW;
int WeldTime = 30; // read value from rotaryEncoder()
int prevRotaryVal;
int W2Addr = 110;       // Address block to store W2 value
int PreWeldAddr = 120;  // Address block to store PreWeld time
int startSrvAddr = 130; // Address block to store servo Start degree
int endSrvAddr = 140;   // Address block to store servo end degree
int SrvPotMap1;
int SrvPotMap2;
int counter;          // Auto weld counter
int WeldStepValue;    // Value of POT in milliseconds
int OldWeldStepValue; // Old value of POT
int PotValue;         // Actual POT value
int ConfigureVal;
int w1Value = 10;
int pValue = 50;
int select;
int Counter1;
int Counter;
unsigned long TimeStamp;
unsigned long ENC_SWpressDuration;
unsigned long buttonPressStartTimeStamp;
unsigned long buttonPressDuration;
unsigned long timeCheck = 1000; // time to check zero cross error
unsigned long currentMillis;
unsigned long prevMillis;
unsigned long prevT;
unsigned long currT;
unsigned long delayT = 500;
boolean startTimeout = false; // zc sense error timeout
volatile boolean zeroCrossingFlag = false;
void setup()
{
  lcd.clear();
  lcd.begin(16, 2);
  thermistor = new NTC_Thermistor(Temp, RR, NR, NT, B_Val);
  ServoReturn();
  //w1Value = EEPROM.read(PreWeldAddr);
  SrvPotMap1 = EEPROM.read(endSrvAddr);
  SrvPotMap2 = EEPROM.read(startSrvAddr);
  //WeldTime = EEPROM.read(W2Addr);
  pinMode(buttonPin, INPUT_PULLUP);
  pinMode(ENC_PinA, INPUT_PULLUP);
  pinMode(ENC_PinB, INPUT_PULLUP);
  pinMode(zCd, INPUT_PULLUP);
  pinMode(cs, INPUT_PULLUP);
  pinMode(ENC_SW, INPUT_PULLUP);
  pinMode(servoPin, OUTPUT);
  pinMode(TRIAC, OUTPUT);
  pinMode(rdy, OUTPUT);
  pinMode(bzr, OUTPUT);
  pinMode(A2, INPUT);
  pinMode(A4, INPUT_PULLUP);
  pinMode(A5, INPUT_PULLUP);
  attachInterrupt(0, setFlag, FALLING); // zero cross
  attachPCINT(digitalPinToPCINT(ENC_PinA), rotaryEncoder, CHANGE);
  //attachPCINT(digitalPinToPCINT(ENC_SW), resetENC, RISING);
  attachPCINT(digitalPinToPCINT(buttonPin), WeldExit, CHANGE);
  delay(10);
  lcd.clear();
  lcd.setCursor(0, 0);
  lcd.print("Max Weld");
  lcd.setCursor(12, 0);
  lcd.print("v3.0");
  lcd.setCursor(0, 1);
  lcd.print("GT Designs");
  delay(2000);
  lcd.clear();
  Display();
  startupTone();
  Serial.begin(115200);
}

// ------------------------------------------------ FUNCTIONS ---------------------------------
void startupTone()
{
  tone(bzr, 2500);
  delay(120);
  noTone(bzr);
  delay(240);
  tone(bzr, 2500);
  delay(120);
  noTone(bzr);
}

void weldTone()
{
  if (manualWeld == 0)
  {
    tone(bzr, 2322);
    delay(70);
    noTone(bzr);
    tone(bzr, 2222);
    delay(70);
    noTone(bzr);
  }
  else
  {
    tone(bzr, 3153);
    delay(50);
    noTone(bzr);
  }
}

void saveSuccess()
{
  pinMode(bzr, OUTPUT);
  tone(bzr, 2025);
  delay(300);
  noTone(bzr);
}

/*void resetENC()
{
  if (resetFlag == false)
  {
    Counter1 = 0;
  }
}*/

void Display()
{
  lcd.clear();
  lcd.setCursor(1, 0);
  lcd.print("W1:");
  lcd.print(w1Value);
  myServo.detach();
}

void rotaryEncoder()
{
  ENC_PinAState = digitalRead(ENC_PinA);
  if (digitalRead(ENC_PinB) != ENC_PinAState)
  {
    Counter1--;
  }
  else
  {
    Counter1++;
  }
}

int readEncoder()
{
  noInterrupts();
  int copyCounter = Counter1;
  interrupts();
  return (copyCounter) >> 1;
}

void Weld() // Actual weld
{
  delay(300);
  myServo.attach(servoPin);
  digitalWrite(rdy, LOW);
  ServoStart();
  //buttonState = digitalRead(buttonPin);
  zeroCrossingFlag = false; // set flag false and wait for next zero crossing
  while (!zeroCrossingFlag)
  {
  };
  delayMicroseconds(tgr_dly);
  digitalWrite(TRIAC, HIGH);
  delay(w1Value); // preWeld time ms
  digitalWrite(TRIAC, LOW);
  delay(pause);
  zeroCrossingFlag = false; // set flag false and wait for next zero crossing
  while (!zeroCrossingFlag)
  {
  };
  delayMicroseconds(tgr_dly);
  digitalWrite(TRIAC, HIGH);
  delay(WeldTime);
  digitalWrite(TRIAC, LOW);
  ServoReturn();
  myServo.detach();
  weldTone();
  lcd.clear();
}

void aWeld() // Auto weld
{
  if (currCtc == 0 && prevCtc == 1)
  {
    Serial.println(currCtc);
    Serial.println(prevCtc);
    Serial.println(" ");
    prevCtc = currCtc;
    Serial.println(currCtc);
    Serial.println(prevCtc);
    Serial.println(" ");
    myServo.attach(servoPin);
    digitalWrite(rdy, LOW);
    ServoStart();
    zeroCrossingFlag = false; // set flag false and wait for next zero crossing
    while (!zeroCrossingFlag)
    {
    };
    delayMicroseconds(tgr_dly);
    digitalWrite(TRIAC, HIGH);
    delay(w1Value); // preWeld time ms
    digitalWrite(TRIAC, LOW);
    delay(pause);
    zeroCrossingFlag = false; // set flag false and wait for next zero crossing
    while (!zeroCrossingFlag)
    {
    };
    delayMicroseconds(tgr_dly);
    digitalWrite(TRIAC, HIGH);
    delay(WeldTime);
    digitalWrite(TRIAC, LOW);
  }
  ServoReturn();
  myServo.detach();
  weldTone();
}

void WeldExit() // Interrupt to exit Auto Weld
{
  weldExitFlag = true;
}

void setFlag()
{
  zeroCrossingFlag = true; // interrupt sets flag true
}

void ServoStart() // Increments to start position from Finish
{
  for (int i = SrvPotMap1; i <= SrvPotMap2; i += 1)
  {
    myServo.attach(servoPin);
    myServo.write(i);
    delay(5);
  }
}

void ServoReturn() // Increments to Finish position from Start
{
  for (int i = SrvPotMap2; i >= SrvPotMap1; i -= 1)
  {
    myServo.write(i);
    delay(5);
  }
}

int clearSelectPointer(int checkPointer)
{
  switch (checkPointer)
  {
  case 1:                // for select 1
    lcd.setCursor(0, 1); // 2
    lcd.print(" ");
    lcd.setCursor(8, 1); // 3
    lcd.print(" ");
    break;
  case 2:                // for select 2
    lcd.setCursor(0, 0); // 1
    lcd.print(" ");
    lcd.setCursor(8, 1); // 3
    lcd.print(" ");
    break;
  case 3:                // for select 3
    lcd.setCursor(0, 0); // 1
    lcd.print(" ");
    lcd.setCursor(0, 1); // 2
    lcd.print(" ");
    break;
  case 4:
    lcd.setCursor(0, 0); // 1
    lcd.print(" ");
    lcd.setCursor(0, 1); // 2
    lcd.print(" ");
    lcd.setCursor(8, 1); //3
    lcd.print(" ");
    break;
  }
  return (checkPointer);
}
// ------------------------------------------------ END OF FUNCTIONS --------------------------
void loop()
{
  while (!zeroCrossingFlag) //&& (millis() - startTime < timeCheck))
  {
    /* hang inside while loop until either zeroCrossFlag or timeout occurs
      both conditions need to be met to stay in while loop
    */
  }
  lcd.setCursor(1, 0);
  lcd.print("W1:");
  lcd.print(w1Value);
  lcd.setCursor(1, 1);
  lcd.print("W2:");
  lcd.print(WeldTime);
  lcd.setCursor(9, 0);
  lcd.print("T:");
  lcd.print(String(thermistor->readCelsius()));
  lcd.setCursor(9, 1);
  lcd.print("P:");
  digitalWrite(rdy, HIGH);

  ENC_SWstate = digitalRead(ENC_SW);
  if (ENC_SWstate != prevENC_SWstate)
  {
    if (ENC_SWstate == LOW)
    {
      Counter1 = w1Value / 10 << 1;

      Counter++;
      confMenu = 1; /*
      Serial.print("Pass:");
      Serial.println(Counter);
      Serial.print("Counter:");
      Serial.println(Counter1);
      Serial.print("W1:");
      Serial.println(w1Value);
      Serial.print("W2:");
      Serial.println(WeldTime);
      Serial.print("pValue:");
      Serial.println(pValue);*/
    }
  }
  prevENC_SWstate = ENC_SWstate;

  while (confMenu == 1)
  {
    ENC_SWstate = digitalRead(ENC_SW);
    if (ENC_SWstate != prevENC_SWstate)
    {
      if (ENC_SWstate == LOW)
      {
        select += 1;
        select = select % 4;
        /*Serial.print("Select:");
        Serial.println(select);
        Serial.println(" ");*/
        if (select == 0)
        {
          noInterrupts();
          Counter1 = w1Value / 10 << 1;
          interrupts();
        }
        if (select == 1)
        {
          noInterrupts();
          Counter1 = WeldTime / 10 << 1;
          interrupts();
        }
        if (select == 2)
        {
          noInterrupts();
          Counter1 = pValue / 10 << 1;
          interrupts();
        }
      }
      prevENC_SWstate = ENC_SWstate;
    }

    switch (select)
    {
    case 0: //W1
      clearSelectPointer(1);
      lcd.setCursor(0, 0);
      lcd.print(">");
      w1Value = readEncoder() % 6 * 10;
      if (w1Value <= 0)
      {
        w1Value = 0;
      }
      lcd.setCursor(1, 0);
      lcd.print("W1:");
      lcd.print(w1Value);
      lcd.print("  ");
      break;

    case 1: //W2
      clearSelectPointer(2);
      lcd.setCursor(0, 1);
      lcd.print(">");
      WeldTime = readEncoder() % 51 * 10;
      if (WeldTime <= 0)
      {
        WeldTime = 0;
      }
      lcd.setCursor(1, 1);
      lcd.print("W2:");
      lcd.print(WeldTime); //lcd.setCursor(5, 1);
      lcd.print("  ");
      break;

    case 2: //P
      clearSelectPointer(3);
      lcd.setCursor(8, 1);
      lcd.print(">");
      pValue = readEncoder() % 11 * 10;
      if (pValue <= 0)
      {
        pValue = 0;
      }
      lcd.setCursor(9, 1);
      lcd.print("P:");
      lcd.print(pValue);
      lcd.print("%");
      lcd.print("  ");
      break;
    default:
      clearSelectPointer(4);
      confMenu = 0;
      select = 0;
      break;
    }
  }

  while (weldExitFlag == false) // begin Auto Weld
  {
    zeroCrossingFlag = false;
    while (!zeroCrossingFlag)
    {
    };
    delayMicroseconds(8600); // Sense voltage (after zero cross). higher number, lower voltage.
    digitalWrite(TRIAC, HIGH);
    delayMicroseconds(200);
    digitalWrite(TRIAC, LOW);
    cs_State = digitalRead(cs);
    currCS_State = cs_State;
    if (currCS_State == prevCS_State)
    {
      ctc = 0;
    }
    else
    {
      ctc = 1;
    }
    prevCS_State = currCS_State;
    currCtc = ctc;
    Serial.println(ctc);
    Serial.println(prevCtc);
    Serial.println(" ");
    if (currCtc != prevCtc)
    {
      if (currCtc == LOW && prevCtc == HIGH)
      {
        delay(300);
        aWeld();
      }
      prevCtc = currCtc;
    }
    buttonState = digitalRead(buttonState);
    previousButtonState = buttonState;
    currCtc = prevCtc;
  } // End Auto weld

  if (zeroCrossingFlag)
  // exit while loop due to flag set
  {
    zeroCrossingFlag = false;
  }

  switch (checkButton())
  {
  case shortPress:
    lcd.clear();
    lcd.print("Welding....");
    Weld();
    break;
  case longPress:
    lcd.clear();
    lcd.setCursor(0, 0);
    lcd.print("Auto Weld");
    delay(800);
    lcd.clear();
    weldExitFlag = false;
    break;
  case longerPress:
    break;
  }
}
// end of Loop
byte checkButton()
{
  byte event = 0;
  buttonState = digitalRead(buttonPin);
  // button pressed
  if (buttonState == LOW && previousButtonState == HIGH)
  {
    delay(20);                            // blocking debounce routine
    buttonState = digitalRead(buttonPin); // read button again
    if (buttonState == LOW && previousButtonState == HIGH)
    {
      buttonPressStartTimeStamp = millis();
      startTimeout = true;
    }
  }
  // button released
  if (buttonState == HIGH && previousButtonState == LOW)
  {
    delay(20);                            // blocking debounce routine
    buttonState = digitalRead(buttonPin); // read button again
    if (buttonState == HIGH && previousButtonState == LOW)
    {
      buttonPressDuration = (millis() - buttonPressStartTimeStamp);
      startTimeout = false; // duration determined no timeout required
    }
  }

  if (buttonPressDuration > 0 && buttonPressDuration <= shortTime)
  {
    event = shortPress;
    buttonPressDuration = 0;
  }

  if (buttonPressDuration > longTime && buttonPressDuration <= longerTime)
  {
    event = longPress;
    buttonPressDuration = 0;
    previousButtonState = buttonState;
  }
  // button not released and still timing
  if (buttonState == LOW && startTimeout == true && (millis() - buttonPressStartTimeStamp) > longerTime)
  {
    event = longerPress;
    digitalWrite(rdy, LOW);
    startTimeout = false;
  }
  buttonPressDuration = 0;
  previousButtonState = buttonState;
  prevENC_SWstate = ENC_SWstate;
  return event;
}

When
while (weldExitFlag ==false) is triggered, the aWeld() is also triggered at times. How can i prevent that ?

 

Impossible to answer without knowing what calls aWeld().

And this thread belongs in the embedded forum.

 

Impossible to answer without knowing what calls aWeld().

it is called within a while loop, While (WeldExitFlag == false) on line 475 in post# 1

 

it is called within a while loop, While (WeldExitFlag == false) on line 475 in post# 1

I am not seeing it in the code you posted. I see a weldExitFlag on line 475. That is not a function.

And please post your code with indents. The purpose of the code tag is to preserve indents. Lack of indents makes your code very hard to follow.

 

That is the bringing for the whole loop that holds fhe call to the function. The actual call is at 502

 

The way your code is posted, it makes it extremely difficult to analyze. Repost with indents and maybe you will stand a chance that someone will be able to see the issue. Your code is very hard to follow as it is. Lack of indents don't make it any easier.

Have you used the debugger and tried to trace the issue? Something is changing currCtc and / or prevCtc . It should not be that difficult to figure out with some basic debugging skills.

 

When while (weldExitFlag ==false) is triggered, the aWeld() is also triggered at times. How can i prevent that ?

it is called within a while loop, While (WeldExitFlag == false) on line 475

If you don't want aWeld() to be called within that while loop, simply delete any calls to it within that while loop.

There must be more to this question than the way you've presented it.

If you sometimes want it called within that loop, but other times not, then you need to create conditionals to check what you're actually looking for. Simply saying you don't want it called within that loop - when that's where you call it from - is nonsense.

 

oh Sorry for the confusion. I want it to be called within the while loop itself but only when this condition is true

if (currCtc != prevCtc)
{
if (currCtc ==LOW&& prevCtc ==HIGH)
{
delay(300);
aWeld();
}

my problem is that when randomly at the begining of the while this condition goes true and triggers the aWeld() function which i need to avoid. I tried setting a if statement in the aWeld() (in line 244) but that is also being bypassed.

 

oh Sorry for the confusion. I want it to be called within the while loop itself but only when this condition is true

if (currCtc != prevCtc)
{
if (currCtc ==LOW&& prevCtc ==HIGH)
{
delay(300);
aWeld();
}

my problem is that when randomly at the begining of the while this condition goes true and triggers the aWeld() function which i need to avoid. I tried setting a if statement in the aWeld() (in line 244) but that is also being bypassed.

Line 511 looks unusual:

currCtc = prevCtc;

I haven't traced all the logic around these variables yet, so I could be wrong, but usually when you're keeping a pair of variables to track current and previous states of an input, you'd do the opposite at the end of your loop - I'd expect to see "prevCtc=currCtc" at that point, not the other way around.

Again, haven't traced it all out, so I have no idea if the way you have it is right for you or not, but it jumps out at be as unusual, so it's worth double checking. If you're not sure either, maybe try flipping it around and see if it makes things better or worse!

 

Here's an example of code formatting that's probably closer to what @spinnaker is looking for. This isn't quite how I would do it - I just copied your code into my codeblocks editor and chose auto-format - but it certainly improves readability quite a lot.

I'm not sure if your raw code lacks indentation and other formatting standards entirely, or if it's just getting lost when you post code. The key when posting code is to include it in code tag brackets when you first upload it. You can type code tags into the post yourself, or click the "+" symbol in with the other formatting buttons, then choose "</> Code"

Mod edit: added C language extension to code tag i.e. code=C between the brackets. Hope that helps. JohnInTX

#include <Arduino.h>
#include <EEPROM.h>
#include <NTC_Thermistor.h>
#include <PinChangeInterrupt.h>
#include <Servo.h>
#include <Wire.h>
#include <hd44780.h>
#include <hd44780ioClass/hd44780_I2Cexp.h>
hd44780_I2Cexp lcd;
Servo myServo;
// Const Variables and pin assinged
const byte ENC_SW = 3;   // Encoder Switch
const byte rdy = 4;      // READY LED
const byte servoPin = 6; // Servo
const int ENC_PinA = 7;  // PIN A of Encoder
const byte bzr = 5;      // Buzzer
const int ENC_PinB = 8;  // PIN B of Encoder
const int buttonPin = 9; // Weld button
const byte cs = 10;      // Contact Sense
const int TRIAC = A1;    // Load
const int shortPress = 1;
const int longPress = 2;
const int longerPress = 3;
const int tgr_dly = 5084;  // delay after zero cross at peak sine - average of 50/60Hz
const int shortTime = 200; // if equal longTime there is no unrecorded press
const int longTime = 500;
const int longerTime = 2000;
const int pause = 450;    // pause value between dual pulses
const int delayTime = 50; // bounce delay for Encoder Switch
// Variables
#define Temp A6  // NTC PIN
#define RR 10000 // Reference Resistance
#define NR 10000 // Nominal Resistance
#define NT 25    // Nominal Temperature
#define B_Val 3435
NTC_Thermistor *thermistor;
byte zCd = 2; // Zero Crossing Detect
//byte weldCont = false;
byte menuSelect = 0;
byte stayInMenu = false;
byte weldExitFlag = true;
byte previousButtonState = HIGH;
byte buttonState = HIGH;
byte prevENC_SWstate = HIGH;
byte ENC_SWstate = HIGH;
byte buttonFlag;
//byte resetFlag = false;
byte manualWeld = 0;
byte testLoop = 1;
byte cs_State = HIGH;
byte prevCS_State;
byte currCS_State;
byte confMenu;
byte rdyState;
byte noCtc;
byte ctc;
byte currCtc;
byte prevCtc;
byte prevWeldFlag;
int ENC_PinAState = LOW;
int ENC_PinALastState = LOW;
int WeldTime = 30; // read value from rotaryEncoder()
int prevRotaryVal;
int W2Addr = 110;       // Address block to store W2 value
int PreWeldAddr = 120;  // Address block to store PreWeld time
int startSrvAddr = 130; // Address block to store servo Start degree
int endSrvAddr = 140;   // Address block to store servo end degree
int SrvPotMap1;
int SrvPotMap2;
int counter;          // Auto weld counter
int WeldStepValue;    // Value of POT in milliseconds
int OldWeldStepValue; // Old value of POT
int PotValue;         // Actual POT value
int ConfigureVal;
int w1Value = 10;
int pValue = 50;
int select;
int Counter1;
int Counter;
unsigned long TimeStamp;
unsigned long ENC_SWpressDuration;
unsigned long buttonPressStartTimeStamp;
unsigned long buttonPressDuration;
unsigned long timeCheck = 1000; // time to check zero cross error
unsigned long currentMillis;
unsigned long prevMillis;
unsigned long prevT;
unsigned long currT;
unsigned long delayT = 500;
boolean startTimeout = false; // zc sense error timeout
volatile boolean zeroCrossingFlag = false;
void setup()
{
    lcd.clear();
    lcd.begin(16, 2);
    thermistor = new NTC_Thermistor(Temp, RR, NR, NT, B_Val);
    ServoReturn();
    //w1Value = EEPROM.read(PreWeldAddr);
    SrvPotMap1 = EEPROM.read(endSrvAddr);
    SrvPotMap2 = EEPROM.read(startSrvAddr);
    //WeldTime = EEPROM.read(W2Addr);
    pinMode(buttonPin, INPUT_PULLUP);
    pinMode(ENC_PinA, INPUT_PULLUP);
    pinMode(ENC_PinB, INPUT_PULLUP);
    pinMode(zCd, INPUT_PULLUP);
    pinMode(cs, INPUT_PULLUP);
    pinMode(ENC_SW, INPUT_PULLUP);
    pinMode(servoPin, OUTPUT);
    pinMode(TRIAC, OUTPUT);
    pinMode(rdy, OUTPUT);
    pinMode(bzr, OUTPUT);
    pinMode(A2, INPUT);
    pinMode(A4, INPUT_PULLUP);
    pinMode(A5, INPUT_PULLUP);
    attachInterrupt(0, setFlag, FALLING); // zero cross
    attachPCINT(digitalPinToPCINT(ENC_PinA), rotaryEncoder, CHANGE);
    //attachPCINT(digitalPinToPCINT(ENC_SW), resetENC, RISING);
    attachPCINT(digitalPinToPCINT(buttonPin), WeldExit, CHANGE);
    delay(10);
    lcd.clear();
    lcd.setCursor(0, 0);
    lcd.print("Max Weld");
    lcd.setCursor(12, 0);
    lcd.print("v3.0");
    lcd.setCursor(0, 1);
    lcd.print("GT Designs");
    delay(2000);
    lcd.clear();
    Display();
    startupTone();
    Serial.begin(115200);
}

// ------------------------------------------------ FUNCTIONS ---------------------------------
void startupTone()
{
    tone(bzr, 2500);
    delay(120);
    noTone(bzr);
    delay(240);
    tone(bzr, 2500);
    delay(120);
    noTone(bzr);
}

void weldTone()
{
    if (manualWeld == 0)
    {
        tone(bzr, 2322);
        delay(70);
        noTone(bzr);
        tone(bzr, 2222);
        delay(70);
        noTone(bzr);
    }
    else
    {
        tone(bzr, 3153);
        delay(50);
        noTone(bzr);
    }
}

void saveSuccess()
{
    pinMode(bzr, OUTPUT);
    tone(bzr, 2025);
    delay(300);
    noTone(bzr);
}

/*void resetENC()
{
  if (resetFlag == false)
  {
    Counter1 = 0;
  }
}*/

void Display()
{
    lcd.clear();
    lcd.setCursor(1, 0);
    lcd.print("W1:");
    lcd.print(w1Value);
    myServo.detach();
}

void rotaryEncoder()
{
    ENC_PinAState = digitalRead(ENC_PinA);
    if (digitalRead(ENC_PinB) != ENC_PinAState)
    {
        Counter1--;
    }
    else
    {
        Counter1++;
    }
}

int readEncoder()
{
    noInterrupts();
    int copyCounter = Counter1;
    interrupts();
    return (copyCounter) >> 1;
}

void Weld() // Actual weld
{
    delay(300);
    myServo.attach(servoPin);
    digitalWrite(rdy, LOW);
    ServoStart();
    //buttonState = digitalRead(buttonPin);
    zeroCrossingFlag = false; // set flag false and wait for next zero crossing
    while (!zeroCrossingFlag)
    {
    };
    delayMicroseconds(tgr_dly);
    digitalWrite(TRIAC, HIGH);
    delay(w1Value); // preWeld time ms
    digitalWrite(TRIAC, LOW);
    delay(pause);
    zeroCrossingFlag = false; // set flag false and wait for next zero crossing
    while (!zeroCrossingFlag)
    {
    };
    delayMicroseconds(tgr_dly);
    digitalWrite(TRIAC, HIGH);
    delay(WeldTime);
    digitalWrite(TRIAC, LOW);
    ServoReturn();
    myServo.detach();
    weldTone();
    lcd.clear();
}

void aWeld() // Auto weld
{
    if (currCtc == 0 && prevCtc == 1)
    {
        Serial.println(currCtc);
        Serial.println(prevCtc);
        Serial.println(" ");
        prevCtc = currCtc;
        Serial.println(currCtc);
        Serial.println(prevCtc);
        Serial.println(" ");
        myServo.attach(servoPin);
        digitalWrite(rdy, LOW);
        ServoStart();
        zeroCrossingFlag = false; // set flag false and wait for next zero crossing
        while (!zeroCrossingFlag)
        {
        };
        delayMicroseconds(tgr_dly);
        digitalWrite(TRIAC, HIGH);
        delay(w1Value); // preWeld time ms
        digitalWrite(TRIAC, LOW);
        delay(pause);
        zeroCrossingFlag = false; // set flag false and wait for next zero crossing
        while (!zeroCrossingFlag)
        {
        };
        delayMicroseconds(tgr_dly);
        digitalWrite(TRIAC, HIGH);
        delay(WeldTime);
        digitalWrite(TRIAC, LOW);
    }
    ServoReturn();
    myServo.detach();
    weldTone();
}

void WeldExit() // Interrupt to exit Auto Weld
{
    weldExitFlag = true;
}

void setFlag()
{
    zeroCrossingFlag = true; // interrupt sets flag true
}

void ServoStart() // Increments to start position from Finish
{
    for (int i = SrvPotMap1; i <= SrvPotMap2; i += 1)
    {
        myServo.attach(servoPin);
        myServo.write(i);
        delay(5);
    }
}

void ServoReturn() // Increments to Finish position from Start
{
    for (int i = SrvPotMap2; i >= SrvPotMap1; i -= 1)
    {
        myServo.write(i);
        delay(5);
    }
}

int clearSelectPointer(int checkPointer)
{
    switch (checkPointer)
    {
    case 1:                // for select 1
        lcd.setCursor(0, 1); // 2
        lcd.print(" ");
        lcd.setCursor(8, 1); // 3
        lcd.print(" ");
        break;
    case 2:                // for select 2
        lcd.setCursor(0, 0); // 1
        lcd.print(" ");
        lcd.setCursor(8, 1); // 3
        lcd.print(" ");
        break;
    case 3:                // for select 3
        lcd.setCursor(0, 0); // 1
        lcd.print(" ");
        lcd.setCursor(0, 1); // 2
        lcd.print(" ");
        break;
    case 4:
        lcd.setCursor(0, 0); // 1
        lcd.print(" ");
        lcd.setCursor(0, 1); // 2
        lcd.print(" ");
        lcd.setCursor(8, 1); //3
        lcd.print(" ");
        break;
    }
    return (checkPointer);
}
// ------------------------------------------------ END OF FUNCTIONS --------------------------
void loop()
{
    while (!zeroCrossingFlag) //&& (millis() - startTime < timeCheck))
    {
        /* hang inside while loop until either zeroCrossFlag or timeout occurs
          both conditions need to be met to stay in while loop
        */
    }
    lcd.setCursor(1, 0);
    lcd.print("W1:");
    lcd.print(w1Value);
    lcd.setCursor(1, 1);
    lcd.print("W2:");
    lcd.print(WeldTime);
    lcd.setCursor(9, 0);
    lcd.print("T:");
    lcd.print(String(thermistor->readCelsius()));
    lcd.setCursor(9, 1);
    lcd.print("P:");
    digitalWrite(rdy, HIGH);

    ENC_SWstate = digitalRead(ENC_SW);
    if (ENC_SWstate != prevENC_SWstate)
    {
        if (ENC_SWstate == LOW)
        {
            Counter1 = w1Value / 10 << 1;

            Counter++;
            confMenu = 1; /*
      Serial.print("Pass:");
      Serial.println(Counter);
      Serial.print("Counter:");
      Serial.println(Counter1);
      Serial.print("W1:");
      Serial.println(w1Value);
      Serial.print("W2:");
      Serial.println(WeldTime);
      Serial.print("pValue:");
      Serial.println(pValue);*/
        }
    }
    prevENC_SWstate = ENC_SWstate;

    while (confMenu == 1)
    {
        ENC_SWstate = digitalRead(ENC_SW);
        if (ENC_SWstate != prevENC_SWstate)
        {
            if (ENC_SWstate == LOW)
            {
                select += 1;
                select = select % 4;
                /*Serial.print("Select:");
                Serial.println(select);
                Serial.println(" ");*/
                if (select == 0)
                {
                    noInterrupts();
                    Counter1 = w1Value / 10 << 1;
                    interrupts();
                }
                if (select == 1)
                {
                    noInterrupts();
                    Counter1 = WeldTime / 10 << 1;
                    interrupts();
                }
                if (select == 2)
                {
                    noInterrupts();
                    Counter1 = pValue / 10 << 1;
                    interrupts();
                }
            }
            prevENC_SWstate = ENC_SWstate;
        }

        switch (select)
        {
        case 0: //W1
            clearSelectPointer(1);
            lcd.setCursor(0, 0);
            lcd.print(">");
            w1Value = readEncoder() % 6 * 10;
            if (w1Value <= 0)
            {
                w1Value = 0;
            }
            lcd.setCursor(1, 0);
            lcd.print("W1:");
            lcd.print(w1Value);
            lcd.print("  ");
            break;

        case 1: //W2
            clearSelectPointer(2);
            lcd.setCursor(0, 1);
            lcd.print(">");
            WeldTime = readEncoder() % 51 * 10;
            if (WeldTime <= 0)
            {
                WeldTime = 0;
            }
            lcd.setCursor(1, 1);
            lcd.print("W2:");
            lcd.print(WeldTime); //lcd.setCursor(5, 1);
            lcd.print("  ");
            break;

        case 2: //P
            clearSelectPointer(3);
            lcd.setCursor(8, 1);
            lcd.print(">");
            pValue = readEncoder() % 11 * 10;
            if (pValue <= 0)
            {
                pValue = 0;
            }
            lcd.setCursor(9, 1);
            lcd.print("P:");
            lcd.print(pValue);
            lcd.print("%");
            lcd.print("  ");
            break;
        default:
            clearSelectPointer(4);
            confMenu = 0;
            select = 0;
            break;
        }
    }

    while (weldExitFlag == false) // begin Auto Weld
    {
        zeroCrossingFlag = false;
        while (!zeroCrossingFlag)
        {
        };
        delayMicroseconds(8600); // Sense voltage (after zero cross). higher number, lower voltage.
        digitalWrite(TRIAC, HIGH);
        delayMicroseconds(200);
        digitalWrite(TRIAC, LOW);
        cs_State = digitalRead(cs);
        currCS_State = cs_State;
        if (currCS_State == prevCS_State)
        {
            ctc = 0;
        }
        else
        {
            ctc = 1;
        }
        prevCS_State = currCS_State;
        currCtc = ctc;
        Serial.println(ctc);
        Serial.println(prevCtc);
        Serial.println(" ");
        if (currCtc != prevCtc)
        {
            if (currCtc == LOW && prevCtc == HIGH)
            {
                delay(300);
                aWeld();
            }
            prevCtc = currCtc;
        }
        buttonState = digitalRead(buttonState);
        previousButtonState = buttonState;
        currCtc = prevCtc;
    } // End Auto weld

    if (zeroCrossingFlag)
        // exit while loop due to flag set
    {
        zeroCrossingFlag = false;
    }

    switch (checkButton())
    {
    case shortPress:
        lcd.clear();
        lcd.print("Welding....");
        Weld();
        break;
    case longPress:
        lcd.clear();
        lcd.setCursor(0, 0);
        lcd.print("Auto Weld");
        delay(800);
        lcd.clear();
        weldExitFlag = false;
        break;
    case longerPress:
        break;
    }
}
// end of Loop
byte checkButton()
{
    byte event = 0;
    buttonState = digitalRead(buttonPin);
    // button pressed
    if (buttonState == LOW && previousButtonState == HIGH)
    {
        delay(20);                            // blocking debounce routine
        buttonState = digitalRead(buttonPin); // read button again
        if (buttonState == LOW && previousButtonState == HIGH)
        {
            buttonPressStartTimeStamp = millis();
            startTimeout = true;
        }
    }
    // button released
    if (buttonState == HIGH && previousButtonState == LOW)
    {
        delay(20);                            // blocking debounce routine
        buttonState = digitalRead(buttonPin); // read button again
        if (buttonState == HIGH && previousButtonState == LOW)
        {
            buttonPressDuration = (millis() - buttonPressStartTimeStamp);
            startTimeout = false; // duration determined no timeout required
        }
    }

    if (buttonPressDuration > 0 && buttonPressDuration <= shortTime)
    {
        event = shortPress;
        buttonPressDuration = 0;
    }

    if (buttonPressDuration > longTime && buttonPressDuration <= longerTime)
    {
        event = longPress;
        buttonPressDuration = 0;
        previousButtonState = buttonState;
    }
    // button not released and still timing
    if (buttonState == LOW && startTimeout == true && (millis() - buttonPressStartTimeStamp) > longerTime)
    {
        event = longerPress;
        digitalWrite(rdy, LOW);
        startTimeout = false;
    }
    buttonPressDuration = 0;
    previousButtonState = buttonState;
    prevENC_SWstate = ENC_SWstate;
    return event;
}

 

I haven't traced all the logic around these variables yet, so I could be wrong, but usually when you're keeping a pair of variables to track current and previous states of an input, you'd do the opposite at the end of your loop - I'd expect to see "prevCtc=currCtc" at that point, not the other way around.

can't seem to get it right. I get a bit confused with pin state within nested conditions.
Mod edit: added C language extension to code tag i.e. code=C between the brackets. Hope that helps. JohnInTX

while (weldExitFlag == false) // begin Auto Weld
  {
    zeroCrossingFlag = false;
    while (!zeroCrossingFlag)
    {
    };
    delayMicroseconds(8600); // Sense voltage (after zero cross). higher number, lower voltage.
    digitalWrite(TRIAC, HIGH);
    delayMicroseconds(200);
    digitalWrite(TRIAC, LOW);
    cs_State = digitalRead(cs);
    currCS_State = cs_State;
    if (currCS_State == prevCS_State)
    {
      ctc = 0;
    }
    else
    {
      ctc = 1;
    }
    prevCS_State = currCS_State; // change CS_State
    Serial.println(ctc);
    currCtc = ctc;
    if (currCtc != prevCtc)
    {
      if (currCtc == LOW && prevCtc == HIGH)
      {
        delay(500);
        aWeld();
      }
       prevCtc = currCtc;
    }
    buttonState = digitalRead(buttonPin);
    previousButtonState = buttonState;
  } // End Auto weld

that did not work. i really get confused when determining the state of a button with several conditions.

 

This is solved.

When exiting the While loop at line 35. The currCtc was HIGH so added two line to set them to '0' in the main loop.

ctc =0;
prevCtc =0;

 

This is solved.

When exiting the While loop at line 35. The currCtc was HIGH so added two line to set them to '0' in the main loop.

ctc =0;
prevCtc =0;

Excellent! I'm glad you got it figured out. Well done!