From 272d4fc0ad1006e17972491986aab558f83f4476 Mon Sep 17 00:00:00 2001
From: Kasim Necdet Percinel <kasim.n.percinel@nasa.gov>
Date: Wed, 13 May 2026 18:19:29 +0000
Subject: [PATCH 1/6] add logging per chunk, and put chunk size to 50 in config

---
 settings/Config.Example.ini                   |  5 +++
 src/Config.php                                |  7 ++--
 src/Event/Api/EventsApi.php                   | 23 +++++++++++--
 src/Event/Api/EventsApiInterface.php          |  4 ++-
 src/Movie/HelioviewerMovie.php                | 34 ++++++++++++++++---
 tests/autoload.php                            |  8 +++++
 .../events/api/GetEventsBatchTest.php         |  4 +--
 7 files changed, 72 insertions(+), 13 deletions(-)

diff --git a/settings/Config.Example.ini b/settings/Config.Example.ini
index d9f907838..64fd3ce96 100644
--- a/settings/Config.Example.ini
+++ b/settings/Config.Example.ini
@@ -91,6 +91,11 @@ events_api_url = "https://events.helioviewer.org"
 ; Timeout in seconds for Events API requests
 events_api_timeout = 10
 
+; Number of timestamps per Events API batch request when building a movie.
+; Smaller = faster individual requests, more requests total; larger = fewer
+; round-trips but slower per request. 50 is a balanced default.
+event_api_events_per_frame_chunksize = 50
+
 [movie_params]
 ; FFmpeg location
 ffmpeg = ffmpeg
diff --git a/src/Config.php b/src/Config.php
index abc9b6215..d48df1226 100644
--- a/src/Config.php
+++ b/src/Config.php
@@ -18,7 +18,8 @@ class Config {
 
     private $_bools  = array('disable_cache', 'enable_statistics_collection', 'db_events','sentry_enabled');
     private $_ints   = array('build_num', 'ffmpeg_max_threads',
-                             'max_jpx_frames', 'max_movie_frames');
+                             'max_jpx_frames', 'max_movie_frames',
+                             'event_api_events_per_frame_chunksize');
     private $_floats = array('events_api_timeout');
     private $config;
 
@@ -86,7 +87,9 @@ private function _fixTypes() {
 
         // integers
         foreach ($this->_ints as $int) {
-            $this->config[$int] = (int)$this->config[$int];
+            if (isset($this->config[$int])) {
+                $this->config[$int] = (int)$this->config[$int];
+            }
         }
 
         // floats
diff --git a/src/Event/Api/EventsApi.php b/src/Event/Api/EventsApi.php
index ae50b2f4c..fc085c228 100644
--- a/src/Event/Api/EventsApi.php
+++ b/src/Event/Api/EventsApi.php
@@ -156,7 +156,7 @@ public function getDistributions(string $size, int $fromTimestamp, int $toTimest
     }
 
     /** {@inheritdoc} */
-    public function getEventsBatch(array $timestamps, array $sources): array
+    public function getEventsBatch(array $timestamps, array $sources, int $chunkSize = 50, string $logLabel = ''): array
     {
         // Only allow known sources
         $validSources = self::filterSources($sources);
@@ -166,9 +166,12 @@ public function getEventsBatch(array $timestamps, array $sources): array
         if (empty($timestamps)) {
             return [];
         }
+        if ($chunkSize < 1) {
+            $chunkSize = 50;
+        }
 
         $sourcesParam = implode('::', $validSources);
-        $chunks = array_chunk($timestamps, 150);
+        $chunks = array_chunk($timestamps, $chunkSize);
         $url = "/helioviewer/events/{$sourcesParam}/observations";
 
         // Closure to fetch a single chunk of timestamps
@@ -193,12 +196,26 @@ public function getEventsBatch(array $timestamps, array $sources): array
             }
         };
 
+        $logChunk = function (int $i, int $total, int $size, int $elapsedMs) use ($logLabel) {
+            if ($logLabel === '') {
+                return;
+            }
+            error_log(sprintf(
+                "[%s] EventsApi chunk %d/%d (%d timestamps) took %dms",
+                $logLabel, $i + 1, $total, $size, $elapsedMs
+            ));
+        };
+
         // First chunk returns full response (event_types + events + observations)
+        $start = microtime(true);
         $merged = $fetchChunk($chunks[0]);
+        $logChunk(0, count($chunks), count($chunks[0]), (int) round((microtime(true) - $start) * 1000));
 
         // Subsequent chunks only add new observations (event_types and events are the same)
         for ($i = 1; $i < count($chunks); $i++) {
+            $start = microtime(true);
             $chunk = $fetchChunk($chunks[$i]);
+            $logChunk($i, count($chunks), count($chunks[$i]), (int) round((microtime(true) - $start) * 1000));
             $merged['observations'] += $chunk['observations'];
         }
 
@@ -216,7 +233,7 @@ public function getEventsBatch(array $timestamps, array $sources): array
      */
     private function parseResponse($response): array
     {
-        $body = (string)$response->getBody();
+         $body = (string)$response->getBody();
         $data = json_decode($body, true);
 
         if (json_last_error() !== JSON_ERROR_NONE) {
diff --git a/src/Event/Api/EventsApiInterface.php b/src/Event/Api/EventsApiInterface.php
index c5d096c3d..a4adcd6fa 100644
--- a/src/Event/Api/EventsApiInterface.php
+++ b/src/Event/Api/EventsApiInterface.php
@@ -45,8 +45,10 @@ public function getDistributions(string $size, int $fromTimestamp, int $toTimest
      *
      * @param string[] $timestamps Array of observation datetime strings
      * @param string[] $sources Array of source names (e.g. ['HEK', 'CCMC', 'RHESSI'])
+     * @param int $chunkSize Max timestamps per upstream POST request
+     * @param string $logLabel Optional label prepended to per-chunk error_log lines (e.g. "Movie:Xp66n")
      * @return array Keyed by timestamp, each value is legacy-format event categories
      * @throws EventsApiException on API errors or unexpected responses
      */
-    public function getEventsBatch(array $timestamps, array $sources): array;
+    public function getEventsBatch(array $timestamps, array $sources, int $chunkSize = 50, string $logLabel = ''): array;
 }
diff --git a/src/Movie/HelioviewerMovie.php b/src/Movie/HelioviewerMovie.php
index 557f0ff82..899e8c9e4 100644
--- a/src/Movie/HelioviewerMovie.php
+++ b/src/Movie/HelioviewerMovie.php
@@ -520,21 +520,45 @@ private function _buildMovieFrames($watermark) {
             'switchSources' => $this->switchSources
         );
 
-        // Preload events for all frames in 1-2 batch requests
+        // Preload events for all frames. EventsApi handles chunking internally
+        // using the configured chunk size and labels per-chunk logs with the movie ID.
         $timestamps = $this->_getTimeStamps();
         $eventsApi = new EventsApi();
         $batchResponse = [];
         $sources = $this->_eventsManager->getSources();
+        $movieId = $this->publicId;
+
+        error_log(sprintf(
+            "[Movie:%s] Starting movie build, frames=%d, sources=%s",
+            $movieId,
+            count($timestamps),
+            $sources ? implode(',', $sources) : '(none)'
+        ));
 
         if ($this->_eventsManager->hasEvents()) {
+            $chunkSize = defined('HV_EVENT_API_EVENTS_PER_FRAME_CHUNKSIZE')
+                ? HV_EVENT_API_EVENTS_PER_FRAME_CHUNKSIZE
+                : 50;
+
+            $totalStart = microtime(true);
             try {
-                $batchResponse = $eventsApi->getEventsBatch($timestamps, $sources);
+                $batchResponse = $eventsApi->getEventsBatch(
+                    $timestamps,
+                    $sources,
+                    $chunkSize,
+                    "Movie:{$movieId}"
+                );
             } catch (EventsApiException $e) {
-                error_log("[Movie:{$this->publicId}] Batch events failed: " . $e->getMessage());
-            } catch (\Exception $e) {
-                error_log("[Movie:{$this->publicId}] Unexpected error fetching events: " . $e->getMessage());
+                error_log("[Movie:{$movieId}] Batch events failed: " . $e->getMessage());
+            } catch (\Throwable $e) {
+                error_log("[Movie:{$movieId}] Unexpected error fetching events: " . $e->getMessage());
                 Sentry::capture($e);
             }
+            $totalMs = (int) round((microtime(true) - $totalStart) * 1000);
+            error_log(sprintf(
+                "[Movie:%s] all event chunks done in %dms (%d frames)",
+                $movieId, $totalMs, count($timestamps)
+            ));
         }
 
         $options['batchEventResponse'] = $batchResponse;
diff --git a/tests/autoload.php b/tests/autoload.php
index e4d5c0395..32e7130ea 100644
--- a/tests/autoload.php
+++ b/tests/autoload.php
@@ -9,6 +9,14 @@
  * included in every main php source file...).
  */
 
+// Redirect PHP's error_log destination off stderr. PHPUnit's
+// @runInSeparateProcess tests use stderr as their IPC channel with the child
+// process, so any stray error_log() call in production code corrupts the IPC
+// and surfaces as a PHPUnit\Framework\Exception. Sending to a temp file keeps
+// the messages around for inspection without breaking the tests.
+ini_set('log_errors', '1');
+ini_set('error_log', sys_get_temp_dir() . '/helioviewer-test.log');
+
 // Load Helioviewer Configuration. This defines all the HV_* variables
 // seen throughout the project
 require_once __DIR__ . '/../src/Config.php';
diff --git a/tests/unit_tests/events/api/GetEventsBatchTest.php b/tests/unit_tests/events/api/GetEventsBatchTest.php
index c28ef9a2e..a871248ae 100644
--- a/tests/unit_tests/events/api/GetEventsBatchTest.php
+++ b/tests/unit_tests/events/api/GetEventsBatchTest.php
@@ -88,7 +88,7 @@ public function testItShouldPaginateTimestampsAt150(): void
 
         $this->mockLegacyEvents->method('convertAll')->willReturn([]);
 
-        $this->eventsApi->getEventsBatch($timestamps, ['HEK']);
+        $this->eventsApi->getEventsBatch($timestamps, ['HEK'], 150);
     }
 
     public function testItShouldThrowAndCaptureSentryOnHttpError(): void
@@ -156,6 +156,6 @@ public function testItShouldMergeObservationsAcrossChunksAndPassToConverter(): v
             }))
             ->willReturn([]);
 
-        $this->eventsApi->getEventsBatch($timestamps, ['HEK']);
+        $this->eventsApi->getEventsBatch($timestamps, ['HEK'], 150);
     }
 }

From 3dd18b4efd7776d5a0b363affd445cd0d64a1239 Mon Sep 17 00:00:00 2001
From: Kasim Necdet Percinel <kasim.n.percinel@nasa.gov>
Date: Wed, 13 May 2026 18:33:22 +0000
Subject: [PATCH 2/6] fix typo comment

---
 src/Event/Api/EventsApi.php | 2 +-
 1 file changed, 1 insertion(+), 1 deletion(-)

diff --git a/src/Event/Api/EventsApi.php b/src/Event/Api/EventsApi.php
index fc085c228..04431c549 100644
--- a/src/Event/Api/EventsApi.php
+++ b/src/Event/Api/EventsApi.php
@@ -233,7 +233,7 @@ public function getEventsBatch(array $timestamps, array $sources, int $chunkSize
      */
     private function parseResponse($response): array
     {
-         $body = (string)$response->getBody();
+        $body = (string)$response->getBody();
         $data = json_decode($body, true);
 
         if (json_last_error() !== JSON_ERROR_NONE) {

From 0760d48888e40311589aa7d98766c1a41aafb314 Mon Sep 17 00:00:00 2001
From: Kasim Necdet Percinel <kasim.n.percinel@nasa.gov>
Date: Wed, 13 May 2026 19:05:35 +0000
Subject: [PATCH 3/6] fix early status check of movie, craete frames directory
 early

---
 src/Movie/HelioviewerMovie.php | 14 ++++++++++++--
 1 file changed, 12 insertions(+), 2 deletions(-)

diff --git a/src/Movie/HelioviewerMovie.php b/src/Movie/HelioviewerMovie.php
index 899e8c9e4..4ffd48d90 100644
--- a/src/Movie/HelioviewerMovie.php
+++ b/src/Movie/HelioviewerMovie.php
@@ -423,9 +423,11 @@ public function getCurrentFrame() {
             }
         }
 
-        // Do not call closedir boolean if we can not open directory
+        // The frames directory may not exist yet when getMovieStatus is polled
+        // very early in PROCESSING -- before _buildMovieFrames has created it.
+        // Treat that as "0 frames written so far" instead of throwing.
         if (false === $handle) {
-            throw new \Exception("Could not find requested movie frames");
+            return 0;
         }
 
         @closedir($handle);
@@ -502,6 +504,14 @@ private function _buildMovieFrames($watermark) {
 
         $this->_dbSetup();
 
+        // Pre-create the frames directory so getMovieStatus polls that arrive
+        // while the events prefetch is still running don't see a missing dir
+        // (status flips to PROCESSING the moment build() is invoked).
+        $framesDir = $this->directory . 'frames';
+        if (!@file_exists($framesDir)) {
+            @mkdir($framesDir, 0775, true);
+        }
+
         $frameNum = 0;
 
         // Movie frame parameters

From bf7f7f9ac3b0219b95499a437079343cc7b2bed6 Mon Sep 17 00:00:00 2001
From: Kasim Necdet Percinel <kasim.n.percinel@nasa.gov>
Date: Wed, 13 May 2026 19:12:03 +0000
Subject: [PATCH 4/6] rename new chunksize configuration name, align with old
 config names

---
 settings/Config.Example.ini    | 2 +-
 src/Config.php                 | 2 +-
 src/Movie/HelioviewerMovie.php | 4 ++--
 3 files changed, 4 insertions(+), 4 deletions(-)

diff --git a/settings/Config.Example.ini b/settings/Config.Example.ini
index 64fd3ce96..5cd878c86 100644
--- a/settings/Config.Example.ini
+++ b/settings/Config.Example.ini
@@ -94,7 +94,7 @@ events_api_timeout = 10
 ; Number of timestamps per Events API batch request when building a movie.
 ; Smaller = faster individual requests, more requests total; larger = fewer
 ; round-trips but slower per request. 50 is a balanced default.
-event_api_events_per_frame_chunksize = 50
+events_api_events_per_frame_chunksize = 50
 
 [movie_params]
 ; FFmpeg location
diff --git a/src/Config.php b/src/Config.php
index d48df1226..d7d29fabc 100644
--- a/src/Config.php
+++ b/src/Config.php
@@ -19,7 +19,7 @@ class Config {
     private $_bools  = array('disable_cache', 'enable_statistics_collection', 'db_events','sentry_enabled');
     private $_ints   = array('build_num', 'ffmpeg_max_threads',
                              'max_jpx_frames', 'max_movie_frames',
-                             'event_api_events_per_frame_chunksize');
+                             'events_api_events_per_frame_chunksize');
     private $_floats = array('events_api_timeout');
     private $config;
 
diff --git a/src/Movie/HelioviewerMovie.php b/src/Movie/HelioviewerMovie.php
index 4ffd48d90..9cc7dedbf 100644
--- a/src/Movie/HelioviewerMovie.php
+++ b/src/Movie/HelioviewerMovie.php
@@ -546,8 +546,8 @@ private function _buildMovieFrames($watermark) {
         ));
 
         if ($this->_eventsManager->hasEvents()) {
-            $chunkSize = defined('HV_EVENT_API_EVENTS_PER_FRAME_CHUNKSIZE')
-                ? HV_EVENT_API_EVENTS_PER_FRAME_CHUNKSIZE
+            $chunkSize = defined('HV_EVENTS_API_EVENTS_PER_FRAME_CHUNKSIZE')
+                ? HV_EVENTS_API_EVENTS_PER_FRAME_CHUNKSIZE
                 : 50;
 
             $totalStart = microtime(true);

From 70700a66267bd0039ec0c34adeea7d387ed68150 Mon Sep 17 00:00:00 2001
From: Kasim Necdet Percinel <kasim.n.percinel@nasa.gov>
Date: Wed, 13 May 2026 19:24:27 +0000
Subject: [PATCH 5/6] add log if chunk requests failing, movie maker starts to
 make requests per frame again

---
 src/Image/Composite/HelioviewerCompositeImage.php | 1 +
 1 file changed, 1 insertion(+)

diff --git a/src/Image/Composite/HelioviewerCompositeImage.php b/src/Image/Composite/HelioviewerCompositeImage.php
index 2f6379af5..ea1e44866 100644
--- a/src/Image/Composite/HelioviewerCompositeImage.php
+++ b/src/Image/Composite/HelioviewerCompositeImage.php
@@ -646,6 +646,7 @@ private function _addEventLayer($imagickImage) {
 
         // Fetch events via batch (movies have pre-fetched, screenshots fetch for single timestamp)
         if (empty($this->batchEventResponse)) {
+            error_log("[date={$this->date}] batchEventResponse empty, fetching single timestamp");
             try {
                 $this->batchEventResponse = $this->eventsApi->getEventsBatch(
                     [$this->date],

From 46ae577df1e0b85497fa72aa65f0d26762d93db0 Mon Sep 17 00:00:00 2001
From: Kasim Necdet Percinel <kasim.n.percinel@nasa.gov>
Date: Wed, 13 May 2026 20:14:20 +0000
Subject: [PATCH 6/6] add more logging for edge cases of event selections

---
 src/Movie/HelioviewerMovie.php | 7 +++++--
 1 file changed, 5 insertions(+), 2 deletions(-)

diff --git a/src/Movie/HelioviewerMovie.php b/src/Movie/HelioviewerMovie.php
index 9cc7dedbf..0b7cecf00 100644
--- a/src/Movie/HelioviewerMovie.php
+++ b/src/Movie/HelioviewerMovie.php
@@ -539,10 +539,11 @@ private function _buildMovieFrames($watermark) {
         $movieId = $this->publicId;
 
         error_log(sprintf(
-            "[Movie:%s] Starting movie build, frames=%d, sources=%s",
+            "[Movie:%s] Starting movie build, frames=%d, sources=%s, hasEvents=%s",
             $movieId,
             count($timestamps),
-            $sources ? implode(',', $sources) : '(none)'
+            $sources ? implode(',', $sources) : '(none)',
+            $this->_eventsManager->hasEvents() ? 'true' : 'false'
         ));
 
         if ($this->_eventsManager->hasEvents()) {
@@ -569,6 +570,8 @@ private function _buildMovieFrames($watermark) {
                 "[Movie:%s] all event chunks done in %dms (%d frames)",
                 $movieId, $totalMs, count($timestamps)
             ));
+        } else {
+            error_log("[Movie:{$movieId}] No event types selected, skipping EventsApi request");
         }
 
         $options['batchEventResponse'] = $batchResponse;