Fix DDP streaming and capture thread safety

- Fix WLED DDP config: use lor=0 (live overrides effects), remove
  live flag (read-only, causes issues on 0.15.x), disable PUSH flag
  which broke rendering on WLED 0.15.x
- Use dedicated single-thread executor for capture engine calls to
  fix thread-local state issues with BetterCam/MSS/DXcam
- Sync processor state on stream/template change even when stopped,
  preventing stale engine references on next start
- Add diagnostic logging for frame sends and DDP packets

Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>

server/src/wled_controller/api/routes.py

@@ -427,14 +427,13 @@ async def update_device(
             picture_stream_id=update_data.picture_stream_id,
         )
 
-        # Hot-swap: If stream/template changed and device was processing, restart it
+        # Sync processor state when stream/template changed
-        if (stream_changed or template_changed) and was_processing:
+        if stream_changed or template_changed:
+            if was_processing:
+                # Hot-swap: restart with new settings
                 logger.info(f"Hot-swapping stream/template for device {device_id}")
                 try:
-                # Stop current processing
                     await manager.stop_processing(device_id)
-
-                # Update processor with new settings
                     manager.remove_device(device_id)
                     manager.add_device(
                         device_id=device.id,
@@ -445,14 +444,22 @@ async def update_device(
                         capture_template_id=device.capture_template_id,
                         picture_stream_id=device.picture_stream_id,
                     )
-
-                # Restart processing
                     await manager.start_processing(device_id)
                     logger.info(f"Successfully hot-swapped stream/template for device {device_id}")
-
                 except Exception as e:
                     logger.error(f"Error during template hot-swap: {e}")
-                # Device is stopped but updated - user can manually restart
+            else:
+                # Not processing — update processor state so next start uses new values
+                manager.remove_device(device_id)
+                manager.add_device(
+                    device_id=device.id,
+                    device_url=device.url,
+                    led_count=device.led_count,
+                    settings=device.settings,
+                    calibration=device.calibration,
+                    capture_template_id=device.capture_template_id,
+                    picture_stream_id=device.picture_stream_id,
+                )
 
         return DeviceResponse(
             id=device.id,

server/src/wled_controller/core/ddp_client.py

@@ -207,9 +207,9 @@ class DDPClient:
             # Split into multiple packets if needed
             num_packets = (total_bytes + bytes_per_packet - 1) // bytes_per_packet
 
-            logger.debug(
+            logger.info(
-                f"Sending {len(pixels)} pixels ({total_bytes} bytes) "
+                f"DDP: Sending {len(pixels)} pixels ({total_bytes} bytes) "
-                f"in {num_packets} DDP packet(s)"
+                f"in {num_packets} packet(s) to {self.host}:{self.port}"
             )
 
             for i in range(num_packets):
@@ -221,10 +221,11 @@ class DDPClient:
                 # Increment sequence number
                 self._sequence = (self._sequence + 1) % 256
 
-                # Build and send packet (set PUSH on last packet)
+                # Build and send packet (no PUSH flag — WLED 0.15.x
+                # handles DDP without it; adding PUSH broke rendering)
                 packet = self._build_ddp_packet(
                     chunk, offset=start,
-                    sequence=self._sequence, push=is_last,
+                    sequence=self._sequence, push=False,
                 )
                 self._transport.sendto(packet)
 

server/src/wled_controller/core/processor_manager.py

@@ -1,6 +1,7 @@
 """Processing manager for coordinating screen capture and WLED updates."""
 
 import asyncio
+import concurrent.futures
 import time
 from dataclasses import dataclass, field
 from datetime import datetime
@@ -115,6 +116,10 @@ class ProcessorState:
     static_image: Optional[np.ndarray] = None
     image_pool: Optional[ImagePool] = None
     filter_instances: Optional[List[PostprocessingFilter]] = None
+    # Dedicated single-thread executor for capture engine calls.
+    # Capture libraries (BetterCam, MSS, DXcam) use thread-local state,
+    # so all calls must run on the same thread.
+    capture_executor: Optional[concurrent.futures.ThreadPoolExecutor] = None
 
 
 class ProcessorManager:
@@ -416,11 +421,23 @@ class ProcessorManager:
                 engine_type = state.resolved_engine_type or "mss"
                 engine_config = state.resolved_engine_config or {}
                 engine = EngineRegistry.create_engine(engine_type, engine_config)
-                engine.initialize()
+
+                # Create a dedicated single-thread executor for capture calls.
+                # Capture libraries use thread-local state (DXGI contexts, GDI DCs)
+                # so initialize + capture + cleanup must all run on the same thread.
+                state.capture_executor = concurrent.futures.ThreadPoolExecutor(
+                    max_workers=1, thread_name_prefix=f"capture-{device_id}"
+                )
+                loop = asyncio.get_event_loop()
+                await loop.run_in_executor(state.capture_executor, engine.initialize)
+
                 state.capture_engine = engine
                 logger.info(f"Initialized capture engine for device {device_id}: {engine_type}")
             except Exception as e:
                 logger.error(f"Failed to initialize capture engine for device {device_id}: {e}")
+                if state.capture_executor:
+                    state.capture_executor.shutdown(wait=False)
+                    state.capture_executor = None
                 if state.wled_client:
                     await state.wled_client.disconnect()
                 raise RuntimeError(f"Failed to initialize capture engine: {e}")
@@ -476,8 +493,19 @@ class ProcessorManager:
             await state.wled_client.close()
             state.wled_client = None
 
-        # Cleanup capture engine
+        # Cleanup capture engine on the same dedicated thread it was created on
         if state.capture_engine:
+            if state.capture_executor:
+                loop = asyncio.get_event_loop()
+                try:
+                    await loop.run_in_executor(
+                        state.capture_executor, state.capture_engine.cleanup
+                    )
+                except Exception as e:
+                    logger.warning(f"Error cleaning up capture engine: {e}")
+                state.capture_executor.shutdown(wait=False)
+                state.capture_executor = None
+            else:
                 state.capture_engine.cleanup()
             state.capture_engine = None
 
@@ -524,6 +552,8 @@ class ProcessorManager:
 
         frame_time = 1.0 / target_fps
         fps_samples = []
+        loop = asyncio.get_event_loop()
+        capture_executor = state.capture_executor  # dedicated single-thread executor
 
         def _apply_filters(image):
             """Apply all postprocessing filters to the captured image."""
@@ -550,13 +580,16 @@ class ProcessorManager:
                             image=state.static_image.copy(), width=w, height=h, display_index=-1
                         )
                     else:
-                        capture = await asyncio.to_thread(
+                        capture = await loop.run_in_executor(
+                            capture_executor,
                             state.capture_engine.capture_display,
                             display_index
                         )
 
                     # Skip processing if no new frame (screen unchanged)
                     if capture is None:
+                        if state.metrics.frames_processed == 0:
+                            logger.info(f"Capture returned None for {device_id} (no new frame yet)")
                         await asyncio.sleep(frame_time)
                         continue
 
@@ -585,6 +618,8 @@ class ProcessorManager:
 
                     # Update metrics
                     state.metrics.frames_processed += 1
+                    if state.metrics.frames_processed <= 3 or state.metrics.frames_processed % 100 == 0:
+                        logger.info(f"Frame {state.metrics.frames_processed} sent for {device_id} ({len(led_colors)} LEDs, bri={brightness_value})")
                     state.metrics.last_update = datetime.utcnow()
                     state.previous_colors = led_colors
 

server/src/wled_controller/core/wled_client.py

@@ -107,14 +107,18 @@ class WLEDClient:
                     self._ddp_client.set_buses(info.buses)
                 await self._ddp_client.connect()
 
-                # Turn on the device and disable Audio Reactive mode for DDP
+                # Configure device for DDP streaming:
+                # - Turn on, set lor=0 (live data overrides effects),
+                #   and disable Audio Reactive.
+                # - Do NOT set live — it's read-only and causes issues on WLED 0.15.x.
+                #   DDP packets automatically enter realtime mode.
                 try:
                     await self._request("POST", "/json/state", json_data={
                         "on": True,
-                        "live": True,
+                        "lor": 0,
                         "AudioReactive": {"on": False}
                     })
-                    logger.debug("Turned on device and enabled live mode for DDP streaming")
+                    logger.info("Configured device for DDP streaming")
                 except Exception as e:
                     logger.warning(f"Could not configure device for DDP: {e}")