Fix #7806 - ExpandObjects error handling

[jmarrec]

Pull request overview

• Fixes ExpandObjects generates bad file and InputProcessor fails to parse #7806

Description of the purpose of this PR

• ExpandObjects return exit code 1 when a Severe is Issued
• If E+ itself calls ExpandObjects via -x flag, terminate if it returns non zero
• If calling E+ on an .idf that has Fatal Output:PreprocessorMessage, we issue those instead of terminating after the Schema Validation, by moving the preProcessorCheck into the InputProcessor instead of SimulationManager::PostIPProcessing

Pull Request Author

• Title of PR should be user-synopsis style (clearly understandable in a standalone changelog context)
• Label the PR with at least one of: Defect, Refactoring, NewFeature, Performance, and/or DoNoPublish
• Pull requests that impact EnergyPlus code must also include unit tests to cover enhancement or defect repair
• Author should provide a "walkthrough" of relevant code changes using a GitHub code review comment process
• If any diffs are expected, author must demonstrate they are justified using plots and descriptions
• If changes fix a defect, the fix should be demonstrated in plots and descriptions
• If any defect files are updated to a more recent version, upload new versions here or on DevSupport
• If IDD requires transition, transition source, rules, ExpandObjects, and IDFs must be updated, and add IDDChange label
• If structural output changes, add to output rules file and add OutputChange label
• If adding/removing any LaTeX docs or figures, update that document's CMakeLists file dependencies
• If adding/removing any output files (e.g., eplustbl.*)
  • Update ..\scripts\Epl-run.bat
  • Update ..\scripts\RunEPlus.bat
  • Update ..\src\EPLaunch\ MainModule.bas, epl-ui.frm, and epl.vbp (VersionComments)
  • Update ...github\workflows\energyplus.py

Reviewer

• Perform a Code Review on GitHub
• If branch is behind develop, merge develop and build locally to check for side effects of the merge
• If defect, verify by running develop branch and reproducing defect, then running PR and reproducing fix
• If feature, test running new feature, try creative ways to break it
• CI status: all green or justified
• Check that performance is not impacted (CI Linux results include performance check)
• Run Unit Test(s) locally
• Check any new function arguments for performance impacts
• Verify IDF naming conventions and styles, memos and notes and defaults
• If new idf included, locally check the err file and other outputs

[jmarrec]

Live testing, using https://github.com/NatLabRockies/EnergyPlusDevSupport/blob/master/DefectFiles/7000s/7806/VAV_Sys_26_2_0.idf (I translated it from the original 9.2 IDF)

Before:

ExpandObjects returns 0, so E+ still tries to simulate it, and only the schema validation errors happen.

$ $ep_build_rel-develop/Products/energyplus -x -D -d out-ori VAV_Sys_26_2_0.idf 
ExpandObjects Started.
 Begin reading Energy+.idd file.
 Done reading Energy+.idd file.
ExpandObjects Finished with Error(s). Time:     0.040
EnergyPlus Starting
EnergyPlus, Version 26.2.0-7cfca988f9, YMD=2026.06.18 17:38
**FATAL:Errors occurred on processing input file. Preceding condition(s) cause termination.
EnergyPlus Run Time=00hr 00min  0.08sec
Program terminated: EnergyPlus Terminated--Error(s) Detected.

$ cat out-ori/eplusout.err 
Program Version,EnergyPlus, Version 26.2.0-7cfca988f9, YMD=2026.06.18 17:38,
   ** Severe  ** Line: 4459 Index: 10 - Field cannot be Autosize or Autocalculate
   ** Severe  ** Line: 4461 Index: 10 - Field cannot be Autosize or Autocalculate
   ** Severe  ** <root>[Connector:Splitter][Chiled Water Loop CndW Supply Splitter][branches][20] - Missing required property 'outlet_branch_name'.
   **  Fatal  ** Errors occurred on processing input file. Preceding condition(s) cause termination.
   ...Summary of Errors that led to program termination:
   ..... Reference severe error count=3
   ..... Last severe error=<root>[Connector:Splitter][Chiled Water Loop CndW Supply Splitter][branches][20] - Missing required property 'outlet_branch_name'.
   ************* Warning:  Node connection errors not checked - most system input has not been read (see previous warning).
   ************* Fatal error -- final processing.  Program exited before simulations began.  See previous error messages.
   ************* EnergyPlus Warmup Error Summary. During Warmup: 0 Warning; 0 Severe Errors.
   ************* EnergyPlus Sizing Error Summary. During Sizing: 0 Warning; 0 Severe Errors.
   ************* EnergyPlus Terminated--Fatal Error Detected. 0 Warning; 3 Severe Errors; Elapsed Time=00hr 00min  0.08se

---

Now:

ExpandObjects returned 1, so E+ stops there.

$ $ep_build_rel/Products/energyplus -x -D -d out-new VAV_Sys_26_2_0.idf 
ExpandObjects Started.
 Begin reading Energy+.idd file.
 Done reading Energy+.idd file.
ExpandObjects Terminated--Error(s) Detected. 1 Warning; 1 Severe Errors; Time:     0.048
ERROR: ExpandObjects failed to expand the HVACTemplate:* or GroundHeatTransfer:* objects in this input file.
See /home/julien/Software/Others/EnergyPlusDevSupport/DefectFiles/7000s/7806/out-new/eplusout.experr for details.

If I try to run the expidf anyways, I get the schema validation errors AND the Output:ProcessorMessage into the eplusout.err

$ cd out-new
$ $ep_build_rel/Products/energyplus -D -d out-force in.idf
EnergyPlus Starting
EnergyPlus, Version 26.2.0-24256e83e2, YMD=2026.06.18 17:42
**FATAL:Errors occurred on processing input file. Preceding condition(s) cause termination.
EnergyPlus Run Time=00hr 00min  0.07sec
Program terminated: EnergyPlus Terminated--Error(s) Detected.

$ cat out-force/eplusout.err 
Program Version,EnergyPlus, Version 26.2.0-24256e83e2, YMD=2026.06.18 17:42,
   ** Severe  ** Line: 4459 Index: 10 - Field cannot be Autosize or Autocalculate
   ** Severe  ** Line: 4461 Index: 10 - Field cannot be Autosize or Autocalculate
   ** Severe  ** <root>[Connector:Splitter][Chiled Water Loop CndW Supply Splitter][branches][20] - Missing required property 'outlet_branch_name'.
   ** Warning ** Output:PreprocessorMessage="ExpandObjects" has the following Warning conditions:
   **   ~~~   ** Warning:  In HVACTemplate:System:VAV "VAV" there is no Heating Coil and no
   **   ~~~   ** Preheat Coil. The Preheat Coil Design Setpoint will be used for the
   **   ~~~   ** Sizing:System Central Heating Design Supply Air Temperature. This will be
   **   ~~~   ** the inlet air temperature for sizing reheat coils.
   ** Severe  ** Output:PreprocessorMessage="ExpandObjects" has the following Fatal conditions:
   **   ~~~   ** Severe:  In HVACTemplate:Plant:ChilledWaterLoop "Chiled Water Loop" there
   **   ~~~   ** is one or more water cooled chiller(s) but there are no towers serving this
   **   ~~~   ** loop.
   **  Fatal  ** Errors occurred on processing input file. Preceding condition(s) cause termination.
   ...Summary of Errors that led to program termination:
   ..... Reference severe error count=4
   ..... Last severe error=Output:PreprocessorMessage="ExpandObjects" has the following Fatal conditions:
   ************* Warning:  Node connection errors not checked - most system input has not been read (see previous warning).
   ************* Fatal error -- final processing.  Program exited before simulations began.  See previous error messages.
   ************* EnergyPlus Warmup Error Summary. During Warmup: 0 Warning; 0 Severe Errors.
   ************* EnergyPlus Sizing Error Summary. During Sizing: 0 Warning; 0 Severe Errors.
   ************* EnergyPlus Terminated--Fatal Error Detected. 1 Warning; 4 Severe Errors; Elapsed Time=00hr 00min  0.07sec

[mitchute]

Don't you still want to fatal out on these before proceeding? If the IDF/epJSON are bad, is there any need to continue processing?

[jmarrec]

    bool const PreP_Fatal = preProcessorCheck(state);

    if (!is_valid || hasErrors || unsupportedFound || PreP_Fatal) {
        ShowFatalError(state, "Errors occurred on processing input file. Preceding condition(s) cause termination.");
    }

is a few lines after, so it will throw, but just will also have issued the Output:ProcessorMessages (if any) beforehand anwyays.

[jmarrec]

    bool const PreP_Fatal = preProcessorCheck(state);

    if (!is_valid || hasErrors || unsupportedFound || PreP_Fatal) {
        ShowFatalError(state, "Errors occurred on processing input file. Preceding condition(s) cause termination.");
    }

is a few lines after, so it will throw, but just will also have issued the Output:ProcessorMessages (if any) beforehand anwyays.

[jmarrec]

New check is here. Will have issued the Output:PreProcessorMessage warnings anyways.