Mirror printer state alert routing

Removes the apps/brochure/ directory entirely from the bluejay-infra
ApplicationSet glob. ArgoCD will:

  1. See infra-brochure has no git source -> mark for delete
  2. Prune the brochure namespace + Deployment + Service + Certificate
     + Secret + IngressRoute (all generated from the now-gone
     apps/brochure/brochure.yaml)
  3. Remove the infra-brochure Application from argocd ns

Operator decision 2026-05-19 (follow-up to 09387f9 ARCHIVED banner
commit): "Yes, prune argo for brochure. Probably fully deleted there."

The brochure subdomain project was a planning-chain misinterpretation
of "make TtsReader + AI Station production-ready" — see
memory/project_brochure_split_misinterpretation_archived_2026_05_19.md
in FlowerCore.Notes for the full decision record.

Reusable artifacts that were the operator's archive concern stay alive
in their actual homes:

- FlowerCore.Intranet.Web PR #8 content-NuGet carve-out: still in
  Intranet's master, may transfer to TtsReader / AI Station prod work
- Sprint 32 Cl-5 substrate (public-twin design ideas): SUPERSEDED banner
  in-place in FlowerCore.Notes docs/standards/, history preserved
- magpie-doc-writer + wren-walkthrough skill output: unchanged in
  Intranet's flowercore-whats-new/walkthroughs/galleries directories

Companion Notes-side commit updates the "scaled to 0 + ARCHIVED banner"
language in mvp-readiness.html + fleet-roadmap-2026-05-19-sprint36-v2.md
+ memory record to reflect full deletion instead.

Wrong-codebase image localhost/fc-brochure-web:v20260524-sprint32 is
being removed from rke2-server / rke2-agent1 / rke2-agent2 in a
follow-up step (reclaims ~800MB per node).

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>

apps/brochure/README.md

@@ -1,27 +0,0 @@
-# FlowerCore Brochure
-
-`apps/brochure` hosts the public brochure split from `FlowerCore.Intranet.Web`.
-ArgoCD's `apps/*` ApplicationSet will create `infra-brochure` after this
-directory lands on `main`.
-
-## Runtime
-
-- Host: `https://brochure.flowercore.io`
-- Namespace: `brochure`
-- Deployment: `brochure-web`
-- Image: `localhost/fc-brochure-web:v20260524-sprint32`
-- Port: `8080`
-- Public route method allowlist: `GET` and `HEAD`
-
-## Operator Actions
-
-1. Publish and import `localhost/fc-brochure-web:v20260524-sprint32` to every
-   RKE2 node before sync, using the same podman save + `ctr images import`
-   flow as the Intranet deployment.
-2. Create the Cloudflare DNS record for `brochure.flowercore.io` pointing at
-   the FlowerCore public edge.
-3. Verify `infra-brochure` appears in ArgoCD, the certificate becomes Ready,
-   and `GET https://brochure.flowercore.io/` returns `200`.
-
-The route intentionally does not expose `/ops/*` or `/admin/*`; the Brochure
-web app returns `404` for those paths and Traefik only forwards read methods.

apps/brochure/brochure.yaml

@@ -1,131 +0,0 @@
-# FlowerCore Brochure public host
-#
-# Thin Blazor host for public What's New, walkthrough, and gallery content
-# carved out of FlowerCore.Intranet.Web. The ApplicationSet creates
-# infra-brochure from this directory after merge.
----
-apiVersion: v1
-kind: Namespace
-metadata:
-  name: brochure
-  labels:
-    app.kubernetes.io/part-of: flowercore
----
-apiVersion: apps/v1
-kind: Deployment
-metadata:
-  name: brochure-web
-  namespace: brochure
-  labels:
-    app: brochure-web
-    app.kubernetes.io/name: brochure-web
-    app.kubernetes.io/part-of: flowercore
-spec:
-  replicas: 1
-  revisionHistoryLimit: 3
-  selector:
-    matchLabels:
-      app: brochure-web
-  template:
-    metadata:
-      labels:
-        app: brochure-web
-        app.kubernetes.io/name: brochure-web
-        app.kubernetes.io/part-of: flowercore
-    spec:
-      containers:
-        - name: brochure-web
-          image: localhost/fc-brochure-web:v20260524-sprint32
-          imagePullPolicy: Never
-          ports:
-            - containerPort: 8080
-              name: http
-          env:
-            - name: ASPNETCORE_ENVIRONMENT
-              value: Production
-            - name: ASPNETCORE_URLS
-              value: "http://+:8080"
-          resources:
-            requests:
-              cpu: "25m"
-              memory: "128Mi"
-            limits:
-              cpu: "500m"
-              memory: "512Mi"
-          readinessProbe:
-            httpGet:
-              path: /health
-              port: http
-            initialDelaySeconds: 10
-            periodSeconds: 10
-          livenessProbe:
-            httpGet:
-              path: /health
-              port: http
-            initialDelaySeconds: 30
-            periodSeconds: 30
-          securityContext:
-            runAsNonRoot: true
-            runAsUser: 1654
-            runAsGroup: 1654
-            allowPrivilegeEscalation: false
-            readOnlyRootFilesystem: true
-            capabilities:
-              drop:
-                - ALL
-          volumeMounts:
-            - name: tmp
-              mountPath: /tmp
-      volumes:
-        - name: tmp
-          emptyDir: {}
----
-apiVersion: v1
-kind: Service
-metadata:
-  name: brochure-web
-  namespace: brochure
-  labels:
-    app: brochure-web
-    app.kubernetes.io/name: brochure-web
-    app.kubernetes.io/part-of: flowercore
-spec:
-  type: ClusterIP
-  selector:
-    app: brochure-web
-  ports:
-    - name: http
-      port: 8080
-      targetPort: http
----
-apiVersion: cert-manager.io/v1
-kind: Certificate
-metadata:
-  name: brochure-web-tls
-  namespace: brochure
-spec:
-  secretName: brochure-web-tls
-  issuerRef:
-    name: step-ca-acme
-    kind: ClusterIssuer
-  dnsNames:
-    - brochure.flowercore.io
-  duration: 720h
-  renewBefore: 240h
----
-apiVersion: traefik.io/v1alpha1
-kind: IngressRoute
-metadata:
-  name: brochure-web-public
-  namespace: brochure
-spec:
-  entryPoints:
-    - websecure
-  routes:
-    - match: Host(`brochure.flowercore.io`) && (Method(`GET`) || Method(`HEAD`))
-      kind: Rule
-      services:
-        - name: brochure-web
-          port: 8080
-  tls:
-    secretName: brochure-web-tls

apps/fc-devicemgmt/deployment-operator.yaml

@@ -47,7 +47,7 @@ spec:
         fsGroupChangePolicy: OnRootMismatch
       containers:
         - name: operator
-          image: localhost/fc-devicemgmt-operator:v20260512-cx5
+          image: localhost/fc-devicemgmt-operator:v20260519-sp34cl3-fix
           imagePullPolicy: Never
           ports:
             - name: metrics

apps/fc-devicemgmt/deployment-web.yaml

@@ -4,6 +4,22 @@
 # Sprint 9+ lane. This manifest is static-valid without requiring the image to
 # exist yet; import localhost/fc-devicemgmt-web:<tag> to all schedulable RKE2
 # nodes before letting ArgoCD sync a live rollout.
+#
+# SCALED TO 0 — 2026-05-19 morning-routine cleanup.
+# The Web pod cannot start until TWO upstream gaps close:
+#   1. MySQL DB instance `flowercore_devicemgmt` (user `fc_devicemgmt`) is
+#      provisioned via fc-mysql Manager. The cluster currently has ZERO
+#      MySqlInstanceCrds and no `mysql.fc-mysql.svc:3306` Service, so the
+#      deployment-web container env `FlowerCore__Database__Host=mysql.fc-mysql.svc`
+#      points at nothing. Provision via the fc-mysql Manager UI/REST/MCP.
+#   2. 1Password vault item `IAmWorkin/FlowerCore DeviceManagement Runtime`
+#      with 5 fields (DB-Password, mtls-ca.pem, mtls-client.crt, mtls-client.key,
+#      mtls-chain.pem) — see apps/fc-devicemgmt/1password-item.yaml. Mint mTLS
+#      from step-ca-agent ClusterIssuer per ADR-126; DB-Password must match the
+#      password configured for the MySQL user.
+# Re-enable: change replicas back to 2 after both gaps close. The image tag
+# in this file (v20260512-cx5) MAY also need a refresh — it predates the
+# Sprint 34 Cl-3 operator fix; Web may have an analogous bug.
 apiVersion: apps/v1
 kind: Deployment
 metadata:
@@ -20,7 +36,7 @@ metadata:
   annotations:
     flowercore.io/traceability-standard: k8s-pod-ownership-and-traceability-standard
 spec:
-  replicas: 2
+  replicas: 0
   revisionHistoryLimit: 3
   selector:
     matchLabels:

apps/monitoring/noc-monitoring.yaml

@@ -656,14 +656,15 @@ data:
               summary: "Print queue backlog on edge2 ({{ $value }} active jobs)"
               description: "CUPS has {{ $value }} active jobs queued. Possible printer jam, USB disconnect, or paper out."
 
-          # Paper roll lifecycle alerts (XL Track I, 2026-04-26).
-          # Source-of-truth gauge: print_paper_remaining_percent (Print.Web OTEL,
-          # hydrated on startup from the active PaperRoll row).
-          # alert_channel=thermal_print routes through irc-notify -> Print.Web
-          # /api/print/alert so the printer announces its own paper-out warning
-          # on its remaining paper. Self-referential humor + operator nudge.
+          # Printer hardware and paper-roll lifecycle alerts.
+          # print_printer_online: 1 when the transport is reachable/selected.
+          # print_printer_state enum: 0 unknown, 1 online, 2 offline,
+          # 3 paper_depleted, 4 jam, 5 head_error, 6 cover_open.
+          # Offline/jam/cover alerts stay IRC-only. Paper depleted and head
+          # error may route to the thermal digest only when the printer is
+          # online enough to make that useful.
           - alert: PrintPaperRollLow
-            expr: print_paper_remaining_percent{job="printweb-otel"} < 10 and print_paper_remaining_percent{job="printweb-otel"} > 5
+            expr: (print_paper_remaining_percent{job="printweb-otel"} < 10 and print_paper_remaining_percent{job="printweb-otel"} > 5) and print_printer_online{job="printweb-otel"} == 1
             for: 5m
             labels:
               severity: warning
@@ -672,15 +673,59 @@ data:
               summary: "Print roll low on edge2 ({{ $value | printf \"%.1f\" }}% remaining)"
               description: "NuPrint 210 paper roll has {{ $value | printf \"%.1f\" }}% remaining. Operator should load a fresh roll soon. Run /api/paper/status for the precise mm + estimated jobs left."
 
+          - alert: PrinterOfflineWarning
+            expr: print_printer_state{job="printweb-otel"} == 2
+            for: 2m
+            labels:
+              severity: warning
+              service: print-web
+              alert_channel: irc
+            annotations:
+              summary: "Print.Web printer offline on edge2"
+              description: "Print.Web reports the NuPrint 210 transport is offline or unreachable. IRC-only by design: do not thermal-print an alert when the thermal printer itself is offline."
+
           - alert: PrintPaperRollCritical
-            expr: print_paper_remaining_percent{job="printweb-otel"} <= 5
+            expr: print_printer_state{job="printweb-otel"} == 3 and print_printer_online{job="printweb-otel"} == 1
             for: 2m
             labels:
               severity: critical
               alert_channel: thermal_print
             annotations:
-              summary: "Print roll critical on edge2 ({{ $value | printf \"%.1f\" }}% remaining)"
-              description: "NuPrint 210 paper roll at {{ $value | printf \"%.1f\" }}% — load a new roll NOW. The 50ft roll has a ~12% red-stripe zone; once paper passes that, the printer can run dry mid-job."
+              summary: "Print paper depleted on edge2"
+              description: "NuPrint 210 reports paper depleted while the printer is still online. Load a new roll, drain the hardware buffer if needed, then replay DeadLetter jobs from /print-log."
+
+          - alert: PrinterJamWarning
+            expr: print_printer_state{job="printweb-otel"} == 4
+            for: 2m
+            labels:
+              severity: warning
+              service: print-web
+              alert_channel: irc
+            annotations:
+              summary: "Print.Web printer jam on edge2"
+              description: "Print.Web reports a paper/cutter jam state. IRC-only: clear the jam, drain the hardware buffer if bytes were queued, then retry affected jobs."
+
+          - alert: PrinterHeadErrorCritical
+            expr: print_printer_state{job="printweb-otel"} == 5
+            for: 2m
+            labels:
+              severity: critical
+              service: print-web
+              alert_channel: thermal_print
+            annotations:
+              summary: "Print.Web printer head error on edge2"
+              description: "Print.Web reports a thermal head or unrecoverable printer error. Critical routing may enter the thermal digest per existing policy; IRC remains the primary triage stream."
+
+          - alert: PrinterCoverOpenWarning
+            expr: print_printer_state{job="printweb-otel"} == 6
+            for: 2m
+            labels:
+              severity: warning
+              service: print-web
+              alert_channel: irc
+            annotations:
+              summary: "Print.Web printer cover open on edge2"
+              description: "Print.Web reports the printer cover/lid is open. IRC-only: close the cover and verify /api/print/status before retrying jobs."
 
           - alert: PrintJobDeadLetter
             expr: increase(print_jobs_dead_letter_total[15m]) > 0
@@ -1273,24 +1318,55 @@ metadata:
 data:
   notify.py: |
     #!/usr/bin/env python3
-    """HTTP->IRC alert relay with thermal printer forwarding for Grafana webhooks.
-    Listens on :9119, posts to #alerts on UnrealIRCd via raw IRC protocol.
-    Alerts tagged alert_channel=thermal_print also POST to Print.Web /api/print/alert.
+    """HTTP->IRC alert relay with thermal-printer DIGEST forwarding.
+
+    Listens on :9119, posts to #alerts on UnrealIRCd, forwards to Print.Web
+    /api/print/alert. Thermal printing is BATCHED into hourly digests by
+    default so the printer no longer spam-fires per Grafana webhook.
+
+    Routing (per Grafana webhook alert):
+      - IRC: always per-event (operator likes the stream)
+      - Thermal printer:
+          * severity in {critical,disaster,page} OR
+            label alert_channel=thermal_print_immediate -> print NOW
+          * label alert_channel=thermal_print -> enqueue into hourly digest
+          * everything else -> IRC only
+      - RESOLVED webhooks remove the alert from the digest buffer
+
+    Env vars (defaults preserve old behavior on first deploy):
+      THERMAL_PRINT_ENABLED  default "true"   - master kill switch
+      BATCH_INTERVAL_MIN     default "60"     - minutes between digest prints
+      BATCH_MAX_PENDING      default "50"     - force-flush threshold
+
+    HTTP surface:
+      POST /         - Grafana webhook entry
+      POST /flush    - manual digest flush (idempotent)
+      GET  /         - status + config + buffer depth + stats
     """
-    import json, socket, sys, time
+    import json, os, socket, sys, threading, time
+    from collections import defaultdict
+    from datetime import datetime, timezone
     from http.server import HTTPServer, BaseHTTPRequestHandler
     from urllib.request import Request, urlopen
-    from urllib.error import URLError
 
-    IRC_HOST = "unrealircd.irc.svc"  # short name: CoreDNS ndots:5 + iamworkin.lan template hijacks full .cluster.local (see memory)
-    IRC_PORT = 6667
-    IRC_NICK = "grafana-bot"
-    IRC_CHANNEL = "#alerts"
-    PRINT_WEB_URL = "http://10.0.57.16:5200/api/print/alert"
-    PRINT_ENABLED = True
+    THERMAL_PRINT_ENABLED = os.environ.get("THERMAL_PRINT_ENABLED", "true").lower() == "true"
+    BATCH_INTERVAL_MIN    = int(os.environ.get("BATCH_INTERVAL_MIN", "60"))
+    BATCH_MAX_PENDING     = int(os.environ.get("BATCH_MAX_PENDING", "50"))
+
+    IRC_HOST      = os.environ.get("IRC_HOST", "unrealircd.irc.svc")
+    IRC_PORT      = int(os.environ.get("IRC_PORT", "6667"))
+    IRC_NICK      = os.environ.get("IRC_NICK", "grafana-bot")
+    IRC_CHANNEL   = os.environ.get("IRC_CHANNEL", "#alerts")
+    PRINT_WEB_URL = os.environ.get("PRINT_WEB_URL", "http://10.0.57.16:5200/api/print/alert")
+
+    _buffer_lock = threading.Lock()
+    _buffer = {}   # fingerprint -> {"alert": dict, "first_seen": float, "last_seen": float}
+    _last_flush_time = time.time()
+    _stats = {"webhooks_received": 0, "irc_sent": 0, "print_immediate": 0,
+              "digest_flushed": 0, "buffer_dedup": 0, "buffer_added": 0,
+              "buffer_resolved": 0, "started_at": time.time()}
 
     def send_irc(message):
-        """Connect, handle PING, join, send, quit."""
         try:
             sock = socket.create_connection((IRC_HOST, IRC_PORT), timeout=15)
             sock.sendall(f"NICK {IRC_NICK}\r\n".encode())
@@ -1323,52 +1399,137 @@ data:
             time.sleep(0.5)
             sock.sendall(b"QUIT :alert delivered\r\n")
             sock.close()
+            _stats["irc_sent"] += 1
             return True
         except Exception as e:
             print(f"[irc-notify] IRC send failed: {e}", file=sys.stderr)
             return False
 
-    def send_thermal_print(alert):
-        if not PRINT_ENABLED: return
-        labels = alert.get("labels", {})
-        annotations = alert.get("annotations", {})
-        status = alert.get("status", "firing").upper()
-        summary = annotations.get("summary", "")
-        description = annotations.get("description", "")
-        runbook = annotations.get("runbook", "")
-        # Build a useful message: summary + description + runbook steps
-        parts = []
-        if summary: parts.append(summary)
-        if description and description != summary: parts.append(description)
-        if runbook: parts.append("STEPS: " + runbook)
-        message = " | ".join(parts) if parts else labels.get("alertname", "Unknown alert")
-        payload = {
-            "title": labels.get("alertname", "Unknown"),
-            "severity": labels.get("severity", "warning").capitalize(),
-            "host": labels.get("instance", labels.get("host", "unknown")),
-            "message": message,
-            "eventId": alert.get("fingerprint", ""),
-            "source": "Grafana",
-            "status": "RESOLVED" if status == "RESOLVED" else "PROBLEM",
-            "acknowledged": False
-        }
+    def post_thermal(payload, kind):
+        if not THERMAL_PRINT_ENABLED:
+            print(f"[irc-notify] thermal disabled; skip {kind} ({payload.get('title','?')[:40]})", file=sys.stderr)
+            return False
         try:
             req = Request(PRINT_WEB_URL, data=json.dumps(payload).encode("utf-8"),
                           headers={"Content-Type": "application/json"}, method="POST")
             resp = urlopen(req, timeout=10)
-            print(f"[irc-notify] Thermal print sent: {resp.read().decode()}", file=sys.stderr)
+            if kind == "immediate": _stats["print_immediate"] += 1
+            print(f"[irc-notify] thermal {kind} sent: {payload.get('title','?')[:50]}", file=sys.stderr)
+            return True
         except Exception as e:
-            print(f"[irc-notify] Thermal print failed: {e}", file=sys.stderr)
-
-    def should_print(alert):
-        labels = alert.get("labels", {})
-        if labels.get("alert_channel") == "thermal_print": return True
-        if labels.get("severity", "").lower() in ("critical", "disaster"): return True
-        if alert.get("status", "").upper() == "RESOLVED": return False
+            print(f"[irc-notify] thermal {kind} failed: {e}", file=sys.stderr)
             return False
 
+    def fingerprint_of(alert):
+        fp = alert.get("fingerprint", "")
+        if fp: return fp
+        labels = alert.get("labels", {})
+        target = labels.get("pod") or labels.get("instance") or labels.get("deployment") or labels.get("statefulset") or labels.get("namespace") or ""
+        return f"{labels.get('alertname','?')}/{labels.get('namespace','')}/{target}"
+
+    def is_critical(alert):
+        return alert.get("labels", {}).get("severity", "").lower() in ("critical", "disaster", "page")
+
+    def is_immediate_label(alert):
+        return alert.get("labels", {}).get("alert_channel") == "thermal_print_immediate"
+
+    def is_batched_label(alert):
+        return alert.get("labels", {}).get("alert_channel") == "thermal_print"
+
+    def add_to_digest(alert):
+        """Add an alert to the digest buffer. Returns True if the buffer GREW
+        (new fingerprint), False if it was a dedup, resolution, or no-op.
+        """
+        if not THERMAL_PRINT_ENABLED: return False
+        fp = fingerprint_of(alert)
+        status = alert.get("status", "firing").lower()
+        with _buffer_lock:
+            if status == "resolved":
+                if fp in _buffer:
+                    del _buffer[fp]
+                    _stats["buffer_resolved"] += 1
+                return False
+            if fp in _buffer:
+                _buffer[fp]["last_seen"] = time.time()
+                _buffer[fp]["alert"] = alert
+                _stats["buffer_dedup"] += 1
+                return False
+            _buffer[fp] = {"alert": alert, "first_seen": time.time(), "last_seen": time.time()}
+            _stats["buffer_added"] += 1
+            return True
+
+    def build_digest_payload():
+        with _buffer_lock:
+            items = list(_buffer.values())
+        if not items: return None
+        by_name = defaultdict(list)
+        for item in items:
+            labels = item["alert"].get("labels", {})
+            by_name[labels.get("alertname", "Unknown")].append(item)
+        lines = []
+        for name, group in sorted(by_name.items()):
+            targets = []
+            for it in group[:5]:
+                labels = it["alert"].get("labels", {})
+                t = (labels.get("pod") or labels.get("instance") or labels.get("deployment")
+                     or labels.get("statefulset") or labels.get("namespace") or "?")
+                targets.append(t)
+            more = f" (+{len(group)-5})" if len(group) > 5 else ""
+            sevs = sorted({it["alert"].get("labels", {}).get("severity", "warning") for it in group})
+            lines.append(f"[{'/'.join(sevs)}] {name} x{len(group)}: {', '.join(targets)}{more}")
+        now = datetime.now(timezone.utc).strftime("%Y-%m-%d %H:%M UTC")
+        title = f"Alert digest: {len(items)} firing"
+        body = "\n".join([
+            f"=== {title} ===",
+            f"as of {now}",
+            "",
+            *lines,
+            "",
+            "Stream: #alerts (IRC)  |  Triage: grafana-noc1.iamworkin.lan",
+            "Force-flush: POST irc-notify.monitoring.svc:9119/flush",
+        ])
+        return {"title": title, "severity": "Warning", "host": "monitoring",
+                "message": body, "eventId": f"digest-{int(time.time())}",
+                "source": "Grafana digest", "status": "PROBLEM", "acknowledged": False}
+
+    def flush_digest():
+        payload = build_digest_payload()
+        if payload is None:
+            print("[irc-notify] flush: buffer empty, no digest sent", file=sys.stderr)
+            return False
+        sent = post_thermal(payload, "digest")
+        with _buffer_lock:
+            _buffer.clear()
+        if sent: _stats["digest_flushed"] += 1
+        return sent
+
+    def digest_loop():
+        global _last_flush_time
+        while True:
+            try:
+                now = time.time()
+                elapsed = now - _last_flush_time
+                if elapsed >= BATCH_INTERVAL_MIN * 60:
+                    print(f"[irc-notify] digest tick: interval reached ({BATCH_INTERVAL_MIN}m); buffer={len(_buffer)}", file=sys.stderr)
+                    flush_digest()
+                    _last_flush_time = now
+                elif len(_buffer) >= BATCH_MAX_PENDING:
+                    print(f"[irc-notify] digest tick: buffer full ({len(_buffer)}); force flush", file=sys.stderr)
+                    flush_digest()
+                    _last_flush_time = now
+                time.sleep(15)
+            except Exception as e:
+                print(f"[irc-notify] digest loop error: {e}", file=sys.stderr)
+                time.sleep(60)
+
     class Handler(BaseHTTPRequestHandler):
         def do_POST(self):
+            if self.path == "/flush":
+                ok = flush_digest()
+                self.send_response(200); self.send_header("Content-Type", "application/json"); self.end_headers()
+                self.wfile.write(json.dumps({"flushed": ok, "buffer_after": len(_buffer)}).encode())
+                return
+            _stats["webhooks_received"] += 1
             length = int(self.headers.get("Content-Length", 0))
             body = json.loads(self.rfile.read(length)) if length else {}
             for alert in body.get("alerts", []):
@@ -1383,22 +1544,56 @@ data:
                 msg = f"{icon}{sev_tag} {name}: {summary}"
                 if desc: msg += f"\n  {desc}"
                 send_irc(msg)
-                if should_print(alert): send_thermal_print(alert)
-            self.send_response(200)
-            self.send_header("Content-Type", "application/json")
-            self.end_headers()
+                # Thermal routing — EVERYTHING (including criticals) goes into
+                # the hourly digest. Only the explicit `alert_channel=thermal_print_immediate`
+                # label bypasses, and even that flushes-the-current-digest rather
+                # than printing a standalone job, so the same fingerprint can't
+                # spam the printer per webhook cycle.
+                if status == "RESOLVED":
+                    add_to_digest(alert)  # removes from buffer
+                    continue
+                if is_immediate_label(alert):
+                    # Explicit opt-in for "paper this NOW" — first arrival of a
+                    # new fingerprint triggers an immediate digest flush; repeat
+                    # webhooks for the same fingerprint dedupe in the buffer
+                    # until the next interval or until the alert resolves.
+                    new_in_buffer = add_to_digest(alert)
+                    if new_in_buffer:
+                        global _last_flush_time
+                        flush_digest()
+                        _last_flush_time = time.time()
+                elif is_critical(alert) or is_batched_label(alert):
+                    add_to_digest(alert)
+                # else: IRC-only (warnings without thermal_print label)
+            self.send_response(200); self.send_header("Content-Type", "application/json"); self.end_headers()
             self.wfile.write(b'{"status":"ok"}')
+
         def do_GET(self):
-            self.send_response(200)
-            self.send_header("Content-Type", "application/json")
-            self.end_headers()
-            self.wfile.write(json.dumps({"service":"irc-notify","thermal_print":PRINT_ENABLED}).encode())
+            self.send_response(200); self.send_header("Content-Type", "application/json"); self.end_headers()
+            with _buffer_lock:
+                alertnames = sorted({it["alert"].get("labels", {}).get("alertname", "?") for it in _buffer.values()})
+                depth = len(_buffer)
+            info = {
+                "service": "irc-notify",
+                "config": {"thermal_print_enabled": THERMAL_PRINT_ENABLED,
+                           "batch_interval_min": BATCH_INTERVAL_MIN,
+                           "batch_max_pending": BATCH_MAX_PENDING,
+                           "irc_target": f"{IRC_HOST}:{IRC_PORT} {IRC_CHANNEL}",
+                           "print_web_url": PRINT_WEB_URL},
+                "buffer": {"depth": depth, "alertnames": alertnames,
+                           "seconds_since_last_flush": int(time.time() - _last_flush_time),
+                           "seconds_until_next_flush": max(0, int(BATCH_INTERVAL_MIN*60 - (time.time() - _last_flush_time)))},
+                "stats": _stats,
+            }
+            self.wfile.write(json.dumps(info, indent=2).encode())
+
         def log_message(self, format, *args):
             print(f"[irc-notify] {args[0]}", file=sys.stderr)
 
     if __name__ == "__main__":
+        threading.Thread(target=digest_loop, daemon=True).start()
         server = HTTPServer(("0.0.0.0", 9119), Handler)
-        print(f"IRC alert relay :9119 -> {IRC_HOST}:{IRC_PORT} {IRC_CHANNEL} (thermal: {PRINT_ENABLED})")
+        print(f"[irc-notify] :9119 -> IRC {IRC_HOST}:{IRC_PORT} {IRC_CHANNEL} | thermal={'ON' if THERMAL_PRINT_ENABLED else 'OFF'} | digest={BATCH_INTERVAL_MIN}m max={BATCH_MAX_PENDING}", file=sys.stderr)
         server.serve_forever()
 
 # =============================================================================
@@ -3485,6 +3680,146 @@ data:
                 relativeTimeRange: {from: 120, to: 0}
                 datasourceUid: __expr__
                 model: {type: threshold, expression: B, conditions: [{evaluator: {params: [600], type: gt}}], refId: C}
+      - orgId: 1
+        name: Print Services
+        folder: Print Alerts
+        interval: 1m
+        rules:
+          - uid: printer-offline-warning
+            title: PrinterOfflineWarning
+            condition: C
+            for: 2m
+            noDataState: OK
+            execErrState: OK
+            annotations:
+              summary: "Print.Web printer offline on edge2"
+              description: "Print.Web reports the NuPrint 210 transport is offline or unreachable. IRC-only by design: do not thermal-print an alert when the thermal printer itself is offline."
+              runbook: "1. Check edge2 power/network 2. Check USB/CUPS queue 3. Open https://print.iamworkin.lan/admin 4. Do not force thermal routing for offline alerts."
+            labels:
+              severity: warning
+              service: print-web
+              alert_channel: irc
+            data:
+              - refId: A
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: prometheus
+                model: {expr: 'print_printer_state{job="printweb-otel"} == 2', instant: true, refId: A}
+              - refId: B
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: __expr__
+                model: {type: reduce, expression: A, reducer: last, refId: B}
+              - refId: C
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: __expr__
+                model: {type: threshold, expression: B, conditions: [{evaluator: {params: [0], type: gt}}], refId: C}
+          - uid: print-paper-roll-critical
+            title: PrintPaperRollCritical
+            condition: C
+            for: 2m
+            noDataState: OK
+            execErrState: OK
+            annotations:
+              summary: "Print paper depleted on edge2"
+              description: "NuPrint 210 reports paper depleted while the printer is still online. Load a new roll, drain the hardware buffer if needed, then replay DeadLetter jobs from /print-log."
+              runbook: "1. Load a fresh roll 2. Drain the hardware buffer if paper-out happened mid-job 3. Open https://print.iamworkin.lan/print-log 4. Retry DeadLetter jobs after the state clears."
+            labels:
+              severity: critical
+              service: print-web
+              alert_channel: thermal_print
+            data:
+              - refId: A
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: prometheus
+                model: {expr: 'print_printer_state{job="printweb-otel"} == 3 and print_printer_online{job="printweb-otel"} == 1', instant: true, refId: A}
+              - refId: B
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: __expr__
+                model: {type: reduce, expression: A, reducer: last, refId: B}
+              - refId: C
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: __expr__
+                model: {type: threshold, expression: B, conditions: [{evaluator: {params: [0], type: gt}}], refId: C}
+          - uid: printer-jam-warning
+            title: PrinterJamWarning
+            condition: C
+            for: 2m
+            noDataState: OK
+            execErrState: OK
+            annotations:
+              summary: "Print.Web printer jam on edge2"
+              description: "Print.Web reports a paper/cutter jam state. IRC-only: clear the jam, drain the hardware buffer if bytes were queued, then retry affected jobs."
+              runbook: "1. Clear paper/cutter path 2. Drain hardware buffer if CUPS queued bytes 3. Verify /api/print/status 4. Retry affected jobs."
+            labels:
+              severity: warning
+              service: print-web
+              alert_channel: irc
+            data:
+              - refId: A
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: prometheus
+                model: {expr: 'print_printer_state{job="printweb-otel"} == 4', instant: true, refId: A}
+              - refId: B
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: __expr__
+                model: {type: reduce, expression: A, reducer: last, refId: B}
+              - refId: C
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: __expr__
+                model: {type: threshold, expression: B, conditions: [{evaluator: {params: [0], type: gt}}], refId: C}
+          - uid: printer-head-error-critical
+            title: PrinterHeadErrorCritical
+            condition: C
+            for: 2m
+            noDataState: OK
+            execErrState: OK
+            annotations:
+              summary: "Print.Web printer head error on edge2"
+              description: "Print.Web reports a thermal head or unrecoverable printer error. Critical routing may enter the thermal digest per existing policy; IRC remains the primary triage stream."
+              runbook: "1. Let the printer cool if overheated 2. Power-cycle only after checking queued jobs 3. Verify /api/print/status 4. Retry jobs after the state clears."
+            labels:
+              severity: critical
+              service: print-web
+              alert_channel: thermal_print
+            data:
+              - refId: A
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: prometheus
+                model: {expr: 'print_printer_state{job="printweb-otel"} == 5', instant: true, refId: A}
+              - refId: B
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: __expr__
+                model: {type: reduce, expression: A, reducer: last, refId: B}
+              - refId: C
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: __expr__
+                model: {type: threshold, expression: B, conditions: [{evaluator: {params: [0], type: gt}}], refId: C}
+          - uid: printer-cover-open-warning
+            title: PrinterCoverOpenWarning
+            condition: C
+            for: 2m
+            noDataState: OK
+            execErrState: OK
+            annotations:
+              summary: "Print.Web printer cover open on edge2"
+              description: "Print.Web reports the printer cover/lid is open. IRC-only: close the cover and verify /api/print/status before retrying jobs."
+              runbook: "1. Close the printer cover 2. Verify /api/print/status returns online 3. Retry affected jobs only after the state clears."
+            labels:
+              severity: warning
+              service: print-web
+              alert_channel: irc
+            data:
+              - refId: A
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: prometheus
+                model: {expr: 'print_printer_state{job="printweb-otel"} == 6', instant: true, refId: A}
+              - refId: B
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: __expr__
+                model: {type: reduce, expression: A, reducer: last, refId: B}
+              - refId: C
+                relativeTimeRange: {from: 120, to: 0}
+                datasourceUid: __expr__
+                model: {type: threshold, expression: B, conditions: [{evaluator: {params: [0], type: gt}}], refId: C}
       - orgId: 1
         name: CI Runners
         folder: CI Alerts

tests/bluejay-infra-lint/FleetManifestLintTests.cs

@@ -304,7 +304,7 @@ public sealed class FleetManifestLintTests
     }
 
     [Fact]
-    public void Monitoring_MustAlertWhenLinuxRunnerDeploymentIsUnavailable()
+    public void Monitoring_MustIncludeRequiredAlertRoutingGuards()
     {
         var monitoring = File.ReadAllText(Path.Combine(Inventory.BluejayRoot, "apps", "monitoring", "noc-monitoring.yaml"));
 
@@ -315,6 +315,15 @@ public sealed class FleetManifestLintTests
         monitoring.Should().Contain("folder: CI Alerts");
         monitoring.Should().Contain("uid: linux-runner-offline");
         monitoring.Should().Contain("alert_channel: irc");
+
+        monitoring.Should().Contain("PrinterOfflineWarning");
+        monitoring.Should().Contain("expr: print_printer_state{job=\"printweb-otel\"} == 2");
+        monitoring.Should().Contain("IRC-only by design: do not thermal-print an alert when the thermal printer itself is offline.");
+        monitoring.Should().Contain("PrintPaperRollCritical");
+        monitoring.Should().Contain("expr: print_printer_state{job=\"printweb-otel\"} == 3 and print_printer_online{job=\"printweb-otel\"} == 1");
+        monitoring.Should().Contain("PrinterJamWarning");
+        monitoring.Should().Contain("PrinterHeadErrorCritical");
+        monitoring.Should().Contain("PrinterCoverOpenWarning");
     }
 
     [Fact]