Merge pull request 'README: install and update from Gitea instead of Google Drive folders' (#1) from docs/readme-gitea into main

Reviewed-on: #1

README.md

@@ -0,0 +1,76 @@
+# KOTA Sensorbox Technician Tool
+
+Diagnoza sensorboxa przez USB, wgrywanie firmware z folderu `firmware/` i przygotowanie karty SD.
+Działa na Windows 10/11 i macOS 13 (Ventura) lub nowszym, na Macach z Intelem i Apple Silicon.
+
+Repozytorium: https://gitea.kota-app.com/kkallas/kota-technician-tool (dostęp nadaje właściciel repozytorium).
+
+## Instalacja
+
+Wybierz jeden sposób. Nie trzymaj narzędzia w folderze Google Drive ani OneDrive.
+
+### A. Paczka zip (najprościej)
+
+1. Na Gitea otwórz **Releases** i przy najnowszej wersji pobierz **Source Code (ZIP)**.
+2. Rozpakuj do zwykłego folderu, np. `Dokumenty\KOTA\technician-tool`.
+3. Nowa wersja: pobierz nowy zip i rozpakuj obok (albo w miejsce starego folderu).
+
+### B. Git (aktualizacja jednym poleceniem)
+
+Wymaga zainstalowanego gita (Windows: https://git-scm.com, macOS: `xcode-select --install`).
+
+```
+git clone https://gitea.kota-app.com/kkallas/kota-technician-tool.git
+```
+
+Przy pierwszym połączeniu podaj login i hasło (lub token) do Gitea; system je zapamięta.
+Aktualizacja do najnowszej wersji, w folderze `kota-technician-tool`:
+
+```
+git pull
+```
+
+Konkretna wersja, np. na potrzeby serwisu starszego boxa: `git switch --detach v0.8`, powrót: `git switch main`.
+
+## Uruchomienie
+
+**Windows:** dwuklik `run_windows.bat`.
+
+**macOS:** dwuklik `run_macos.command`. Jeśli Finder odpowie, że pliku nie można uruchomić (zdarza się po
+rozpakowaniu zip), otwórz Terminal, wpisz `bash ` (ze spacją), przeciągnij plik do okna i naciśnij Enter.
+Na stałe naprawia to `chmod +x run_macos.command`. Przy instalacji przez git ten problem nie występuje.
+
+Przy pierwszym uruchomieniu skrypt proponuje instalację `uv` (menedżer Pythona, tylko dla bieżącego użytkownika)
+i pobiera biblioteki. Potrzebny jest internet, trwa to 1–2 minuty. Kolejne starty są natychmiastowe.
+Środowisko Pythona jest poza folderem narzędzia:
+`%LOCALAPPDATA%\KotaTechnicianTool\venv-<wersja>` (Windows), `~/Library/Caches/KotaTechnicianTool/venv-<wersja>` (macOS).
+
+Sesje, kopie zapasowe flash i ustawienia są w `~/KotaTechnicianTool` (Windows: `C:\Users\<użytkownik>\KotaTechnicianTool`).
+
+## Port sensorboxa
+
+- Windows: `COMx - Sensorbox (native USB) [MAC]`
+- macOS: `/dev/cu.usbmodemXXXX - Sensorbox (native USB) [MAC]`
+
+Kabel USB musi przenosić dane (nie tylko ładowanie). Przy restartach z komunikatem o brownout użyj innego portu
+lub zasilacza.
+
+## Firmware
+
+Wgrać można tylko pliki `.bin` z folderu `firmware/`. Lista pokazuje datę kompilacji zapisaną w pliku,
+najnowszy build jest na górze. Nowy build: wrzuć plik do `firmware/` i kliknij **Refresh list**.
+
+## Dla zespołu
+
+- Praca nad zmianą: gałąź (`git switch -c feature/<nazwa>`) → commity z przechodzącymi testami →
+  `git push -u origin feature/<nazwa>` → pull request na Gitea → merge do `main`.
+- Wydanie wersji: numer w `pyproject.toml`, `kota_tech/__init__.py` i skryptach `run_*`, tag `vX.Y`
+  (`git tag -a vX.Y -m "Technician tool vX.Y"`, `git push origin vX.Y`), opis w **Releases** na Gitea.
+- Nie commitujemy `ENV.TXT` z prawdziwym tokenem ani haseł Wi-Fi.
+- Testy:
+
+```
+uv run --frozen pytest -q
+```
+
+Zmiany w wersjach: `docs/CHANGES-v0.7.md`, `docs/CHANGES-v0.8.md`; historia v0.1–v0.8 jest w tagach gita.

docs/CHANGES-v0.7.md

@@ -0,0 +1,23 @@
+# Technician tool v0.7 - changes
+
+## Serial reading (firmware 1.0.16+, see firmware-diagnostics-what-changed.md)
+- `KOTA: <record> key=value` lines are parsed into fields (`core/logline.py`, kind `KOTA`) and interpreted
+  directly by the engine (`diag/engine.py` `_kota_*`, knowledge in `diag/kota.py`) instead of regex rules:
+  boot, i2c, rtc, sd, matter, mic, health, status, led, restart.
+- Exact status LED (colour + pattern + meaning) from `led` lines; `status` lines give the reason and a
+  status finding that is resolved when the status changes. Cyan LED supported.
+- Restart cause from `last_restart=` / `restart reason=`; state before a restart from `led previous_boot`.
+- Error IDs `[E-XX-NN]`: looked up in `diag/error_ids.csv` (copy of the firmware's docs/error_ids.csv);
+  shown with the technician action. Old message rules still match (ID prefix is stripped for matching).
+- Diagnosis panel: new "Box self-report" section; log view filter "KOTA diagnostics + errors".
+- Matter QR dialog uses the exact QR/manual code reported by the box.
+- Older firmware (v1.0) is still diagnosed as before.
+
+## Flashing
+- Only `.bin` files in the tool's `firmware/` folder can be flashed (import / developer library removed,
+  no manifest needed). The list shows the compile date read from the firmware itself, newest first.
+- "Refresh list" and "Open firmware folder" buttons; broken or duplicate files are listed as "Not offered".
+- Flash verification compares the 8-digit build hash from the `KOTA: boot` line.
+
+Note: the KOTA lines are tested against lines built from the firmware source; the firmware has not yet
+been confirmed on hardware.

docs/CHANGES-v0.8.md

@@ -0,0 +1,21 @@
+# Technician tool v0.8 - changes
+
+## Windows + macOS
+- Dependencies verified to install on macOS arm64 and x86_64 (uv.lock: PySide6 6.11 universal2 wheels,
+  requires macOS 13+); Windows unchanged.
+- SD card check: macOS `diskutil` reports FAT32 partitions as `DOS_FAT_32` / `Windows_FAT_32`; these are now
+  accepted (previously a correct card was reported as "not FAT32" on a Mac).
+- Unit tests for the macOS serial-port filter (`/dev/cu.*` only) and FAT32 names.
+- README.md with launch steps for both systems (incl. the Google Drive executable-bit workaround on macOS);
+  docs/mac_agent_command.txt updated for a v0.8 test run on a Mac.
+
+## Diagnosis
+- Harmless Wi-Fi start-up errors are ignored (rule `benign.wifi_start`): `wifi:sta is connecting, return error`,
+  `esp_wifi_connect() failed: ESP_ERR_WIFI_CONN`, `Failed to get configured network when updating network
+  status` (unpaired box).
+- Brown-out resets are detected (`E BOD: Brownout detector was triggered`, ROM reports RTC_SW_SYS_RST).
+- Service report note = the Diagnosis panel as text (LED, firmware, box self-report, start-up progress with
+  times, findings with "Seen Nx, first at ... s, last at ... s" and log line), shortened to fit the service
+  form's 5000 characters.
+
+Not yet run on a real Mac: see docs/mac_agent_command.txt.

docs/firmware-diagnostics-proposals.md

@@ -0,0 +1,90 @@
+# Firmware diagnostics improvement proposals
+
+> **Status: draft proposal, AI-generated (Claude) for review by the firmware team.**
+> Nothing here is implemented. The firmware source was only read for analysis;
+> no firmware was changed. Every item links to an observation from bench
+> testing box `A4:CB:8F:C9:46:F8` (firmware v1.0, build `45fa9d5b9`) or from the
+> sample logs, so the value of each change can be judged.
+
+## Why
+
+Troubleshooting currently depends on reverse-engineering free-text log lines and
+on a status LED whose states overlap. Observed problems:
+
+| # | Observation | Effect for technicians |
+|---|---|---|
+| O1 | A new, uncommissioned box shows **green** for about 60 s, then purple | Looks healthy during installation |
+| O2 | Three different states share **white** (SD error, factory reset, setup portal) | Needs serial or guesswork |
+| O3 | **Blue** means "RTC did not answer", but the RTC is just the first I2C device | A loose I2C cable is misreported as an RTC fault |
+| O4 | Every build reports `App version: 1.0` | Builds are told apart only by ELF SHA |
+| O5 | Restarts after 150 s in an error state happen **without any log line** | A self-restart looks like a crash |
+| O6 | With the RTC not running and no Internet, sensor tasks **loop forever** on `RTC is uninitialized` | An offline box records nothing, and it isn't obvious why |
+| O7 | The OTA token is printed in plain text (`OTA token loaded from NVS: %s`, `received token: %s`) | Secrets end up in technician logs |
+| O8 | Native USB loses output while no host is reading; a stale FIFO fragment is glued to the next line | The early boot after a power cycle is lost, and lines get corrupted |
+| O9 | The microphone reports "shutdown state" (GPIO3) with no hint of the cause | A technician can't tell a switch from a fault |
+| O10 | The deployed build logs some messages under different tags than the source (e.g. SD mount under `INFLUX_BUFFER`) | Parsers must ignore tags |
+
+## Serial output
+
+Priority: **P1** = large gain for little effort, **P2** = valuable, **P3** = nice to have.
+
+### P1
+
+1. **One structured boot line** with a fixed prefix, printed right after `app_init`:
+   ```
+   KOTA: boot fw=1.0.15 build=45fa9d5b hw=2 mac=A4CB8FC946F8 reset=USB_UART_CHIP_RESET mode=matter commissioned=0 last_restart=status_watchdog
+   ```
+   The tool can then identify firmware, hardware and mode from a single line (fixes O4 and O10). Fill `PROJECT_VER` from `FIRMWARE_VERSION` (currently `15` in `pinout.hpp`) so every build has a unique version.
+2. **Log every status change** inside `Status::set_status()`, with a reason argument:
+   ```
+   KOTA: status OK -> CONNECTION_ERROR reason=influx_flush_failed
+   ```
+   This is the exact LED colour. Today the tool has to infer it from about 15 different messages.
+3. **Log the reason before every `esp_restart()`** and store it (RTC memory or NVS) so it can be printed at the next boot as `last_restart=`. Values: `status_watchdog_150s`, `out_of_resources_30s`, `button_factory_reset`, `setup_portal_toggle`, `ota_done`, `init_failed:<step>` (fixes O5).
+4. **Stop printing secrets**: print only the first and last 4 characters of the OTA token, or `token=present` (fixes O7).
+5. **Warn once and continue when the time is unset**, instead of the `while (now == 946684800)` loops in `device_status.cpp` and the sensors. Record data with a `time_valid=false` field or buffer it with uptime, then correct it after SNTP (fixes O6). This is a behaviour change, but the biggest data-loss risk found.
+
+### P2
+
+6. **I2C bus scan at boot**, before any sensor init:
+   ```
+   KOTA: i2c SDA=1 SCL=1 0x39=AS7341 0x68=DS1307 0x6B=SEN66(missing) 0x76=BME688
+   ```
+   Reading the SDA/SCL levels first detects a stuck-low bus (shorted or broken cable). The scan then separates "whole cable" from "one sensor" (fixes O3).
+7. **RTC detail**: at init, print the DS1307 clock-halt (CH) bit and the raw time (`KOTA: rtc running=0 time=2000-01-01 (coin cell?)`). After SNTP sets the time, re-read it 2 s later to verify it's ticking.
+8. **SD card detail**: card type, size, FAT type, free space, which `ENV.TXT` keys are present (names only, never values) and the buffer size in lines. Example: `KOTA: sd type=SDHC size=7.4GB fs=FAT32 free=7.3GB env_keys=INFLUX_URL,INFLUX_TOKEN buffer_lines=42`.
+9. **Periodic health line** every 60 s. `DeviceStatus` already computes almost everything:
+   ```
+   KOTA: health up=312s status=CONNECTION_ERROR wifi=disconnected rssi=0 time_valid=0 sd=ok buffer=42 heap=81234 psram=6.1M last_upload=never ota=unregistered
+   ```
+10. **Matter commissioning status at boot**: `KOTA: matter fabrics=0 window=open` plus the QR payload and manual code, so the tool can show the QR code on screen when the sticker is missing.
+11. **Microphone enable reason**: `KOTA: mic enabled=0 (GPIO3=1, expected 0)` once at boot, instead of a warning every 10 s (fixes O9).
+12. **Stable error IDs** in messages, e.g. `[E-SD-01] Failed to initialize the card`, documented in one table shared by the firmware, the technician tool and the service docs.
+
+### P3
+
+13. **Console commands** over USB (the firmware already runs a `console` task): `diag` (full health dump), `i2cscan`, `sdinfo`, `ledtest` (cycles all colours so the technician can confirm the LED hardware), `version`, `bootlog`. The tool could then run checks without a reboot.
+14. **Boot-log ring buffer** in RAM, dumped with `bootlog` or on first host connect. This recovers the early boot lost on native USB after a power-switch cycle (fixes O8).
+15. **Button events**: log the press start and release with duration (`KOTA: button press 1.2s -> setup_portal`). This allows a safe button test and shows accidental factory resets.
+
+## RGB LED
+
+1. **Separate "not connected yet" from "OK"** (fixes O1): **cyan breathing** while the box is uncommissioned / advertising over BLE, fast cyan while a phone is connected, and a green flash when commissioning completes.
+2. **Split the white states** with patterns (fixes O2):
+   - SD card / `ENV.TXT` error: white, fast blink (2 Hz)
+   - factory reset in progress: white, solid
+   - Wi-Fi setup portal: white, slow breathing
+3. **Blink codes for red and blue** (fixes O3): N short pulses followed by a pause identify the part.
+   - Red: 1 = BME688, 2 = SEN66, 3 = AS7341, 4 = microphone, 5 = flicker, 6 = self-check failed
+   - Blue: 1 = RTC not responding, 2 = I2C bus stuck low
+4. **Split purple**: solid = no network/DNS; blinking = Internet works but the server rejected the box (InfluxDB 401/404, OTA 401). These need different fixes (network vs SD card settings).
+5. **Show the cause before a self-restart**: flash the error colour 3 times before `esp_restart()`. After boot, show the previous boot's error colour for 3 s (from RTC memory), so a reboot loop has a visible cause.
+6. **Update progress**: yellow blinking while downloading (faster as progress grows); orange stays solid for the self-check.
+7. **Brightness and distinguishability**: colours are set at 10 % (`255/10`). Yellow and orange, and white and cyan, are hard to tell apart in daylight. Prefer fewer colours plus patterns, and raise brightness for error states.
+8. **Heartbeat LED (GPIO6)**: keep 1 Hz for "running", add a double-blink when offline, so the heartbeat alone gives a rough state even when the RGB LED is faulty.
+
+## What changes in the technician tool
+
+- The structured `KOTA:` lines (items 1, 2, 3, 9) would replace most regex rules in `rules.toml` and make the LED model exact rather than inferred.
+- The console commands (item 13) would let guided checks test hardware directly (I2C scan, LED test) instead of asking the technician to power-cycle.
+- The new LED patterns would add answers to the Quick check (e.g. "white, blinking fast") and remove the follow-up questions currently needed to separate the white states.

docs/mac_agent_command.txt

@@ -0,0 +1,35 @@
+You are testing the KOTA sensorbox technician tool v0.8 on macOS. The current folder is
+004-technician_tool/v0.8 (a Python/PySide6 desktop app; tested on Windows 11, macOS paths are covered by
+unit tests but not yet run on a real Mac).
+
+Rules:
+- Python only via uv or conda/mamba. Never use bare/system python or pip.
+- Do not build or modify firmware. Flash only files from the tool's firmware/ folder.
+- Do not push anything to Git or GitLab. This is a local demo.
+- Ask me before any destructive action: formatting an SD card, Full-mode flashing, or deleting files.
+  Before formatting, show me the exact disk (identifier, name, size, current files).
+- Do not change code without telling me. Report bugs with evidence (commands and output).
+
+Tests, in order. Report pass/fail with evidence for each:
+1. Launch: `bash run_macos.command` (it offers to install uv). The app window opens; note any warnings.
+   Also check whether a double-click in Finder works (Google Drive may drop the executable bit).
+2. Tests: `UV_PROJECT_ENVIRONMENT="$HOME/Library/Caches/KotaTechnicianTool/venv-0.8" uv run --frozen pytest -q`
+   (expect 172 passed).
+3. Serial: plug in the sensorbox (native USB). The port list shows a /dev/cu.usbmodem* "Sensorbox (native USB)"
+   entry with a MAC (no /dev/tty.* duplicate). Connect, press "Reset & capture": the log starts at
+   "ESP-ROM:esp32s3" and the Diagnosis panel shows firmware v1.0.16 (build 4f10989e), the "Box self-report"
+   section and the LED with its pattern. Check whether the port disappears after the reset and whether the
+   tool reconnects. Wait 2 minutes: a "KOTA: health" line appears every 60 s.
+4. Show filter "KOTA diagnostics + errors" shows only KOTA lines and errors.
+5. Guided troubleshooting: run "Quick check" and answer truthfully with what I tell you the LED shows.
+6. Flash (App only, the newest file in firmware/, chosen by its compile date): the tool must enter flashing mode
+   by itself, write, restart the box and report "Success ... build 4f10989e". Capture the esptool output.
+7. SD card tab: the card reader and card are listed (internal disks must NOT be listed). "Check card" must NOT
+   report a wrong file system for a FAT32 card. After my OK, "Format card and write ENV.TXT" must use
+   `diskutil eraseDisk FAT32 KOTA MBRFormat` on the correct disk, write ENV.TXT and eject the card.
+8. "Service report..." opens the browser at https://service.kota-app.com/<MAC>#kota-report=...; the note in
+   the form must match the Diagnosis panel (self-report, start-up progress with times, findings with
+   "Seen Nx, first at ... s").
+
+At the end, write a short report: macOS version, Mac model/architecture, each test with result, errors, and
+suggested fixes (file:line).

environment.yml

@@ -7,4 +7,6 @@ dependencies:
   - python=3.12
   - pyserial>=3.5
   - pyside6>=6.7
+  - esptool>=4.8,<5
+  - segno>=1.6
   - pytest>=8

kota_tech/__init__.py

@@ -1,3 +1,3 @@
 """KOTA sensorbox technician tool."""
 
-__version__ = "0.2.0"
+__version__ = "0.8.0"

kota_tech/core/logline.py

@@ -4,6 +4,12 @@ ESP-IDF log format: "<L> (<ms since boot>) <TAG>: <message>", optionally
 wrapped in ANSI colour codes. ROM/bootloader output (boot banner, reset
 reason) has no level prefix and is classified separately, since a boot
 banner is the only reliable reboot marker.
+
+Firmware 1.0.16+ adds structured diagnostic lines logged under the "KOTA"
+tag ("I (812) KOTA: boot fw=1.0.16 build=4f10989e ... last_restart=none")
+and prefixes every ESP_LOGE message with a stable error ID ("[E-SD-03] ").
+Both are parsed here so the diagnostics engine reads fields directly
+instead of matching message text.
 """
 
 from __future__ import annotations
@@ -21,6 +27,9 @@ ESP_LOG_RE = re.compile(r"^([EWIDV]) \((\d+)\) ([^:]{1,40}?): ?(.*)$")
 # "rst:0x1 (POWERON),boot:0x8 (SPI_FAST_FLASH_BOOT)".
 BOOT_BANNER_RE = re.compile(r"^ESP-ROM:")
 RESET_REASON_RE = re.compile(r"^rst:0x([0-9a-fA-F]+) \(([A-Z0-9_]+)\)")
+# "[E-SD-03] Failed to initialize the card ..." (firmware error_ids.csv).
+ERROR_ID_RE = re.compile(r"^\[(E-[A-Z0-9]+-\d{2,})\] ?")
+KOTA_TAG = "KOTA"
 PANIC_RE = re.compile(
     r"Guru Meditation Error|abort\(\) was called|ESP_ERROR_CHECK failed|"
     r"^Backtrace:|Rebooting\.\.\.$"
@@ -32,6 +41,7 @@ class LineKind(str, Enum):
     BOOT = "boot"        # ROM boot banner (start of a new boot)
     RESET = "reset"      # ROM reset-reason line
     PANIC = "panic"      # crash / abort output
+    KOTA = "kota"        # structured "KOTA: <record> key=value ..." line
     RAW = "raw"          # anything else (task list rows, line protocol, ...)
     HOST = "host"        # event generated by this tool (connect, reset, ...)
 
@@ -50,6 +60,44 @@ class LogLine:
     tag: str | None = None
     message: str | None = None
     reset_reason: str | None = None
+    error_id: str | None = None    # "E-SD-03" when the message carries one
+    record: str | None = None      # KOTA lines: "boot", "i2c", "health", ...
+    fields: dict[str, str] = field(default_factory=dict)   # KOTA key=value pairs
+    words: tuple[str, ...] = ()    # KOTA bare words ("verify", "OK", "->", ...)
+
+    @property
+    def match_text(self) -> str:
+        """Text for message rules: the error-ID prefix removed, so rules
+        written for older firmware keep matching."""
+        if self.error_id and self.message is not None and self.tag:
+            return self.text.replace(f"[{self.error_id}] ", "", 1)
+        return self.text
+
+
+def parse_kota(body: str) -> tuple[str, dict[str, str], tuple[str, ...]]:
+    """'rtc verify running=1 delta=2s ok=1' -> ('rtc', {...}, ('verify',)).
+
+    Values never contain spaces. The mic line has a parenthesised aside
+    ("(GPIO3=1, expected 1)"): brackets and commas are stripped from keys
+    and values, and the aside's words are kept as bare words.
+    """
+    tokens = body.split()
+    if not tokens:
+        return "", {}, ()
+    fields: dict[str, str] = {}
+    words: list[str] = []
+    for tok in tokens[1:]:
+        key, eq, value = tok.partition("=")
+        if eq and key.strip("(,"):
+            key = key.lstrip("(")
+            # "0x68=DS1307(missing)" keeps its bracket; "(GPIO3=1," loses it.
+            value = value.rstrip(",")
+            if tok.startswith("(") or value.endswith(")") and "(" not in value:
+                value = value.rstrip(")")
+            fields[key] = value
+        else:
+            words.append(tok.strip("(),"))
+    return tokens[0], fields, tuple(w for w in words if w)
 
 
 def clean(raw: str) -> str:
@@ -61,7 +109,15 @@ def parse_line(raw: str, host_time: float | None = None) -> LogLine:
     t = time.time() if host_time is None else host_time
     if m := ESP_LOG_RE.match(text):
         level, ms, tag, msg = m.groups()
-        return LogLine(text, LineKind.LOG, t, level, int(ms), tag.strip(), msg)
+        tag = tag.strip()
+        if tag == KOTA_TAG:
+            record, fields, words = parse_kota(msg)
+            return LogLine(text, LineKind.KOTA, t, level, int(ms), tag, msg,
+                           record=record, fields=fields, words=words)
+        eid = None
+        if em := ERROR_ID_RE.match(msg):
+            eid, msg = em.group(1), msg[em.end():]
+        return LogLine(text, LineKind.LOG, t, level, int(ms), tag, msg, error_id=eid)
     if BOOT_BANNER_RE.match(text):
         return LogLine(text, LineKind.BOOT, t)
     if m := RESET_REASON_RE.match(text):

kota_tech/diag/engine.py

@@ -6,7 +6,11 @@ line cannot express:
     was missed) and classification of why the previous boot ended;
   * the status-LED model (Status::set_status / set_status_conditional);
   * crash capture (panic / ESP_ERROR_CHECK output);
-  * root-cause grouping via `explained_by` chains.
+  * root-cause grouping via `explained_by` chains;
+  * the structured "KOTA:" lines of firmware 1.0.16+ (diag/kota.py): exact
+    status/LED, restart reasons, I2C/SD/RTC/Matter/mic self-report and the
+    60 s health line, plus error IDs ("[E-SD-03]") looked up in
+    error_ids.csv. Older firmware is still diagnosed from message text.
 
 Findings are session-wide (a reboot loop must keep its cause visible);
 milestones and the LED are per boot.
@@ -22,9 +26,11 @@ from enum import IntEnum
 from pathlib import Path
 
 from ..core.logline import LineKind, LogLine
+from . import kota
 from .firmware import FirmwareInfo
 
 RULES_PATH = Path(__file__).with_name("rules.toml")
+_MAC_LINE = re.compile(r"Device MAC address: ([0-9A-Fa-f]{2}(?::[0-9A-Fa-f]{2}){5})")
 
 
 class Severity(IntEnum):
@@ -47,6 +53,7 @@ LED = {
     "PURPLE": ("Purple", "#8e44ad"),
     "RED": ("Red", "#d64541"),
     "BLUE": ("Blue", "#2f6fd6"),
+    "CYAN": ("Cyan", "#1fc8d8"),
     "YELLOW": ("Yellow", "#e6c229"),
     "ORANGE": ("Orange", "#f08c1a"),
     "WHITE": ("White", "#f4f4f4"),
@@ -59,10 +66,13 @@ MILESTONES = [
     ("sd_mounted", "SD card mounted", False),
     ("env_loaded", "ENV.TXT read (InfluxDB settings)", False),
     ("matter_started", "Matter started", True),
+    ("matter_commissioned", "Paired in Matter", True),
     ("local_wifi_mode", "Local Wi-Fi mode (SSID from SD card)", True),
+    ("i2c_ok", "All sensors answer on the I2C bus", True),
     ("sensors_ready", "All sensors started", False),
     ("wifi_connected", "Connected to Wi-Fi", False),
     ("time_synced", "Clock set from the Internet", False),
+    ("clock_verified", "Clock keeps time (RTC verified)", True),
     ("data_uploaded", "Data uploaded to InfluxDB", False),
     ("ota_registered", "Registered for firmware updates", False),
     ("ota_checked", "Checked for firmware updates", False),
@@ -75,11 +85,15 @@ MILESTONES = [
 _INIT_FAILURES = [
     "rtc.init_failed", "sensor.init_failed", "sd.card_fail", "sd.mount_fail",
     "sd.env_open_fail", "influx.env_missing", "influx.init_fail",
+    "kota.i2c_stuck", "kota.sensor_missing", "kota.rtc_read_failed", "kota.sd_unmounted",
 ]
 _NETWORK_ROOTS = [
     "influx.buffer_fail", "ota.check_failed", "net.dns_fail",
     "matter.not_commissioned", "wifi.disconnected",
 ]
+# Printed by the brown-out handler without a timestamp ("E BOD: ..."); on the
+# ESP32-S3 the ROM then reports RTC_SW_SYS_RST, not a brown-out reset.
+_BROWNOUT = "Brownout detector was triggered"
 _RESET_BY_TOOL_WINDOW_S = 5.0
 _SHORT_BOOT_MS = 60_000
 
@@ -96,7 +110,7 @@ def _fmt(s: str, groups: dict[str, str]) -> str:
 @dataclass(frozen=True)
 class Rule:
     id: str
-    pattern: re.Pattern[str]
+    pattern: re.Pattern[str] | None     # None: raised from KOTA: fields
     severity: Severity
     title: str = ""
     meaning: str = ""
@@ -117,7 +131,7 @@ def load_rules(path: Path = RULES_PATH) -> list[Rule]:
     for r in data["rule"]:
         rules.append(Rule(
             id=r["id"],
-            pattern=re.compile(r["pattern"]),
+            pattern=re.compile(r["pattern"]) if "pattern" in r else None,
             severity=Severity[r["severity"].upper()],
             title=r.get("title", ""),
             meaning=r.get("meaning", ""),
@@ -143,7 +157,8 @@ def _validate(rules: list[Rule]) -> None:
     known = set(ids)
     for r in rules:
         for ref in (*r.explained_by, *r.clears):
-            if ref not in known:
+            # status.* / reboot.* findings are created by the engine itself.
+            if ref not in known and not ref.startswith(("status.", "reboot.")):
                 raise ValueError(f"{r.id}: unknown rule id {ref!r}")
         for colour in (r.led, r.led_from):
             if colour and colour not in LED:
@@ -170,11 +185,25 @@ class Finding:
     resolved: bool = False
     resolved_by: str | None = None
     evidence: deque[str] = field(default_factory=lambda: deque(maxlen=3))
+    error_ids: dict[str, str] = field(default_factory=dict)   # "E-SD-03" -> technician action
 
     @property
     def active(self) -> bool:
         return self.count >= self.min_count and not self.resolved
 
+    def seen_text(self) -> str:
+        """'Seen 3x, first at 2.9 s after start, last at 61.2 s' (panel and service note)."""
+        s = f"Seen {self.count}x"
+        if self.first_uptime_ms is not None:
+            first = f"{self.first_uptime_ms / 1000:.1f}"
+            s += f", first at {first} s after start"
+            last = f"{self.last_uptime_ms / 1000:.1f}" if self.last_uptime_ms is not None else first
+            if self.count > 1 and last != first:
+                s += f", last at {last} s"
+        if self.resolved and self.resolved_by:
+            s += f" - resolved ({self.resolved_by})"
+        return s
+
 
 @dataclass
 class BootRecord:
@@ -187,8 +216,15 @@ class BootRecord:
     saw_log: bool = False
     led_at_end: str | None = None
     panic_lines: list[str] = field(default_factory=list)
+    brownout: bool = False             # "E BOD: Brownout detector was triggered" before the restart
     recent_errors: deque[str] = field(default_factory=lambda: deque(maxlen=5))
     intentional_restart: bool = False  # factory reset / setup-mode toggle
+    # KOTA: lines (firmware 1.0.16+)
+    kota: dict[str, LogLine] = field(default_factory=dict)   # last line per record
+    last_restart: str | None = None      # "boot ... last_restart=" (why the previous boot ended)
+    restart_reason: str | None = None    # "restart reason=" printed just before this boot ended
+    previous_status: tuple[str, int] | None = None   # "led previous_boot status= code="
+    mode: str | None = None              # matter | wifi | provisioning
 
 
 @dataclass
@@ -215,14 +251,28 @@ class Report:
     boots: list[BootRecord]
     lines: int
     mid_run: bool                         # no boot seen yet
+    technician: list[str] = field(default_factory=list)   # guided-check answers
+    led_pattern: str = ""                 # "2 pulses", "solid", ... (exact when from a KOTA led line)
+    led_meaning: str = ""
+    led_exact: bool = False               # reported by the box itself
+    box: list[tuple[str, str, str]] = field(default_factory=list)   # (topic, text, ok|warn|bad|info)
+    matter_qr: str | None = None
+    matter_manual: str | None = None
+
+    def led_text(self) -> str:
+        t = LED[self.led][0] + (f", {self.led_pattern}" if self.led_pattern else "")
+        return t + (f" = {self.led_meaning}" if self.led_meaning else "")
 
     def to_text(self) -> str:
         out = [f"VERDICT: {self.verdict}",
-               f"Expected status LED: {LED[self.led][0]}"
+               f"Expected status LED: {self.led_text()}"
                + (f"  (last change: {self.led_reason})" if self.led_reason else ""),
                f"Firmware: {self.firmware.describe()}",
-               f"Boots seen: {max(len(self.boots) - (0 if self.boots and self.boots[0].explicit else 1), 0)}",
-               "", "Milestones (current boot):"]
+               f"Boots seen: {max(len(self.boots) - (0 if self.boots and self.boots[0].explicit else 1), 0)}"]
+        if self.box:
+            out += ["", "Box self-report (KOTA lines):"]
+            out += [f"  {topic}: {text}" for topic, text, _ in self.box]
+        out += ["", "Milestones (current boot):"]
         for _, label, t in self.milestones:
             out.append(f"  [{'x' if t is not None else ' '}] {label}"
                        + (f"  @ {t / 1000:.1f} s" if t is not None else ""))
@@ -243,12 +293,18 @@ class Report:
             out.append("Resolved during this session:")
             for f in self.resolved:
                 out.append(f"  - {f.title}" + (f" (by: {f.resolved_by})" if f.resolved_by else ""))
+        if self.technician:
+            out.append("")
+            out.append("Technician checks:")
+            out += [f"  - {t}" for t in self.technician]
         return "\n".join(out)
 
 
 def _finding_text(f: Finding, ind: str) -> list[str]:
     lines = [f"{ind}- [{f.severity.label}] {f.title}  (x{f.count})", f"{ind}  {f.meaning}"]
     lines += [f"{ind}  {i}. {a}" for i, a in enumerate(f.actions, 1)]
+    for eid, action in f.error_ids.items():
+        lines.append(f"{ind}  error {eid}" + (f": {action}" if action else ""))
     if f.evidence:
         lines.append(f"{ind}  log: {f.evidence[-1]}")
     return lines
@@ -258,6 +314,8 @@ class DiagnosticsEngine:
     def __init__(self, rules: list[Rule] | None = None):
         self.rules = rules if rules is not None else load_rules()
         self._rule_by_id = {r.id: r for r in self.rules}
+        self._pattern_rules = [r for r in self.rules if r.pattern is not None]
+        self.error_ids = kota.load_error_ids()
         self.reset()
 
     # ---------------------------------------------------------------- API
@@ -271,6 +329,18 @@ class DiagnosticsEngine:
         self.lines = 0
         self._tool_reset_at: float | None = None
         self._panic_tail = 0     # RAW lines after a panic line to keep
+        self.technician: list[str] = []
+        self.mac: str | None = None      # from "ID: Device MAC address: ..." at boot
+        self.matter_advert: str | None = None   # "Advertise commission parameter vendorID=..." line
+        self.matter_qr: str | None = None       # "KOTA: matter ... qr=MT:..."
+        self.matter_manual: str | None = None
+        self.kota_seen = False                  # firmware prints KOTA: lines
+        self._reset_led_state()
+
+    def _reset_led_state(self) -> None:
+        self.led_pattern = ""
+        self.led_exact = False                  # a KOTA led line was seen this boot
+        self.status: tuple[str, int] | None = None
 
     @property
     def boot(self) -> BootRecord:
@@ -283,6 +353,8 @@ class DiagnosticsEngine:
             if "reset issued by tool" in text:
                 self._tool_reset_at = line.host_time
             return
+        if _BROWNOUT in text:
+            self.boot.brownout = True
         if line.kind == LineKind.BOOT:
             self._new_boot(line.host_time, explicit=True)
             self.milestones["rom_boot"] = 0
@@ -292,7 +364,7 @@ class DiagnosticsEngine:
             if line.reset_reason and "POWERON" in line.reset_reason:
                 self.led, self.led_reason = "OFF", "power-on - firmware not started yet"
             return
-        if line.kind == LineKind.LOG and line.uptime_ms is not None:
+        if line.kind in (LineKind.LOG, LineKind.KOTA) and line.uptime_ms is not None:
             b = self.boot
             # Uptime jumped back to a fresh-boot value: the ROM banner was
             # missed (port reconnect, capture started late).
@@ -309,10 +381,20 @@ class DiagnosticsEngine:
             self._panic_tail -= 1
             self._crash_finding().evidence.append(text)
 
+        if line.kind == LineKind.KOTA:
+            self._on_kota(line)
+            return
+
         self.firmware.observe(text)
+        if m := _MAC_LINE.search(text):
+            self.mac = m.group(1).upper()
+        if "Advertise commission parameter" in text:
+            self.matter_advert = text
         matched = False
-        for rule in self.rules:
-            m = rule.pattern.search(text)
+        hit: list[Finding] = []
+        rule_text = line.match_text
+        for rule in self._pattern_rules:
+            m = rule.pattern.search(rule_text)
             if not m:
                 continue
             matched = True
@@ -321,7 +403,8 @@ class DiagnosticsEngine:
             groups = {k: v for k, v in m.groupdict().items() if v is not None}
             if rule.milestone and rule.milestone not in self.milestones:
                 self.milestones[rule.milestone] = line.uptime_ms or 0
-            if rule.led:
+            # The box's own "KOTA: led" lines are exact; message rules only guess.
+            if rule.led and not self.led_exact:
                 self._set_led(rule.led, rule.led_from, text)
             for cid in rule.clears:
                 for f in self.findings.values():
@@ -331,12 +414,18 @@ class DiagnosticsEngine:
             if rule.id in ("sys.factory_reset",) or "Short press:" in text:
                 self.boot.intentional_restart = True
             if rule.severity != Severity.IGNORE:
-                self._hit(rule, groups, line)
+                hit.append(self._hit(rule, groups, line))
 
         self._stateful(line)
+        if line.error_id:
+            info = self.error_ids.get(line.error_id)
+            for f in hit:
+                f.error_ids[line.error_id] = info.action if info else ""
+            if not matched:
+                self._hit_error_id(line, info)
         if line.level == "E":
             self.boot.recent_errors.append(text)
-            if not matched and line.tag:
+            if not matched and line.tag and not line.error_id:
                 self._hit_other(line)
 
     def report(self) -> Report:
@@ -350,7 +439,8 @@ class DiagnosticsEngine:
         # Worst consequence first, then the root's own severity, then order seen.
         roots.sort(key=lambda rc: (-rc.severity, -rc.finding.severity, rc.finding.first_uptime_ms or 0))
 
-        mid_run = not any(b.explicit for b in self.boots) and self.boot.index == 0
+        mid_run = (not any(b.explicit or "i2c" in b.kota or "boot" in b.kota for b in self.boots)
+                   and self.boot.index == 0)
         if self.lines == 0:
             verdict, vsev = "Waiting for data from the sensorbox...", None
         elif roots and roots[0].severity >= Severity.WARNING:
@@ -368,8 +458,27 @@ class DiagnosticsEngine:
               if not optional or mid in self.milestones]
         # Reached milestones in the order they happened, then the pending ones.
         ms.sort(key=lambda m: (m[2] is None, m[2] or 0))
+        pattern = self.led_pattern
         return Report(verdict, vsev, self.led, self.led_reason, self.firmware, ms, roots,
-                      earlier, resolved, list(self.boots), self.lines, mid_run)
+                      earlier, resolved, list(self.boots), self.lines, mid_run, list(self.technician),
+                      led_pattern=pattern, led_meaning=kota.led_meaning(self.led, pattern) if pattern else "",
+                      led_exact=self.led_exact, box=self._box_summary(),
+                      matter_qr=self.matter_qr, matter_manual=self.matter_manual)
+
+    def add_confirmed(self, key: str, severity: Severity, title: str, meaning: str,
+                      actions: tuple[str, ...]) -> Finding:
+        """A finding established by a guided check (technician answer + log)."""
+        f = self.findings.get(key)
+        if f is None:
+            f = self.findings[key] = Finding(key, key, severity, title, meaning, tuple(actions))
+        f.count += 1
+        f.boot = self.boot.index
+        f.resolved = False
+        f.evidence.append("confirmed by the technician during a guided check")
+        return f
+
+    def note_technician(self, text: str) -> None:
+        self.technician.append(text)
 
     # ------------------------------------------------------------ internals
     def _new_boot(self, host_time: float, explicit: bool) -> None:
@@ -389,6 +498,7 @@ class DiagnosticsEngine:
         self.led_reason = "restarting - LED keeps its last colour until the firmware starts"
         self.firmware = FirmwareInfo()
         self._panic_tail = 0
+        self._reset_led_state()
 
     def _set_led(self, colour: str, led_from: str | None, text: str) -> None:
         if led_from and self.led != led_from:
@@ -406,6 +516,7 @@ class DiagnosticsEngine:
                 key, rule.id, rule.severity, _fmt(rule.title, groups), _fmt(rule.meaning, groups),
                 tuple(_fmt(a, groups) for a in rule.actions), rule.explained_by, rule.min_count)
         self._touch(f, line)
+        return f
 
     def _touch(self, f: Finding, line: LogLine) -> None:
         f.count += 1
@@ -438,7 +549,7 @@ class DiagnosticsEngine:
             "sys.crash", Severity.CRITICAL, "Firmware stopped with an error and restarts",
             "The firmware hit a fatal error. The error printed just before it is the real cause.",
             ("See the grouped cause; otherwise save the session log for the firmware team.",),
-            tuple(_INIT_FAILURES))
+            tuple(_INIT_FAILURES) + ("reboot.brownout",))
 
     def _on_panic(self, line: LogLine) -> None:
         b = self.boot
@@ -464,35 +575,361 @@ class DiagnosticsEngine:
                 ("Replace the RTC module (inside the case).",))
             self._touch(f, line)
 
+    # ------------------------------------------------------- KOTA: lines
+    def _on_kota(self, line: LogLine) -> None:
+        self.kota_seen = True
+        rec, f = line.record or "", line.fields
+        # A second boot line in one boot: the ROM banner and the uptime drop
+        # were both missed (e.g. capture started with a gap).
+        if rec == "boot" and "boot" in self.boot.kota:
+            self._new_boot(line.host_time, explicit=False)
+        key = f"{rec}.verify" if rec == "rtc" and "verify" in line.words else rec
+        self.boot.kota[key] = line
+        handler = getattr(self, f"_kota_{rec}", None)
+        if handler is not None:
+            handler(line, f)
+
+    def _raise(self, rule_id: str, line: LogLine, groups: dict[str, str] | None = None) -> Finding:
+        """Raise a rules.toml finding from parsed KOTA fields (no pattern matching)."""
+        return self._hit(self._rule_by_id[rule_id], groups or {}, line)
+
+    def _resolve(self, rule_id: str, by: str, key: str | None = None) -> None:
+        for f in self.findings.values():
+            if f.rule_id == rule_id and (key is None or f.key == key) and not f.resolved:
+                f.resolved, f.resolved_by = True, by
+
+    def _milestone(self, mid: str, line: LogLine) -> None:
+        if mid not in self.milestones:
+            self.milestones[mid] = line.uptime_ms or 0
+
+    def _kota_boot(self, line: LogLine, f: dict[str, str]) -> None:
+        b = self.boot
+        self.firmware.observe_kota(f)
+        mac = f.get("mac", "")
+        if re.fullmatch(r"[0-9A-Fa-f]{12}", mac):
+            self.mac = ":".join(mac[i:i + 2] for i in range(0, 12, 2)).upper()
+        b.reset_reason = b.reset_reason or f.get("reset")
+        b.last_restart = f.get("last_restart")
+        b.mode = f.get("mode")
+        self._milestone("app_started", line)
+
+    def _kota_restart(self, line: LogLine, f: dict[str, str]) -> None:
+        reason = f.get("reason", "")
+        self.boot.restart_reason = reason
+        if reason in kota.INTENTIONAL_RESTARTS:
+            self.boot.intentional_restart = True
+
+    def _kota_i2c(self, line: LogLine, f: dict[str, str]) -> None:
+        if f.get("bus") == "stuck":
+            self._raise("kota.i2c_stuck", line, {"sda": f.get("SDA", "?"), "scl": f.get("SCL", "?")})
+            return
+        self._resolve("kota.i2c_stuck", "I2C bus free again")
+        missing = False
+        for addr, value in f.items():
+            if not addr.startswith("0x") or value == "?":
+                continue
+            name = value.removesuffix("(missing)")
+            if value.endswith("(missing)"):
+                missing = True
+                self._raise("kota.sensor_missing", line, {"sensor": name, "addr": addr})
+            else:
+                self._resolve("kota.sensor_missing", f"{name} found on I2C", f"kota.sensor_missing:{name}")
+        if not missing:
+            self._milestone("i2c_ok", line)
+
+    def _kota_rtc(self, line: LogLine, f: dict[str, str]) -> None:
+        if "verify" in line.words:
+            if f.get("ok") == "1":
+                self._milestone("clock_verified", line)
+                self._resolve("kota.rtc_not_ticking", "clock verified")
+            else:
+                self._raise("kota.rtc_not_ticking", line,
+                            {"running": f.get("running", "?"), "delta": f.get("delta", "no reading")})
+        elif "read_failed" in line.words:
+            self._raise("kota.rtc_read_failed", line, {"err": f.get("err", "?")})
+        elif f.get("running") == "0":
+            self._raise("kota.rtc_stopped", line, {"time": f.get("time", "?")})
+        elif f.get("running") == "1":
+            self._resolve("kota.rtc_read_failed", "clock answers")
+            self._resolve("kota.rtc_stopped", "clock running")
+
+    def _kota_sd(self, line: LogLine, f: dict[str, str]) -> None:
+        if f.get("mounted") == "0":
+            self._raise("kota.sd_unmounted", line, {"err": f.get("err", "card missing or unreadable")})
+            return
+        self._milestone("sd_mounted", line)
+        self._resolve("kota.sd_unmounted", "SD card mounted")
+        keys = {k for k in f.get("env_keys", "").split(",") if k and k != "-"}
+        missing = [k for k in ("INFLUX_URL", "INFLUX_TOKEN") if k not in keys]
+        for k in missing:
+            self._raise("influx.env_missing", line, {"key": k})
+        if not missing:
+            self._milestone("env_loaded", line)
+        if f.get("fs") and f["fs"] != "FAT32":
+            self._raise("kota.sd_not_fat32", line, {"fs": f["fs"]})
+        free = kota.parse_size_gb(f.get("free", ""))
+        if free is not None and free < 0.1:
+            self._raise("kota.sd_full", line, {"free": f["free"]})
+        lines = f.get("buffer_lines", "0")
+        if lines.isdigit() and int(lines) > 500:
+            self._raise("kota.buffer_backlog", line, {"lines": lines})
+
+    def _kota_matter(self, line: LogLine, f: dict[str, str]) -> None:
+        if f.get("qr", "-").startswith("MT:"):
+            self.matter_qr = f["qr"]
+        if f.get("manual", "-") != "-":
+            self.matter_manual = f["manual"]
+        fabrics = f.get("fabrics", "")
+        if fabrics == "0":
+            self._raise("matter.not_commissioned", line)
+        elif fabrics.isdigit():
+            self._milestone("matter_commissioned", line)
+            self._resolve("matter.not_commissioned", "paired in Matter")
+
+    def _kota_mic(self, line: LogLine, f: dict[str, str]) -> None:
+        if f.get("enabled") == "0":
+            self._raise("mic.disabled", line)
+        elif f.get("enabled") == "1":
+            self._resolve("mic.disabled", "microphone switched on")
+
+    def _kota_status(self, line: LogLine, f: dict[str, str]) -> None:
+        w = line.words
+        new = w[w.index("->") + 1] if "->" in w and w.index("->") + 1 < len(w) else (w[-1] if w else "")
+        code = int(f["code"]) if f.get("code", "").isdigit() else 0
+        self._apply_status(new, code, line, f.get("reason", ""))
+
+    def _apply_status(self, status: str, code: int, line: LogLine, reason: str) -> None:
+        self.status = (status, code)
+        if not self.led_exact:
+            self.led, self.led_pattern = kota.led_for_status(status, code)
+        self.led_reason = f"status {status}" + (f" code={code}" if code else "") + (
+            f", reason: {reason}" if reason else "")
+        sf = kota.status_finding(status, code)
+        key = sf[0] if sf else None
+        for fd in self.findings.values():
+            if fd.rule_id.startswith("status.") and fd.key != key and not fd.resolved:
+                fd.resolved, fd.resolved_by = True, f"status -> {status}"
+        if sf:
+            key, sev, title, meaning, actions, expl = sf
+            fd = self._custom(key, Severity[sev.upper()], title, meaning, actions, expl)
+            self._touch(fd, line)
+
+    def _kota_led(self, line: LogLine, f: dict[str, str]) -> None:
+        if "previous_boot" in line.words:
+            code = f.get("code", "0")
+            self.boot.previous_status = (f.get("status", "?"), int(code) if code.isdigit() else 0)
+            return
+        if "restart_flash" in line.words:
+            return
+        colour = kota.LED_COLOURS.get(f.get("color", ""))
+        if colour is None:
+            return
+        pattern = kota.pattern_text(f)
+        self.led, self.led_pattern, self.led_exact = ("OFF", "", True) if pattern == "off" else (colour, pattern, True)
+        if not self.led_reason or self.status is None:
+            self.led_reason = "reported by the box"
+
+    def _kota_health(self, line: LogLine, f: dict[str, str]) -> None:
+        up = kota.parse_seconds(f.get("up", "")) or 0
+        status = f.get("status", "")
+        # Connected mid-run: the health line is the first exact status we get.
+        if status and (self.status is None or self.status[0] != status):
+            self._apply_status(status, 0, line, "from the health report")
+        mode = self.boot.mode
+        wifi = f.get("wifi")
+        rssi = int(f["rssi"]) if f.get("rssi", "").lstrip("-").isdigit() else None
+        if wifi == "connected":
+            self._milestone("wifi_connected", line)
+            self._resolve("kota.wifi_down", "Wi-Fi connected")
+            if rssi is not None and rssi < -75:
+                self._raise("kota.weak_wifi", line, {"rssi": str(rssi)})
+            elif rssi is not None:
+                self._resolve("kota.weak_wifi", "signal OK")
+        elif wifi == "disconnected" and mode != "provisioning":
+            self._raise("kota.wifi_down", line)
+        if f.get("time_valid") == "1":
+            self._milestone("time_synced", line)
+            self._resolve("kota.time_invalid", "time valid")
+        elif f.get("time_valid") == "0" and up >= 120:
+            self._raise("kota.time_invalid", line)
+        if f.get("sd") == "missing":
+            self._raise("kota.sd_unmounted", line, {"err": "reported missing by the health check"})
+        last = f.get("last_upload", "never")
+        if last != "never":
+            self._milestone("data_uploaded", line)
+            self._resolve("kota.no_upload", "data uploaded")
+        elif wifi == "connected" and up >= 300:
+            self._raise("kota.no_upload", line)
+        heap = f.get("heap", "")
+        if heap.isdigit() and int(heap) < 20_000:
+            self._raise("kota.low_heap", line, {"heap": heap})
+        ota = f.get("ota")
+        if ota == "registered":
+            self._milestone("ota_registered", line)
+            self._resolve("kota.ota_unregistered", "registered")
+        elif ota == "unregistered" and wifi == "connected" and mode != "provisioning":
+            self._raise("kota.ota_unregistered", line)
+
+    def _hit_error_id(self, line: LogLine, info: kota.ErrorId | None) -> None:
+        eid = line.error_id or "?"
+        msg = (line.message or "").strip()
+        msg = msg if len(msg) <= 90 else msg[:87] + "..."
+        if info:
+            sev = Severity.WARNING if info.severity == "warning" else Severity.ERROR
+            f = self._custom(f"eid.{eid}", sev, f"{info.module_name}: {msg}",
+                             f"The firmware reported error {eid} ({info.module_name}).",
+                             (info.action, "If it repeats, save the session log for the firmware team."))
+            f.rule_id = f"eid.{info.module}"
+            f.error_ids[eid] = info.action
+        else:
+            f = self._custom(f"eid.{eid}", Severity.WARNING, f"Error {eid}: {msg}",
+                             "This error ID is not in the tool's error table (newer firmware?).",
+                             ("Save the session log and send it to the firmware team.",))
+        self._touch(f, line)
+
+    def _box_summary(self) -> list[tuple[str, str, str]]:
+        """What the box reported about itself in this boot (KOTA lines), for the panel."""
+        k = self.boot.kota
+        out: list[tuple[str, str, str]] = []
+        if ln := k.get("boot"):
+            f = ln.fields
+            lr = f.get("last_restart", "none")
+            bad = kota.restart_finding(lr) is not None
+            out.append(("Boot", f"v{f.get('fw', '?')} build {f.get('build', '?')}, mode {f.get('mode', '?')}, "
+                        f"reset {f.get('reset', '?')}, last restart: {lr}", "warn" if bad else "ok"))
+        if ps := self.boot.previous_status:
+            if ps[0] != "OK":
+                out.append(("Before restart", f"status {ps[0]}" + (f" code={ps[1]}" if ps[1] else ""), "warn"))
+        if ln := k.get("i2c"):
+            f = ln.fields
+            if f.get("bus") == "stuck":
+                out.append(("I2C", f"bus stuck (SDA={f.get('SDA')}, SCL={f.get('SCL')})", "bad"))
+            else:
+                devs = [(v.removesuffix("(missing)"), v.endswith("(missing)"))
+                        for a, v in f.items() if a.startswith("0x") and v != "?"]
+                miss = [n for n, m in devs if m]
+                text = ("missing: " + ", ".join(miss) + "; " if miss else "") + "found: " + (
+                    ", ".join(n for n, m in devs if not m) or "none")
+                out.append(("I2C", text, "bad" if miss else "ok"))
+        if ln := k.get("sd"):
+            f = ln.fields
+            if f.get("mounted") == "0":
+                out.append(("SD card", "not mounted" + (f" ({f['err']})" if f.get("err") else ""), "bad"))
+            else:
+                keys = f.get("env_keys", "-")
+                ok = "INFLUX_URL" in keys and "INFLUX_TOKEN" in keys
+                out.append(("SD card", f"{f.get('type', '?')} {f.get('size', '?')} {f.get('fs', '?')}, "
+                            f"{f.get('free', '?')} free, ENV keys: {keys}, buffered: {f.get('buffer_lines', '?')}",
+                            "ok" if ok else "bad"))
+        rtc, verify = k.get("rtc"), k.get("rtc.verify")
+        if rtc or verify:
+            parts, state = [], "ok"
+            if rtc:
+                if "read_failed" in rtc.words:
+                    parts.append(f"read failed ({rtc.fields.get('err', '?')})")
+                    state = "bad"
+                else:
+                    running = rtc.fields.get("running") == "1"
+                    parts.append(("running" if running else "STOPPED") + f", time {rtc.fields.get('time', '?')}")
+                    state = "ok" if running else "warn"
+            if verify:
+                ok = verify.fields.get("ok") == "1"
+                parts.append("verified ticking" if ok else "NOT keeping time")
+                state = state if ok else "bad"
+            out.append(("Clock (RTC)", "; ".join(parts), state))
+        if ln := k.get("matter"):
+            f = ln.fields
+            fabrics = f.get("fabrics", "?")
+            out.append(("Matter", f"{'paired' if fabrics not in ('0', '?') else 'NOT paired'} (fabrics {fabrics}), "
+                        f"pairing window {f.get('window', '?')}", "ok" if fabrics not in ("0", "?") else "warn"))
+        if ln := k.get("mic"):
+            on = ln.fields.get("enabled") == "1"
+            out.append(("Microphone", "on" if on else "switched OFF (switch on the back)", "ok" if on else "info"))
+        if ln := k.get("health"):
+            f = ln.fields
+            wifi = f.get("wifi", "?")
+            text = (f"up {f.get('up', '?')}, status {f.get('status', '?')}, Wi-Fi {wifi}"
+                    + (f" ({f.get('rssi')} dBm)" if wifi == "connected" else "")
+                    + f", time {'OK' if f.get('time_valid') == '1' else 'NOT set'}, SD {f.get('sd', '?')}, "
+                    f"buffer {f.get('buffer', '?')}, heap {f.get('heap', '?')}, last upload {f.get('last_upload', '?')}"
+                    + ("" if f.get("last_upload") == "never" else " ago") + f", OTA {f.get('ota', '?')}")
+            good = f.get("status") == "OK" and wifi == "connected" and f.get("last_upload") != "never"
+            out.append(("Health", text, "ok" if good else "warn"))
+        return out
+
+    # ------------------------------------------------------------ reboots
     def _reboot_findings(self) -> list[Finding]:
         """Classify why each earlier boot ended (needs the next boot's reset reason)."""
         out: list[Finding] = []
         short_unexpected: list[BootRecord] = []
+        cur = self.boot
+        # The box keeps its status across a restart ("led previous_boot"): if
+        # it was in an error state right before the latest restart (often the
+        # technician's Reset & capture), that state is worth showing.
+        if cur.previous_status and cur.previous_status[0] not in ("OK", "UPDATING", "SELF_CHECK"):
+            sf = kota.status_finding(*cur.previous_status)
+            st, code = cur.previous_status
+            # Only informative once the box reports OK again in this boot.
+            sev = Severity.INFO if self.status and self.status[0] == "OK" else Severity.WARNING
+            f = Finding("boot.previous_status", "boot.previous_status", sev,
+                        f"Before the last restart: {sf[2] if sf else st}",
+                        "The box remembers its status across a restart. Right before the latest restart it was in "
+                        f"state {st}" + (f" code={code}" if code else "") + ". "
+                        + (sf[3] if sf else "") + " Check whether the problem comes back in this boot.",
+                        sf[4] if sf else ())
+            f.count, f.boot, f.last_seen = 1, cur.index, cur.host_time
+            f.evidence.append(f"led previous_boot status={st} code={code}")
+            out.append(f)
         for prev, nxt in zip(self.boots, self.boots[1:]):
             if not prev.saw_log and prev.index == 0:
                 continue  # nothing captured before the first boot
             reason = nxt.reset_reason or "unknown"
             if nxt.tool_reset or prev.intentional_restart:
                 continue
+            # Firmware 1.0.16+ records why it restarted itself.
+            last = nxt.last_restart or prev.restart_reason
+            if last in kota.INTENTIONAL_RESTARTS:
+                continue
             key, sev, title, meaning, actions, expl = None, Severity.INFO, "", "", (), ()
-            if "USB_UART_CHIP_RESET" in reason:
+            rf = kota.restart_finding(last) if last else None
+            if prev.brownout or "BROWN" in reason or last == "brownout":
+                # A crash right after a brown-out is its effect, not a firmware bug.
+                key, sev, title = "reboot.brownout", Severity.CRITICAL, "Power supply voltage drops (brown-out)"
+                meaning = ("The supply voltage fell too low and the chip reset itself - typically when the "
+                           "Wi-Fi/Bluetooth radio starts. The box cannot run like this.")
+                actions = ("Switch the box's power switch ON - USB from a laptop alone may not be enough.",
+                           "Check the power supply, cable and connectors; try another supply.",
+                           "If it persists on a good supply: the board's power circuit is faulty.")
+            elif rf and not (last == "panic" and prev.panic_lines):
+                sev_name, title, meaning, actions = rf
+                sev = Severity[sev_name.upper()]
+                key = {"status_watchdog": "reboot.status_watchdog", "panic": "reboot.crash",
+                       "brownout": "reboot.brownout", "task_wdt": "reboot.watchdog", "int_wdt": "reboot.watchdog",
+                       "wdt": "reboot.watchdog"}.get(last, f"reboot.{last}")
+                if nxt.previous_status and nxt.previous_status[0] != "OK":
+                    st, code = nxt.previous_status
+                    meaning += f" Before the restart the box was in state {st}" + (f" code={code}" if code else "") + "."
+                if last == "status_watchdog":
+                    expl = tuple(_INIT_FAILURES) + kota._SENSOR_ROOTS + ("status.error", "sys.out_of_resources")
+                elif last == "status_oom_watchdog":
+                    expl = ("sys.out_of_resources",)
+            elif rf:
+                pass  # panic with captured crash output: covered by sys.crash
+            elif "USB_UART_CHIP_RESET" in reason:
                 key, title = "reboot.usb", "Box was reset over USB"
                 meaning = "The board was reset through its USB port (a flashing tool, a serial program, or this tool in an earlier session)."
             elif "POWERON" in reason:
                 key, title = "reboot.power", "Box was switched off and on"
                 meaning = "Power was interrupted (power switch, cable or supply)."
                 actions = ("If nobody switched it off: check the power supply and cable.",)
-            elif "BROWN" in reason:
-                key, sev, title = "reboot.brownout", Severity.ERROR, "Power supply voltage dropped (brown-out)"
-                meaning = "The supply voltage fell too low and the chip reset itself."
-                actions = ("Check the power supply, cable and connectors.",)
             elif "WDT" in reason:
                 key, sev, title = "reboot.watchdog", Severity.ERROR, "Firmware froze and was restarted by the watchdog"
                 meaning = "The firmware stopped responding; the hardware watchdog restarted it."
                 actions = ("Save the session log for the firmware team.",)
             elif prev.panic_lines:
                 pass  # covered by sys.crash
-            elif prev.led_at_end in ("PURPLE", "RED") and prev.last_uptime_ms >= 140_000:
+            elif (not nxt.last_restart and prev.led_at_end in ("PURPLE", "RED")
+                  and prev.last_uptime_ms >= 140_000):   # older firmware: no restart record
                 key, title = "reboot.status_watchdog", "Box restarted itself after 2.5 minutes of errors"
                 meaning = "By design the firmware restarts when it stays in an error state (purple/red) for 150 s."
                 actions = ("Fix the grouped cause; the restarts stop by themselves.",)
@@ -511,10 +948,18 @@ class DiagnosticsEngine:
                 "reboot.loop", Severity.CRITICAL, "Reboot loop",
                 f"The box restarted {len(short_unexpected)} times, about every {avg:.0f} s. "
                 "The error printed just before each restart is the cause.",
-                ("Fix the grouped cause below.",), tuple(_INIT_FAILURES), self.boot)
+                ("Fix the grouped cause below.",), tuple(_INIT_FAILURES) + ("reboot.brownout",), self.boot)
             f.count = len(short_unexpected)
             out.append(f)
-        return out
+        # One finding per cause, counting how often it happened.
+        merged: dict[str, Finding] = {}
+        for f in out:
+            if f.key in merged:
+                merged[f.key].count += f.count
+                merged[f.key].evidence.extend(f.evidence)
+            else:
+                merged[f.key] = f
+        return list(merged.values())
 
     def _reboot_finding(self, key, sev, title, meaning, actions, expl, boot: BootRecord) -> Finding:
         f = Finding(key, key, sev, title, meaning, actions, expl)

kota_tech/diag/error_ids.csv

@@ -0,0 +1,193 @@
+id,module,severity,message,action
+E-SD-01,SD,error,Failed to take SPI mutex,Internal error - send the log to the firmware team
+E-SD-02,SD,error,"Failed to mount filesystem. If you want the card to be formatted, set the CONFIG_EXAMPLE_FORMAT_IF_MOUNT_FAILED menuconfig option.",SD card is not FAT formatted or is corrupt; reformat it as FAT32 and restore ENV.TXT
+E-SD-03,SD,error,Failed to initialize the card (%s). Make sure SD card lines have pull-up resistors in place.,Reseat the SD card; if it persists replace the card or check the SD connector
+E-SD-04,SD,error,Failed to stat %s,Reseat the SD card; if it persists replace the card or check the SD connector
+E-SD-05,SD,error,Failed to take SPI mutex,Internal error - send the log to the firmware team
+E-ENV-01,ENV,error,Failed to take SPI mutex,Internal error - send the log to the firmware team
+E-ENV-02,ENV,error,Failed to open .env file for reading,Check ENV.TXT on the SD card exists and has NAME=VALUE lines
+E-ENV-03,ENV,error,Failed to take SPI mutex,Internal error - send the log to the firmware team
+E-ENV-04,ENV,error,Failed to open existing .env file for reading; aborting write to avoid losing other variables,Check ENV.TXT on the SD card exists and has NAME=VALUE lines
+E-ENV-05,ENV,error,Failed to open .env file for writing,Check ENV.TXT on the SD card exists and has NAME=VALUE lines
+E-ENV-06,ENV,error,Failed to take SPI mutex,Internal error - send the log to the firmware team
+E-ENV-07,ENV,error,Failed to open existing .env file for reading; aborting delete to avoid losing other variables,Check ENV.TXT on the SD card exists and has NAME=VALUE lines
+E-ENV-08,ENV,error,Failed to open .env file for writing,Check ENV.TXT on the SD card exists and has NAME=VALUE lines
+E-ENV-09,ENV,error,Failed to take SPI mutex,Internal error - send the log to the firmware team
+E-INF-01,INF,error,Error %d at %s:%d,Internal error - send the log to the firmware team
+E-INF-02,INF,error,Failed to initialize HTTP client,Internal error - send the log to the firmware team
+E-INF-03,INF,error,"Failed to perform HTTP request: %d, %s",Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-04,INF,error,"Bad request, check line protocol format: %s",Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-05,INF,error,Failed to read INFLUX_URL from .env file,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-06,INF,error,Failed to read INFLUX_TOKEN from .env file,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-07,INF,error,Failed to take SPI mutex,Internal error - send the log to the firmware team
+E-INF-08,INF,error,Failed to open buffer file for reading,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-09,INF,error,Failed to take SPI mutex,Internal error - send the log to the firmware team
+E-INF-10,INF,error,Failed to open buffer file for clearing,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-11,INF,error,Failed to take SPI mutex,Internal error - send the log to the firmware team
+E-INF-12,INF,error,Failed to create buffer file,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-13,INF,error,Failed to open buffer file for appending,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-14,INF,error,Failed to take SPI mutex,Internal error - send the log to the firmware team
+E-INF-15,INF,error,Failed to open buffer file for counting,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-16,INF,error,Failed to read buffer for flushing: %s,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-17,INF,error,Failed to write chunk to Influx: %s,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-18,INF,error,Failed to write chunk with 5 retries to Influx: %s,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-19,INF,error,Failed to clear buffer after flushing: %s,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-20,INF,error,Failed to flush buffer before writing: %s,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-21,INF,error,Failed to write to Influx: %s,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-INF-22,INF,error,Failed to append new entry to buffer: %s,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-OTA-01,OTA,error,Error %s at %s:%d,Internal error - send the log to the firmware team
+E-OTA-02,OTA,error,Failed to create OTA task,Internal error - send the log to the firmware team
+E-OTA-03,OTA,error,Failed to open NVS: %s,Internal error - send the log to the firmware team
+E-OTA-04,OTA,error,Failed to read OTA token from NVS: %s,Internal error - send the log to the firmware team
+E-OTA-05,OTA,error,Failed to read OTA token from NVS: %s,Internal error - send the log to the firmware team
+E-OTA-06,OTA,error,Failed to get running partition,Check the network connection; if it persists send the log to the firmware team
+E-OTA-07,OTA,error,Failed to get OTA state,Check the network connection; if it persists send the log to the firmware team
+E-OTA-08,OTA,error,Failed to read update metadata from NVS: %s,Internal error - send the log to the firmware team
+E-OTA-09,OTA,error,Failed to report failed selfcheck: %s,Check the network connection; if it persists send the log to the firmware team
+E-OTA-10,OTA,error,Failed to initialize HTTP client,Internal error - send the log to the firmware team
+E-OTA-11,OTA,error,Device registration failed with status code: %d,Check the network connection; if it persists send the log to the firmware team
+E-OTA-12,OTA,error,Device registration failed: %s,Check the network connection; if it persists send the log to the firmware team
+E-OTA-13,OTA,error,Failed to check for updates: %s,Check the network connection; if it persists send the log to the firmware team
+E-OTA-14,OTA,error,Free stack size decreased from %u to %u,Internal error - send the log to the firmware team
+E-OTA-15,OTA,error,Failed to initialize HTTP client,Internal error - send the log to the firmware team
+E-OTA-16,OTA,error,OTA Update check failed with status code: %d,Check the network connection; if it persists send the log to the firmware team
+E-OTA-17,OTA,error,"Update %s has already been tried %u times and failed, not trying again",Internal error - send the log to the firmware team
+E-OTA-18,OTA,error,OTA update failed: %s,Check the network connection; if it persists send the log to the firmware team
+E-OTA-19,OTA,error,Failed to read update metadata from NVS: %s,Internal error - send the log to the firmware team
+E-OTA-20,OTA,error,Failed to read update ID from NVS: %s,Internal error - send the log to the firmware team
+E-OTA-21,OTA,error,Failed to read update ID from NVS: %s,Internal error - send the log to the firmware team
+E-OTA-22,OTA,error,Failed to read update tries from NVS: %s,Internal error - send the log to the firmware team
+E-OTA-23,OTA,error,Failing selfcheck: %s,Firmware update failed its self check and will roll back; check the sensors listed in the log
+E-OTA-24,OTA,error,Failed to send update result: %s,Check the network connection; if it persists send the log to the firmware team
+E-OTA-25,OTA,error,Failed to mark app as invalid for rollback: %s,Internal error - send the log to the firmware team
+E-OTA-26,OTA,error,Failed to send update result: %s,Check the network connection; if it persists send the log to the firmware team
+E-OTA-27,OTA,error,Failed to mark app as valid to commit update: %s,Internal error - send the log to the firmware team
+E-OTA-28,OTA,error,Failed to initialize HTTP client,Internal error - send the log to the firmware team
+E-OTA-29,OTA,error,Failed to send update result with status code: %d,Check the network connection; if it persists send the log to the firmware team
+E-WIFI-01,WIFI,error,esp_netif_init() failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-02,WIFI,error,esp_event_loop_create_default() failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-03,WIFI,error,esp_wifi_init() failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-04,WIFI,error,Failed to register WIFI_EVENT handler: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-05,WIFI,error,Failed to register IP_EVENT handler: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-06,WIFI,error,esp_wifi_set_mode() failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-07,WIFI,error,esp_timer_create() failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-08,WIFI,error,esp_wifi_start() failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-09,WIFI,error,esp_wifi_set_config() failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-10,WIFI,error,esp_wifi_connect() failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-11,WIFI,error,esp_wifi_set_mode(APSTA) failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-12,WIFI,error,esp_wifi_set_config(AP) failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-13,WIFI,error,esp_wifi_connect() failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-14,WIFI,error,esp_wifi_scan_start() failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-15,WIFI,error,esp_wifi_scan_get_ap_num() failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-WIFI-16,WIFI,error,esp_wifi_scan_get_ap_records() failed: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-PROV-01,PROV,error,mdns_init() failed: %s,Retry WiFi provisioning (short button press); restart the device if it persists
+E-PROV-02,PROV,error,httpd_start() failed: %s,Retry WiFi provisioning (short button press); restart the device if it persists
+E-MAIN-01,MAIN,error,Error %d at %s:%d,Internal error - send the log to the firmware team
+E-MAIN-02,MAIN,error,"Failed to open commissioning window, err:%",Internal error - send the log to the firmware team
+E-MAIN-03,MAIN,error,"Attribute update callback: endpoint_id: %u, cluster_id: 0x%lx, attribute_id: 0x%lx",Internal error - send the log to the firmware team
+E-MAIN-04,MAIN,error,Device MAC address: %02X:%02X:%02X:%02X:%02X:%02X,Internal error - send the log to the firmware team
+E-MAIN-05,MAIN,error,Failed to initialize SD card: %s,Reseat the SD card; if it persists replace the card or check the SD connector
+E-MAIN-06,MAIN,error,Failed to initialize EnvironmentService: %s,Check ENV.TXT on the SD card exists and has NAME=VALUE lines
+E-MAIN-07,MAIN,error,Failed to initialize WifiCredentialsService: %s,Check ENV.TXT on the SD card exists and has NAME=VALUE lines
+E-MAIN-08,MAIN,error,WiFi provisioning server failed to start: %s; clearing HTTP_SERVER and restarting,Retry WiFi provisioning (short button press); restart the device if it persists
+E-MAIN-09,MAIN,error,Failed to create Matter node,Internal error - send the log to the firmware team
+E-MAIN-10,MAIN,error,Failed to start ESP-Matter,Internal error - send the log to the firmware team
+E-MAIN-11,MAIN,error,Failed to start WifiService: %s,Check WiFi signal and credentials; re-run WiFi provisioning (short button press)
+E-MAIN-12,MAIN,error,"Failed to initialized the encrypted OTA, err: %d",Internal error - send the log to the firmware team
+E-MAIN-13,MAIN,error,Failed to initialize RTC: %s,Check the RTC (DS1307) and the sensor cable
+E-MAIN-14,MAIN,error,Failed to initialize Influx buffer: %s,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-MAIN-15,MAIN,error,Failed to initialize BME688: %s,Check the BME688 sensor and the sensor cable
+E-MAIN-16,MAIN,error,Failed to initialize SEN66: %s,"Check the SEN66 sensor, its power supply and the sensor cable"
+E-MAIN-17,MAIN,error,Failed to initialize AS7341: %s,Check the AS7341 light sensor and the sensor cable
+E-MAIN-18,MAIN,error,Failed to initialize Microphone: %s,Check the microphone board and its cable
+E-MAIN-19,MAIN,error,Failed to initialize Flicker sensor: %s,Check the flicker sensor and its cable
+E-MAIN-20,MAIN,error,Failed to initialize DeviceStatus: %s,Internal error - send the log to the firmware team
+E-MAIN-21,MAIN,error,BME688 self check failed: %s,Check the BME688 sensor and the sensor cable
+E-MAIN-22,MAIN,error,SEN66 self check failed: %s,"Check the SEN66 sensor, its power supply and the sensor cable"
+E-MAIN-23,MAIN,error,AS7341 self check failed: %s,Check the AS7341 light sensor and the sensor cable
+E-MAIN-24,MAIN,error,Microphone self check failed: %s,Check the microphone board and its cable
+E-MAIN-25,MAIN,error,Flicker sensor self check failed: %s,Check the flicker sensor and its cable
+E-MAIN-26,MAIN,error,Failed to report passed selfcheck: %s,Internal error - send the log to the firmware team
+E-MAIN-27,MAIN,error,Failed to flush Influx buffer: %s,Check the network connection and INFLUX_URL / INFLUX_TOKEN in ENV.TXT
+E-STAT-01,STAT,error,Failed to initialize LED strip: %s,Internal error - send the log to the firmware team
+E-SPI-01,SPI,error,Failed to take SPI mutex,Internal error - send the log to the firmware team
+E-RTC-01,RTC,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-RTC-02,RTC,error,Failed to add I2C device: %s,Check the RTC (DS1307) and the sensor cable
+E-RTC-03,RTC,error,Failed to initialize DS1307 control register: %s,Check the RTC (DS1307) and the sensor cable
+E-RTC-04,RTC,error,Attempted to set time on uninitialized DS1307,Internal error - send the log to the firmware team
+E-RTC-05,RTC,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-RTC-06,RTC,error,Attempted to get time on uninitialized DS1307,Internal error - send the log to the firmware team
+E-RTC-07,RTC,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-RTC-08,RTC,error,Attempted to start updating time on uninitialized DS1307,Internal error - send the log to the firmware team
+E-BME-01,BME,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-BME-02,BME,error,Failed to add I2C device: %d,Check the BME688 sensor and the sensor cable
+E-BME-03,BME,error,Failed to initialize BME688: %d,Check the BME688 sensor and the sensor cable
+E-BME-04,BME,error,Failed to set BME688 configuration: %d,Check the BME688 sensor and the sensor cable
+E-BME-05,BME,error,Failed to set BME688 heater configuration: %d,Check the BME688 sensor and the sensor cable
+E-BME-06,BME,error,Failed to set BME688 operation mode: %d,Check the BME688 sensor and the sensor cable
+E-BME-07,BME,error,Failed to get BME688 data: %d,Check the BME688 sensor and the sensor cable
+E-BME-08,BME,error,No new data available from BME688,Check the BME688 sensor and the sensor cable
+E-BME-09,BME,error,Failed to get data from BME688: %s,Check the BME688 sensor and the sensor cable
+E-BME-10,BME,error,Self check failed: %s,Check the BME688 sensor and the sensor cable
+E-BME-11,BME,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-BME-12,BME,error,I2C read failed: %s,Check the BME688 sensor and the sensor cable
+E-BME-13,BME,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-BME-14,BME,error,Failed to allocate memory for I2C write buffer,Internal error - send the log to the firmware team
+E-BME-15,BME,error,I2C write failed: %s,Check the BME688 sensor and the sensor cable
+E-SEN-01,SEN,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-SEN-02,SEN,error,Failed to add I2C device: %d,"Check the SEN66 sensor, its power supply and the sensor cable"
+E-SEN-03,SEN,error,Attempted to wake up uninitialized SEN66,Internal error - send the log to the firmware team
+E-SEN-04,SEN,error,Failed to take sensor mutex,Internal error - send the log to the firmware team
+E-SEN-05,SEN,error,Failed to send start measurement command: %d,"Check the SEN66 sensor, its power supply and the sensor cable"
+E-SEN-06,SEN,error,Attempted to sleep uninitialized SEN66,Internal error - send the log to the firmware team
+E-SEN-07,SEN,error,Failed to take sensor mutex,Internal error - send the log to the firmware team
+E-SEN-08,SEN,error,Failed to send stop measurement command: %d,"Check the SEN66 sensor, its power supply and the sensor cable"
+E-SEN-09,SEN,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-SEN-10,SEN,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-SEN-11,SEN,error,Failed to read ready status: %d,"Check the SEN66 sensor, its power supply and the sensor cable"
+E-SEN-12,SEN,error,"Sensor not ready after %d attempts, trying to wake it up","Check the SEN66 sensor, its power supply and the sensor cable"
+E-SEN-13,SEN,error,Failed to read measurement: %d,"Check the SEN66 sensor, its power supply and the sensor cable"
+E-SEN-14,SEN,error,Failed while awaiting sensor ready: %d,"Check the SEN66 sensor, its power supply and the sensor cable"
+E-SEN-15,SEN,error,Failed to read measurement for line protocol: %d,"Check the SEN66 sensor, its power supply and the sensor cable"
+E-SEN-16,SEN,error,Self-check failed: Sensor not ready: %d,"Check the SEN66 sensor, its power supply and the sensor cable"
+E-SEN-17,SEN,error,Self-check failed: Failed to read measurement: %d,"Check the SEN66 sensor, its power supply and the sensor cable"
+E-AS-01,AS,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-AS-02,AS,error,Failed to initialize AS7341: %s,Check the AS7341 light sensor and the sensor cable
+E-AS-03,AS,error,Attempted to wake up uninitialized AS7341,Internal error - send the log to the firmware team
+E-AS-04,AS,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-AS-05,AS,error,Failed to wake up AS7341: %s,Check the AS7341 light sensor and the sensor cable
+E-AS-06,AS,error,Attempted to put uninitialized AS7341 to sleep,Internal error - send the log to the firmware team
+E-AS-07,AS,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-AS-08,AS,error,Failed to put AS7341 to sleep: %s,Check the AS7341 light sensor and the sensor cable
+E-AS-09,AS,error,Attempted to get line protocol on uninitialized AS7341,Internal error - send the log to the firmware team
+E-AS-10,AS,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-AS-11,AS,error,Failed to read spectral data: %s,Check the AS7341 light sensor and the sensor cable
+E-AS-12,AS,error,Failed to read basic counts data: %s,Check the AS7341 light sensor and the sensor cable
+E-AS-13,AS,error,Failed to read flicker detection state: %s,Check the AS7341 light sensor and the sensor cable
+E-AS-14,AS,error,Self-check failed: Failed to read spectral data: %s,Check the AS7341 light sensor and the sensor cable
+E-MIC-01,MIC,error,Failed to create I2S channel: %s,Check the microphone board and its cable
+E-MIC-02,MIC,error,Failed to initialize I2S channel in standard mode: %s,Check the microphone board and its cable
+E-MIC-03,MIC,error,Failed to configure shutdown pin: %s,Check the microphone board and its cable
+E-MIC-04,MIC,error,Failed to read samples from I2S channel: %s,Check the microphone board and its cable
+E-MIC-05,MIC,error,Failed to read samples for line protocol: %s,Check the microphone board and its cable
+E-FLK-01,FLK,error,Error %s at %s:%d,Internal error - send the log to the firmware team
+E-FLK-02,FLK,error,Attempting to initialize sensor that is already initialized,Check the flicker sensor and its cable
+E-FLK-03,FLK,error,Failed to allocate memory for FFT buffers,Internal error - send the log to the firmware team
+E-FLK-04,FLK,error,Failed to initialize FFT: %s,Check the flicker sensor and its cable
+E-FLK-05,FLK,error,Attempting to read from uninitialized sensor,Internal error - send the log to the firmware team
+E-FLK-06,FLK,error,Failed to take I2C mutex,Internal error - send the log to the firmware team
+E-FLK-07,FLK,error,Failed to get dominant frequency: %s,Check the flicker sensor and its cable
+E-FLK-08,FLK,error,Attempting to read from uninitialized sensor,Internal error - send the log to the firmware team
+E-FLK-09,FLK,error,Failed to read ADC value: %s,Check the flicker sensor and its cable
+E-FLK-10,FLK,error,Failed to create gather task: %s,Internal error - send the log to the firmware team
+E-FLK-11,FLK,error,Attempting to self check uninitialized sensor,Internal error - send the log to the firmware team
+E-FLK-12,FLK,error,Self check failed to get dominant frequency: %s,Check the flicker sensor and its cable
+E-DEV-01,DEV,error,Failed to initialize ADC unit: %s,Internal error - send the log to the firmware team
+E-DEV-02,DEV,error,Failed to configure ADC channel: %s,Internal error - send the log to the firmware team
+E-DEV-03,DEV,error,Failed to install temperature sensor: %s,Internal error - send the log to the firmware team
+E-DEV-04,DEV,error,Failed to read ADC value: %s,Internal error - send the log to the firmware team
+E-DEV-05,DEV,error,Failed to allocate memory for task list buffer,Internal error - send the log to the firmware team
+E-GATH-01,GATH,error,Failed to take line protocol mutex,Internal error - send the log to the firmware team
+E-GATH-02,GATH,error,Failed to get line protocol from sensor,Device ran out of memory; restart it and send the log to the firmware team
+E-GATH-03,GATH,error,Failed to create task for sensor,Internal error - send the log to the firmware team
+E-GATH-04,GATH,error,Failed to create main gather task,Internal error - send the log to the firmware team

kota_tech/diag/firmware.py

@@ -1,8 +1,14 @@
 """Firmware identification from the boot log.
 
-The app version string is "1.0" in every build seen so far, so builds are
-told apart by the ELF SHA256 prefix printed by app_init. Boxes receive new
-firmware over OTA; an unknown SHA usually means a box has already updated.
+Up to firmware 1.0 the app version string was "1.0" in every build, so
+builds are told apart by the ELF SHA256 prefix printed by app_init. Boxes
+receive new firmware over OTA; an unknown SHA usually means a box has already
+updated.
+
+Firmware 1.0.16+ prints "KOTA: boot fw=1.0.16 build=4f10989e ..." (version
+unique per build, first 8 hex digits of the ELF SHA256). Builds found in the
+tool's firmware/ folder are registered with `register_local_build` so the
+box's build can be shown with its compile date.
 """
 
 from __future__ import annotations
@@ -26,8 +32,35 @@ KNOWN: dict[str, KnownFirmware] = {
         sd_wifi=False,
         setup_portal=False,
     ),
+    "c94ba0e9b": KnownFirmware(
+        name="v1.0 source build (Sep 26 2026)",
+        source="developer build, built by Krzysztof Kallas",
+        sd_wifi=True,
+        setup_portal=True,
+    ),
 }
 
+# elf sha (full or prefix) -> (version, compile time, file name) of builds in firmware/
+LOCAL_BUILDS: dict[str, tuple[str, str, str]] = {}
+
+
+def register_local_build(elf_sha: str, version: str, built: str, file_name: str) -> None:
+    LOCAL_BUILDS[elf_sha.lower()] = (version, built, file_name)
+
+
+def same_build(a: str | None, b: str | None) -> bool:
+    """ELF SHA prefixes of different lengths (8 from KOTA: boot, 9+ from
+    app_init, 64 from an image) name the same build if they agree."""
+    if not a or not b:
+        return False
+    n = min(len(a), len(b))
+    return n >= 6 and a[:n].lower() == b[:n].lower()
+
+
+def local_build(elf_sha: str | None) -> tuple[str, str, str] | None:
+    return next((v for sha, v in LOCAL_BUILDS.items() if same_build(sha, elf_sha)), None)
+
+
 _ELF = re.compile(r"app_init: ELF file SHA256:\s+(?P<sha>[0-9a-f]{6,})")
 _VER = re.compile(r"app_init: App version:\s+(?P<v>\S+)")
 _BUILT = re.compile(r"app_init: Compile time:\s+(?P<t>.+)$")
@@ -45,8 +78,21 @@ class FirmwareInfo:
     version: str | None = None
     built: str | None = None
     idf: str | None = None
+    hw: str | None = None
     evidence: set[str] = field(default_factory=set)
 
+    def observe_kota(self, fields: dict[str, str]) -> None:
+        """'KOTA: boot fw=1.0.16 build=4f10989e hw=2 ...'"""
+        if fields.get("fw"):
+            self.version = fields["fw"]
+        build = fields.get("build", "")
+        # app_init's longer prefix is kept if it agrees.
+        if build and not same_build(self.elf_sha, build):
+            self.elf_sha = build.lower()
+        if fields.get("hw"):
+            self.hw = fields["hw"]
+        self.evidence.add("kota")      # 1.0.16+: SD Wi-Fi and setup portal exist
+
     def observe(self, text: str) -> None:
         if m := _ELF.search(text):
             self.elf_sha = m.group("sha")
@@ -67,14 +113,14 @@ class FirmwareInfo:
     def known(self) -> KnownFirmware | None:
         if not self.elf_sha:
             return None
-        return next((k for sha, k in KNOWN.items() if self.elf_sha.startswith(sha)), None)
+        return next((k for sha, k in KNOWN.items() if same_build(self.elf_sha, sha)), None)
 
     @property
     def supports_sd_wifi(self) -> bool | None:
         """True/False when determinable, None when unknown (no boot seen)."""
         if k := self.known:
             return k.sd_wifi
-        if "sd_wifi" in self.evidence:
+        if "sd_wifi" in self.evidence or "kota" in self.evidence:
             return True
         if "legacy_v1" in self.evidence:
             return False
@@ -83,6 +129,16 @@ class FirmwareInfo:
     def describe(self) -> str:
         if k := self.known:
             return f"{k.name} - {k.source}"
+        if self.elf_sha and (self.version not in (None, "1.0") or local_build(self.elf_sha)):
+            local = local_build(self.elf_sha)
+            built = self.built or (local[1] if local else None)
+            text = f"v{self.version or (local[0] if local else '?')} (build {self.elf_sha[:8]}"
+            text += f", compiled {built})" if built else ")"
+            if self.hw:
+                text += f", hardware {self.hw}"
+            if local:
+                text += f" - same as firmware/{local[2]}"
+            return text
         if self.elf_sha:
             built = f", built {self.built}" if self.built else ""
             return f"Unknown build {self.elf_sha[:9]}{built} (probably updated over OTA)"

kota_tech/diag/guides.py

@@ -0,0 +1,401 @@
+"""Guided troubleshooting: executes the decision trees in guides.toml.
+
+GUI-independent. The runner is fed the same LogLines as the diagnostics
+engine, reads the engine's report to route and to skip questions the log
+already answers, asks the host to perform tool actions (board reset), and
+records every answer and conclusion in the engine so they appear in the
+report and the session log.
+"""
+
+from __future__ import annotations
+
+import re
+import time
+import tomllib
+from collections.abc import Callable
+from dataclasses import dataclass, field
+from pathlib import Path
+
+from ..core.logline import LogLine
+from .engine import LED, DiagnosticsEngine, Severity
+
+GUIDES_PATH = Path(__file__).with_name("guides.toml")
+# LED answers a technician can give (engine colours + a reboot-loop pattern).
+LED_ANSWERS = ["GREEN", "PURPLE", "RED", "BLUE", "WHITE", "YELLOW", "ORANGE", "CYAN", "OFF", "CYCLING"]
+LED_ANSWER_LABELS = {**{k: v[0] for k, v in LED.items()},
+                     "CYCLING": "Keeps changing / goes dark every few seconds"}
+STEP_TYPES = {"led", "question", "info", "wait", "route"}
+END_SEVERITY = {"ok": None, "info": Severity.INFO, "warning": Severity.WARNING,
+                "error": Severity.ERROR, "critical": Severity.CRITICAL}
+
+
+@dataclass(frozen=True)
+class Option:
+    label: str
+    next: str
+
+
+@dataclass(frozen=True)
+class Step:
+    id: str
+    type: str
+    text: str = ""
+    options: tuple[Option, ...] = ()
+    route: dict[str, str] = field(default_factory=dict)      # led colour -> target
+    routes: dict[str, str] = field(default_factory=dict)     # rule id -> target
+    default: str | None = None
+    next: str | None = None
+    tool_action: str | None = None
+    until: re.Pattern[str] | None = None
+    until_milestone: str | None = None
+    fail_on: re.Pattern[str] | None = None
+    timeout_s: float = 60.0
+    pass_on_timeout: bool = False
+    on_ok: str | None = None
+    on_fail: str | None = None
+    on_timeout: str | None = None
+    skip_if_finding: str | None = None
+    skip_unless_feature: str | None = None
+    skip_to: str | None = None
+    show_qr: bool = False              # show the Matter pairing QR next to the step text
+
+    def targets(self) -> list[str]:
+        t = [o.next for o in self.options] + list(self.route.values()) + list(self.routes.values())
+        t += [x for x in (self.default, self.next, self.on_ok, self.on_fail, self.on_timeout, self.skip_to) if x]
+        return t
+
+
+@dataclass(frozen=True)
+class End:
+    id: str
+    severity: str
+    title: str
+    text: str
+    actions: tuple[str, ...] = ()
+
+
+@dataclass(frozen=True)
+class Guide:
+    id: str
+    title: str
+    summary: str
+    recommend: tuple[str, ...]
+    start: str
+    steps: dict[str, Step]
+    ends: dict[str, End]
+
+
+def load_guides(path: Path = GUIDES_PATH) -> dict[str, Guide]:
+    data = tomllib.loads(path.read_text(encoding="utf-8"))
+    guides: dict[str, Guide] = {}
+    for g in data["guide"]:
+        steps = {}
+        for s in g.get("step", []):
+            steps[s["id"]] = Step(
+                id=s["id"], type=s["type"], text=s.get("text", ""),
+                options=tuple(Option(o["label"], o["next"]) for o in s.get("options", ())),
+                route=dict(s.get("route", {})), routes=dict(s.get("routes", {})),
+                default=s.get("default"), next=s.get("next"), tool_action=s.get("tool_action"),
+                until=re.compile(s["until"]) if "until" in s else None,
+                until_milestone=s.get("until_milestone"),
+                fail_on=re.compile(s["fail_on"]) if "fail_on" in s else None,
+                timeout_s=float(s.get("timeout_s", 60)), pass_on_timeout=bool(s.get("pass_on_timeout", False)),
+                on_ok=s.get("on_ok"), on_fail=s.get("on_fail"), on_timeout=s.get("on_timeout"),
+                skip_if_finding=s.get("skip_if_finding"), skip_unless_feature=s.get("skip_unless_feature"),
+                skip_to=s.get("skip_to"), show_qr=bool(s.get("show_qr", False)),
+            )
+        ends = {e["id"]: End(e["id"], e["severity"], e["title"], e["text"], tuple(e.get("actions", ())))
+                for e in g.get("end", [])}
+        guides[g["id"]] = Guide(g["id"], g["title"], g["summary"], tuple(g.get("recommend", ())),
+                                g["start"], steps, ends)
+    _validate(guides)
+    return guides
+
+
+def _validate(guides: dict[str, Guide]) -> None:
+    for g in guides.values():
+        if g.start not in g.steps:
+            raise ValueError(f"guide {g.id}: start step {g.start!r} missing")
+        for s in g.steps.values():
+            if s.type not in STEP_TYPES:
+                raise ValueError(f"{g.id}.{s.id}: unknown step type {s.type!r}")
+            if s.type == "led" and set(s.route) - set(LED_ANSWERS):
+                raise ValueError(f"{g.id}.{s.id}: unknown LED colours {set(s.route) - set(LED_ANSWERS)}")
+            if s.type == "wait" and not (s.until or s.until_milestone or s.pass_on_timeout):
+                raise ValueError(f"{g.id}.{s.id}: wait step needs until/until_milestone/pass_on_timeout")
+            if s.tool_action not in (None, "reset"):
+                raise ValueError(f"{g.id}.{s.id}: unknown tool_action {s.tool_action!r}")
+            for t in s.targets():
+                kind, _, ref = t.partition(":")
+                if kind == "end" and ref not in g.ends:
+                    raise ValueError(f"{g.id}.{s.id}: unknown end {ref!r}")
+                elif kind == "guide" and ref not in guides:
+                    raise ValueError(f"{g.id}.{s.id}: unknown guide {ref!r}")
+                elif not ref and t not in g.steps:
+                    raise ValueError(f"{g.id}.{s.id}: unknown step {t!r}")
+        for e in g.ends.values():
+            if e.severity not in END_SEVERITY:
+                raise ValueError(f"{g.id}.end.{e.id}: unknown severity {e.severity!r}")
+
+
+def recommended(guides: dict[str, Guide], engine: DiagnosticsEngine) -> list[Guide]:
+    """Guides matching the current root findings (in root order), then the LED."""
+    report = engine.report()
+    keys: list[str] = []
+    for rc in report.roots:
+        keys.append(rc.finding.rule_id)
+        keys += [c.rule_id for c in rc.consequences]
+    if report.led not in ("UNKNOWN",):
+        keys.append(f"led:{report.led}")
+    out: list[Guide] = [g for g in guides.values() if "always" in g.recommend]
+    for k in keys:
+        for g in guides.values():
+            if k in g.recommend and g not in out:
+                out.append(g)
+    return out
+
+
+@dataclass
+class View:
+    """What the UI should show right now."""
+    guide: Guide | None = None
+    step: Step | None = None
+    text: str = ""
+    options: list[tuple[str, str]] = field(default_factory=list)   # (key, label)
+    waiting: bool = False
+    remaining_s: float = 0.0
+    note: str = ""
+    end: End | None = None
+    can_back: bool = False
+
+
+class GuideRunner:
+    def __init__(self, engine: DiagnosticsEngine, guides: dict[str, Guide] | None = None,
+                 on_action: Callable[[str], bool] | None = None,
+                 on_log: Callable[[str], None] | None = None,
+                 clock: Callable[[], float] = time.monotonic):
+        self.engine = engine
+        self.guides = guides if guides is not None else load_guides()
+        self._on_action = on_action or (lambda _a: False)
+        self._on_log = on_log or (lambda _t: None)
+        self._clock = clock
+        self.cancel()
+
+    # ------------------------------------------------------------ control
+    def cancel(self) -> None:
+        self.guide: Guide | None = None
+        self.step: Step | None = None
+        self.end: End | None = None
+        self.note = ""
+        self._stack: list[tuple[str, str]] = []   # (guide id, step id) for Back
+        self._wait_started = 0.0
+        self._wait_boot = 0
+        self._wait_milestones: set[str] = set()
+
+    def start(self, guide_id: str) -> None:
+        self.cancel()
+        self._enter_guide(guide_id)
+
+    def answer(self, key: str) -> None:
+        """Pick an option: LED colour name for led steps, option index otherwise."""
+        s = self.step
+        if s is None:
+            return
+        if s.type == "led":
+            label = LED_ANSWER_LABELS.get(key, key)
+            self._record(s, label)
+            self._check_led(key)
+            target = s.route.get(key)
+        elif s.type == "question":
+            opt = s.options[int(key)]
+            self._record(s, opt.label)
+            target = opt.next
+        else:
+            return
+        if target:
+            self._push()
+            self._go(target)
+
+    def proceed(self) -> None:
+        """Continue on info steps; 'skip waiting' on wait steps."""
+        s = self.step
+        if s is None:
+            return
+        if s.type == "info" and s.next:
+            self._push()
+            self._go(s.next)
+        elif s.type == "wait":
+            self._record(s, "technician skipped the wait")
+            self._finish_wait("timeout")
+
+    def back(self) -> None:
+        # Never step back into a wait: re-entering it could restart the box.
+        while self._stack:
+            gid, sid = self._stack.pop()
+            if self.guides[gid].steps[sid].type != "wait":
+                self.guide, self.end, self.note = self.guides[gid], None, ""
+                self._enter_step(sid)
+                return
+
+    # --------------------------------------------------------------- feed
+    def feed(self, line: LogLine) -> None:
+        s = self.step
+        if s is None or s.type != "wait":
+            return
+        if s.fail_on and s.fail_on.search(line.text):
+            self._record(s, f"log: {line.text}")
+            self._finish_wait("fail")
+        elif s.until and s.until.search(line.text):
+            self._record(s, f"log: {line.text}")
+            self._finish_wait("ok")
+        elif s.until_milestone and self._milestone_new(s.until_milestone):
+            self._record(s, f"milestone reached: {s.until_milestone}")
+            self._finish_wait("ok")
+
+    def tick(self) -> None:
+        s = self.step
+        if s is not None and s.type == "wait" and self._clock() - self._wait_started >= s.timeout_s:
+            self._finish_wait("ok" if s.pass_on_timeout else "timeout")
+
+    # --------------------------------------------------------------- view
+    def view(self) -> View:
+        v = View(guide=self.guide, step=self.step, end=self.end, note=self.note, can_back=bool(self._stack))
+        s = self.step
+        if s is None:
+            return v
+        v.text = self._render(s.text)
+        if s.type == "led":
+            v.options = [(k, LED_ANSWER_LABELS[k]) for k in LED_ANSWERS if k in s.route]
+        elif s.type == "question":
+            v.options = [(str(i), o.label) for i, o in enumerate(s.options)]
+        elif s.type == "wait":
+            v.waiting = True
+            v.remaining_s = max(0.0, s.timeout_s - (self._clock() - self._wait_started))
+        return v
+
+    # ---------------------------------------------------------- internals
+    def _push(self) -> None:
+        if self.guide and self.step:
+            self._stack.append((self.guide.id, self.step.id))
+
+    def _enter_guide(self, guide_id: str) -> None:
+        self.guide = self.guides[guide_id]
+        self._on_log(f"technician: started guide '{self.guide.title}'")
+        self._enter_step(self.guide.start)
+
+    def _go(self, target: str) -> None:
+        kind, _, ref = target.partition(":")
+        if kind == "end" and ref:
+            self._conclude(self.guide.ends[ref])
+        elif kind == "guide" and ref:
+            self._enter_guide(ref)
+        else:
+            self._enter_step(target)
+
+    def _enter_step(self, step_id: str) -> None:
+        s = self.guide.steps[step_id]
+        self.step, self.note = s, ""
+        if s.skip_if_finding and self._finding_active(s.skip_if_finding):
+            self._auto(s, f"skipped - log already shows {s.skip_if_finding}", s.skip_to)
+            return
+        if s.skip_unless_feature and not self._feature(s.skip_unless_feature):
+            self._auto(s, f"skipped - firmware has no {s.skip_unless_feature}", s.skip_to)
+            return
+        if s.type == "route":
+            target = self._route(s)
+            self._auto(s, f"routed by log findings -> {target}", target)
+            return
+        if s.type == "wait":
+            self._wait_started = self._clock()
+            self._wait_boot = self.engine.boot.index
+            self._wait_milestones = set(self.engine.milestones)
+            if s.tool_action and not self._on_action(s.tool_action):
+                self.note = "Could not restart the box from the tool - connect to it first, or switch it off and on."
+            # A milestone that is already reached satisfies the wait at once
+            # unless the step first restarts the box.
+            if s.until_milestone and not s.tool_action and s.until_milestone in self.engine.milestones:
+                self._record(s, f"already reached: {s.until_milestone}")
+                self._finish_wait("ok")
+
+    def _auto(self, s: Step, why: str, target: str | None) -> None:
+        self._on_log(f"technician guide: {s.id}: {why}")
+        if target:
+            self._go(target)
+
+    def _finish_wait(self, outcome: str) -> None:
+        s = self.step
+        target = {"ok": s.on_ok, "fail": s.on_fail or s.on_timeout, "timeout": s.on_timeout or s.on_fail}[outcome]
+        if target is None:
+            return
+        self._push()
+        self._go(target)
+
+    def _milestone_new(self, mid: str) -> bool:
+        if mid not in self.engine.milestones:
+            return False
+        return self.engine.boot.index != self._wait_boot or mid not in self._wait_milestones
+
+    def _route(self, s: Step) -> str:
+        report = self.engine.report()
+        for rc in report.roots:
+            for f in (rc.finding, *rc.consequences):
+                if f.rule_id in s.routes:
+                    return s.routes[f.rule_id]
+        return s.default or "end:" + next(iter(self.guide.ends))
+
+    def _check_led(self, seen: str) -> None:
+        expected = self.engine.led
+        if expected in ("UNKNOWN", "OFF") or seen == "CYCLING" or seen == expected:
+            return
+        exp_label, see_label = LED[expected][0], LED_ANSWER_LABELS[seen]
+        self.engine.add_confirmed(
+            "tech.led_mismatch", Severity.WARNING,
+            f"LED shows {see_label}, but the log implies {exp_label}",
+            f"The firmware state in the log corresponds to {exp_label}, while the technician sees {see_label}. "
+            "Either the LED just changed (check again in a few seconds), the LED/its wiring is faulty, "
+            "or the box runs different firmware. Trust the log findings.",
+            ("Look at the LED again for 10 seconds.", "If it stays different: note it for repair (LED board)."))
+
+    def _conclude(self, end: End) -> None:
+        self.step, self.end = None, end
+        self._on_log(f"technician guide result: {end.title}")
+        sev = END_SEVERITY[end.severity]
+        self.engine.note_technician(f"{self.guide.title}: {end.title}")
+        if sev is not None:
+            self.engine.add_confirmed(f"tech.{self.guide.id}.{end.id}", sev, end.title, end.text, end.actions)
+
+    def _record(self, s: Step, answer: str) -> None:
+        q = self._render(s.text)
+        self.engine.note_technician(f"{q} -> {answer}")
+        self._on_log(f"technician: {q[:80]} -> {answer}")
+
+    def _finding_active(self, rule_id: str) -> bool:
+        return any(f.rule_id == rule_id and f.active for f in self.engine.findings.values())
+
+    def _feature(self, name: str) -> bool:
+        fw = self.engine.firmware
+        if name == "sd_wifi":
+            return fw.supports_sd_wifi is not False
+        if name == "setup_portal":
+            if fw.known is not None:
+                return fw.known.setup_portal
+            if "setup_portal" in fw.evidence:
+                return True
+            return "legacy_v1" not in fw.evidence   # unknown firmware: ask
+        return False
+
+    def _render(self, text: str) -> str:
+        report = self.engine.report()
+        sensors = sorted({f.title.removesuffix(" failed to start") for f in self.engine.findings.values()
+                          if f.rule_id == "sensor.init_failed" and f.active})
+        ctx = {
+            "expected_led": LED[report.led][0],
+            "failing_sensors": ", ".join(sensors) or "see the Diagnosis tab",
+            "top_finding": report.roots[0].finding.title if report.roots else "none",
+        }
+        return text.format_map(_Fmt(ctx))
+
+
+class _Fmt(dict):
+    def __missing__(self, key: str) -> str:
+        return "{" + key + "}"

kota_tech/diag/guides.toml

@@ -0,0 +1,740 @@
+# Guided troubleshooting: decision trees that combine technician answers
+# with live log evidence (diag.guides.GuideRunner executes them).
+#
+# Guide:  id, title, summary, recommend (rule ids / "led:<COLOUR>" / "always"),
+#         start (first step id), [[guide.step]], [[guide.end]]
+# Step types:
+#   led       technician picks the LED colour; `route` maps colour -> target.
+#             Colours: GREEN PURPLE RED BLUE YELLOW ORANGE WHITE OFF CYCLING
+#             The answer is compared with the colour the firmware log implies.
+#   question  `options` = [{label, next}]
+#   info      instruction + Continue (`next`)
+#   wait      optional `tool_action` ("reset"), then watch the log:
+#             `until` (regex) / `until_milestone`, `fail_on` (regex),
+#             `timeout_s`; go to on_ok / on_fail / on_timeout.
+#             `pass_on_timeout = true`: reaching the timeout without fail_on
+#             counts as ok (used for "watch for N seconds").
+#   route     automatic: first current root finding whose rule id is in
+#             `routes` decides; otherwise `default`.
+# Targets: "<step id>", "end:<end id>", "guide:<guide id>".
+# Optional on any step: skip_if_finding / skip_unless_feature (+ skip_to).
+# Text placeholders: {expected_led} {failing_sensors} {top_finding}
+# End severity: ok | info | warning | error | critical
+
+# ================================================================= quick
+[[guide]]
+id = "quick"
+title = "Quick check - start here"
+summary = "Tell the tool what the LED shows; it picks the right checks."
+recommend = ["always"]
+start = "led"
+
+[[guide.step]]
+id = "led"
+type = "led"
+text = "Look at the RGB status LED on the box (no need to open it). Which colour is it?"
+route = { GREEN = "heartbeat", PURPLE = "guide:network", RED = "guide:sensors", BLUE = "guide:rtc_i2c", WHITE = "guide:white", YELLOW = "guide:update", ORANGE = "guide:update", CYAN = "guide:network", OFF = "guide:power", CYCLING = "guide:reboot_loop" }
+
+[[guide.step]]
+id = "heartbeat"
+type = "question"
+text = "Is the small LED next to the RGB LED blinking about once per second?"
+options = [
+  { label = "Yes, blinking", next = "green_route" },
+  { label = "No - steady on or off", next = "end:hung" },
+]
+
+[[guide.step]]
+id = "green_route"
+type = "route"
+routes = { "rtc.clock_not_running" = "guide:clock", "mic.silent" = "guide:mic", "mic.disabled" = "guide:mic", "matter.not_commissioned" = "guide:network", "net.dns_fail" = "guide:network" }
+default = "end:healthy"
+
+[[guide.end]]
+id = "healthy"
+severity = "ok"
+title = "Box looks healthy"
+text = "Green LED, firmware running and no problems in the log."
+actions = ["If the customer still reports missing data, keep the tool connected for 5 minutes and check that 'Data uploaded to InfluxDB' gets ticked."]
+
+[[guide.end]]
+id = "hung"
+severity = "error"
+title = "Firmware is not running normally"
+text = "The heartbeat LED should blink once per second whenever the firmware runs. A steady heartbeat LED means the firmware has frozen."
+actions = [
+  "Switch the box off and on with the power switch.",
+  "If it happens again: save the session log and re-flash the official firmware (Flash firmware tab, App only).",
+]
+
+# =============================================================== network
+[[guide]]
+id = "network"
+title = "Purple LED / no Internet"
+summary = "Pairing in Matter, site Wi-Fi and Internet checks, with live confirmation."
+recommend = ["led:PURPLE", "led:CYAN", "matter.not_commissioned", "net.dns_fail", "influx.buffer_fail", "ota.registration_failed",
+             "status.conn", "status.conn.1", "kota.wifi_down", "kota.no_upload", "kota.weak_wifi", "kota.ota_unregistered"]
+start = "paired"
+
+[[guide.step]]
+id = "paired"
+type = "question"
+skip_if_finding = "matter.not_commissioned"
+skip_to = "pair_intro"
+text = "Was this box already added to the customer's Matter app (Apple Home, Google Home, ...) at this site?"
+options = [
+  { label = "Yes, it was paired before", next = "internet" },
+  { label = "No / not sure", next = "pair_intro" },
+]
+
+[[guide.step]]
+id = "internet"
+type = "question"
+text = "Does the site Wi-Fi have working Internet? Check with a phone connected to the same Wi-Fi (open any website)."
+options = [
+  { label = "Yes, Internet works", next = "changed" },
+  { label = "No Internet on the site Wi-Fi", next = "end:site_offline" },
+]
+
+[[guide.step]]
+id = "changed"
+type = "question"
+text = "Was the Wi-Fi name or password changed, or the router replaced, since the box was installed?"
+options = [
+  { label = "Yes / possibly", next = "end:repair_needed" },
+  { label = "No", next = "end:offline_unknown" },
+]
+
+[[guide.step]]
+id = "pair_intro"
+type = "info"
+text = "The box is not on any Wi-Fi yet: it must be paired in Matter. You need: a phone with Bluetooth on, the customer's Matter app, the 2.4 GHz Wi-Fi password, and the QR sticker of this box. Keep the tool connected - it follows the pairing live."
+next = "pair_start"
+
+[[guide.step]]
+id = "pair_start"
+type = "wait"
+text = "In the Matter app choose 'Add device' and scan the QR code shown here (the same as the sticker), or type the 11-digit manual code. Keep the phone within 1 m of the box."
+show_qr = true
+until = 'MAIN: Commissioning session started'
+timeout_s = 300
+on_ok = "pair_wifi"
+on_timeout = "not_found"
+
+[[guide.step]]
+id = "not_found"
+type = "question"
+text = "The box has not seen the phone connect yet. What does the app show?"
+options = [
+  { label = "Still searching / let me try again", next = "pair_start" },
+  { label = "'Device not found' or similar", next = "end:ble_not_found" },
+]
+
+[[guide.step]]
+id = "pair_wifi"
+type = "wait"
+text = "The phone is connected to the box. Follow the app: choose the 2.4 GHz Wi-Fi network and enter its password."
+until = 'MAIN: Commissioning complete|MAIN: Fabric is committed'
+fail_on = 'Commissioning failed, fail safe timer expired'
+timeout_s = 300
+on_ok = "pair_time"
+on_fail = "end:pair_failed"
+on_timeout = "end:pair_failed"
+
+[[guide.step]]
+id = "pair_time"
+type = "wait"
+text = "Paired! The box is joining the Wi-Fi and getting the time from the Internet..."
+until_milestone = "time_synced"
+timeout_s = 120
+on_ok = "pair_upload"
+on_timeout = "end:joined_no_internet"
+
+[[guide.step]]
+id = "pair_upload"
+type = "wait"
+text = "Online. Waiting for the first measurements to reach the database (up to 4 minutes)..."
+until = 'INFLUX: HTTP request performed, status code: 2\d\d'
+fail_on = 'INFLUX: Failed to perform HTTP request: (401|403|404)'
+timeout_s = 240
+on_ok = "end:online"
+on_fail = "end:influx_rejected"
+on_timeout = "end:no_upload"
+
+[[guide.end]]
+id = "online"
+severity = "ok"
+title = "Box is paired and uploading data"
+text = "Pairing, Internet time and the first upload all worked."
+actions = [
+  "The box may now download a firmware update (yellow, then orange LED, a few minutes). Do not switch it off.",
+  "It should end green.",
+]
+
+[[guide.end]]
+id = "site_offline"
+severity = "warning"
+title = "Site network has no Internet"
+text = "The box cannot work until the site Wi-Fi reaches the Internet. This is not a box fault."
+actions = ["Ask the customer to fix the Internet connection, then power-cycle the box."]
+
+[[guide.end]]
+id = "repair_needed"
+severity = "warning"
+title = "Box must be paired again"
+text = "The box still remembers the old Wi-Fi. It needs a factory reset and new pairing."
+actions = [
+  "Hold the Matter button for 5 seconds (LED turns white) - this erases the old pairing.",
+  "Remove the box from the customer's Matter app, then run this guide again and choose 'No / not sure'.",
+]
+
+[[guide.end]]
+id = "offline_unknown"
+severity = "error"
+title = "Box is paired but cannot reach the Internet - cause unclear"
+text = "The network works for other devices, but not for this box."
+actions = [
+  "Check the router does not block new devices (guest isolation, MAC filter). Box MAC is shown in the port list.",
+  "Move the box closer to the router to rule out weak signal.",
+  "If nothing helps: factory reset (hold the Matter button 5 s) and pair again.",
+]
+
+[[guide.end]]
+id = "ble_not_found"
+severity = "error"
+title = "Phone cannot find the box over Bluetooth"
+text = "The box only accepts pairing for a limited time after start-up."
+actions = [
+  "Switch the box off and on to reopen the pairing window, then try again within 10 minutes.",
+  "Check Bluetooth and location permission are on for the Matter app.",
+  "If the box was paired to another app before: hold the Matter button 5 s (factory reset) first.",
+]
+
+[[guide.end]]
+id = "pair_failed"
+severity = "error"
+title = "Pairing did not finish"
+text = "The phone connected but the box did not join the Wi-Fi."
+actions = [
+  "Use a 2.4 GHz network (many routers have a separate 2.4 GHz name).",
+  "Re-enter the Wi-Fi password carefully.",
+  "Switch the box off and on, then pair again.",
+]
+
+[[guide.end]]
+id = "joined_no_internet"
+severity = "error"
+title = "Box joined the Wi-Fi but has no Internet"
+text = "Pairing worked, but the box cannot reach time or data servers."
+actions = [
+  "Check the network allows outgoing connections (HTTPS, NTP) for new devices.",
+  "Try a phone hotspot to rule out the site network.",
+]
+
+[[guide.end]]
+id = "influx_rejected"
+severity = "critical"
+title = "Database rejected the box (token / bucket)"
+text = "The box is online but InfluxDB refused the upload. The SD card settings are wrong."
+actions = ["Re-provision the SD card with the current ENV.TXT (SD card is inside the case)."]
+
+[[guide.end]]
+id = "no_upload"
+severity = "warning"
+title = "Online, but no upload seen yet"
+text = "Uploads happen every minute; the first one can be delayed while the air sensor warms up."
+actions = ["Keep the tool connected a few more minutes and watch the Diagnosis tab."]
+
+# ================================================================= RTC / I2C
+[[guide]]
+id = "rtc_i2c"
+title = "Blue LED - clock / I2C cable"
+summary = "Re-seat the I2C cable and verify the start-up live."
+recommend = ["led:BLUE", "rtc.init_failed", "i2c.errors", "kota.i2c_stuck", "kota.rtc_read_failed", "status.rtc.1", "status.rtc.2"]
+start = "explain"
+
+[[guide.step]]
+id = "explain"
+type = "info"
+text = "Blue means the clock chip did not answer. It is the first chip on the shared I2C cable between the boards, so a loose cable is the most common cause. This check needs the case opened."
+next = "reseat"
+
+[[guide.step]]
+id = "reseat"
+type = "info"
+text = "Switch the power OFF. Open the case. Unplug and firmly re-plug the I2C cable between the boards at both ends. Close the case and switch the power ON. Then press Continue."
+next = "verify"
+
+[[guide.step]]
+id = "verify"
+type = "wait"
+text = "Watching the start-up (up to 60 s)..."
+until_milestone = "sensors_ready"
+fail_on = 'MAIN: Failed to initialize RTC'
+timeout_s = 60
+on_ok = "end:i2c_fixed"
+on_fail = "damaged"
+on_timeout = "damaged"
+
+[[guide.step]]
+id = "damaged"
+type = "question"
+text = "The clock still does not answer. Is the I2C cable or its connector visibly damaged (pinched, broken wire, bent pin)?"
+options = [
+  { label = "Yes, damaged", next = "end:replace_cable" },
+  { label = "No, looks fine", next = "end:rtc_module" },
+]
+
+[[guide.end]]
+id = "i2c_fixed"
+severity = "ok"
+title = "Fixed - all sensors start again"
+text = "After re-seating the cable the clock and all sensors started."
+actions = ["Make sure the cable is routed without strain before closing the case."]
+
+[[guide.end]]
+id = "replace_cable"
+severity = "error"
+title = "Replace the I2C cable"
+text = "A damaged I2C cable stops the clock and all sensors."
+actions = ["Replace the cable, then run this check again."]
+
+[[guide.end]]
+id = "rtc_module"
+severity = "error"
+title = "Clock (RTC) module is probably faulty"
+text = "The cable is fine but the clock chip does not answer."
+actions = ["Replace the RTC module, or send the box for repair with the session log."]
+
+# ==================================================================== white
+[[guide]]
+id = "white"
+title = "White LED - SD card / reset / setup mode"
+summary = "Tell apart the three white states and check the SD card."
+recommend = ["led:WHITE", "sd.card_fail", "sd.mount_fail", "sd.env_open_fail", "influx.env_missing", "influx.init_fail",
+             "kota.sd_unmounted", "status.sd", "status.portal", "status.reset"]
+start = "button"
+
+[[guide.step]]
+id = "button"
+type = "question"
+text = "Did anyone hold the Matter button (outside the case) for about 5 seconds just before the LED turned white?"
+options = [
+  { label = "Yes", next = "end:factory_reset" },
+  { label = "No / don't know", next = "portal" },
+]
+
+[[guide.step]]
+id = "portal"
+type = "question"
+skip_unless_feature = "setup_portal"
+skip_to = "sd_reseat"
+text = "On a phone, look at the Wi-Fi list: is there a network called 'KotaSensorBox-....'?"
+options = [
+  { label = "Yes", next = "end:setup_mode" },
+  { label = "No", next = "sd_reseat" },
+]
+
+[[guide.step]]
+id = "sd_reseat"
+type = "info"
+text = "The SD card is probably not readable. This needs the case opened: switch the power OFF, open the case, push the SD card in until it clicks (or remove and re-insert it). Close the case, switch the power ON, then press Continue."
+next = "sd_verify"
+
+[[guide.step]]
+id = "sd_verify"
+type = "wait"
+text = "Watching the SD card start-up (up to 60 s)..."
+until = 'Read INFLUX_URL from \.env file'
+fail_on = 'Failed to initialize the card|Failed to mount filesystem|Failed to read INFLUX_(URL|TOKEN)|Failed to open \.env file'
+timeout_s = 60
+on_ok = "end:sd_fixed"
+on_fail = "end:sd_reprovision"
+on_timeout = "end:sd_reprovision"
+
+[[guide.end]]
+id = "factory_reset"
+severity = "info"
+title = "White = factory reset in progress"
+text = "The box erased its Matter pairing and restarts."
+actions = ["Pair it again in the Matter app (Purple LED guide)."]
+
+[[guide.end]]
+id = "setup_mode"
+severity = "info"
+title = "White = Wi-Fi setup mode"
+text = "The box is waiting for Wi-Fi settings on its own network."
+actions = [
+  "Connect a phone to KotaSensorBox-.... and open http://sensorbox.local/ to enter the Wi-Fi,",
+  "or short-press the Matter button (< 2 s) to leave setup mode.",
+]
+
+[[guide.end]]
+id = "sd_fixed"
+severity = "ok"
+title = "Fixed - SD card is read again"
+text = "The box found the SD card and read ENV.TXT."
+actions = ["Close the case and watch the Diagnosis tab for a minute."]
+
+[[guide.end]]
+id = "sd_reprovision"
+severity = "critical"
+title = "SD card is unreadable or has wrong settings"
+text = "Even after re-seating, the card or its ENV.TXT cannot be used."
+actions = [
+  "Re-provision the card with the tool (SD card tab) or use a new card.",
+  "The Diagnosis tab shows which step failed (card, file system or ENV.TXT keys).",
+]
+
+# ================================================================== sensors
+[[guide]]
+id = "sensors"
+title = "Red LED - sensor or hardware fault"
+summary = "Find the failing sensor and verify after re-seating its cable."
+recommend = ["led:RED", "sensor.init_failed", "sensor.selfcheck_failed", "sys.out_of_resources", "ota.selfcheck_failed",
+             "kota.sensor_missing", "status.error", "status.error.1", "status.error.2", "status.error.3", "status.error.4",
+             "status.error.5", "status.error.6", "status.oom"]
+start = "which"
+
+[[guide.step]]
+id = "which"
+type = "route"
+routes = { "sensor.init_failed" = "reseat", "rtc.init_failed" = "guide:rtc_i2c", "ota.selfcheck_failed" = "end:selfcheck", "sensor.selfcheck_failed" = "end:selfcheck", "sys.out_of_resources" = "end:oom" }
+default = "capture"
+
+[[guide.step]]
+id = "capture"
+type = "wait"
+text = "The log does not show the cause yet. The tool restarts the box and records its start-up (45 s)..."
+tool_action = "reset"
+timeout_s = 45
+pass_on_timeout = true
+on_ok = "which_again"
+
+[[guide.step]]
+id = "which_again"
+type = "route"
+routes = { "sensor.init_failed" = "reseat", "rtc.init_failed" = "guide:rtc_i2c", "sys.out_of_resources" = "end:oom" }
+default = "end:red_unclear"
+
+[[guide.step]]
+id = "reseat"
+type = "info"
+text = "Failing: {failing_sensors}. This needs the case opened: switch the power OFF, open the case and re-seat the cable of that sensor. Close the case, switch the power ON, then press Continue."
+next = "verify"
+
+[[guide.step]]
+id = "verify"
+type = "wait"
+text = "Watching the sensor start-up (up to 60 s)..."
+until_milestone = "sensors_ready"
+fail_on = 'MAIN: Failed to initialize'
+timeout_s = 60
+on_ok = "end:sensor_fixed"
+on_fail = "end:sensor_replace"
+on_timeout = "end:sensor_replace"
+
+[[guide.end]]
+id = "sensor_fixed"
+severity = "ok"
+title = "Fixed - all sensors start again"
+text = "After re-seating, every sensor started."
+actions = ["Close the case and watch the Diagnosis tab for a minute."]
+
+[[guide.end]]
+id = "sensor_replace"
+severity = "error"
+title = "Sensor still fails - replace it"
+text = "The sensor does not start even with a re-seated cable."
+actions = ["Replace the named sensor (or its cable) and run this check again."]
+
+[[guide.end]]
+id = "selfcheck"
+severity = "error"
+title = "A firmware update was rejected by its self-check"
+text = "The box rolled back to its previous firmware because a sensor failed the test."
+actions = ["Check the sensor named in the Diagnosis tab (inside the case), then power-cycle."]
+
+[[guide.end]]
+id = "oom"
+severity = "error"
+title = "Firmware ran out of memory"
+text = "Not a hardware fault; the firmware restarts itself."
+actions = ["Power-cycle. If it repeats, send the session log to the firmware team."]
+
+[[guide.end]]
+id = "red_unclear"
+severity = "warning"
+title = "Red LED without a clear cause in the log"
+text = "The start-up did not show a failing sensor."
+actions = ["Save the session log and send it to the firmware team."]
+
+# ============================================================= reboot loop
+[[guide]]
+id = "reboot_loop"
+title = "LED keeps changing / box restarts"
+summary = "Record several start-ups and find the error just before each restart."
+recommend = ["led:CYCLING", "reboot.loop", "sys.crash", "reboot.unexpected", "reboot.brownout", "reboot.watchdog",
+             "reboot.crash", "reboot.status_watchdog", "reboot.status_oom_watchdog"]
+start = "record"
+
+[[guide.step]]
+id = "record"
+type = "wait"
+text = "The tool restarts the box and records 45 seconds of start-up..."
+tool_action = "reset"
+timeout_s = 45
+pass_on_timeout = true
+on_ok = "cause"
+
+[[guide.step]]
+id = "cause"
+type = "route"
+routes = { "rtc.init_failed" = "guide:rtc_i2c", "sd.card_fail" = "guide:white", "sd.mount_fail" = "guide:white", "sd.env_open_fail" = "guide:white", "influx.env_missing" = "guide:white", "influx.init_fail" = "guide:white", "sensor.init_failed" = "guide:sensors", "reboot.brownout" = "end:power_supply", "matter.not_commissioned" = "guide:network", "net.dns_fail" = "guide:network", "influx.buffer_fail" = "guide:network" }
+default = "end:loop_unclear"
+
+[[guide.end]]
+id = "power_supply"
+severity = "error"
+title = "Power supply is too weak or unstable"
+text = "The chip reset itself because the voltage dropped."
+actions = ["Check the power supply, cable and connectors; try another supply."]
+
+[[guide.end]]
+id = "loop_unclear"
+severity = "warning"
+title = "No clear restart cause in 45 s"
+text = "The box did not show a known start-up error during the recording."
+actions = ["Keep the tool connected for 5 minutes, then save the session log for the firmware team."]
+
+# ================================================================== update
+[[guide]]
+id = "update"
+title = "Yellow / orange LED - firmware update"
+summary = "Wait for the update and its self-check to finish."
+recommend = ["led:YELLOW", "led:ORANGE", "ota.updating", "ota.selfcheck"]
+start = "wait"
+
+[[guide.step]]
+id = "wait"
+type = "wait"
+text = "A firmware update or its self-check is running. Do NOT switch the box off. Waiting up to 10 minutes..."
+until = 'Passing selfcheck|OTA update successful'
+fail_on = 'OTA update failed|Failing selfcheck'
+timeout_s = 600
+on_ok = "end:update_ok"
+on_fail = "end:update_failed"
+on_timeout = "end:update_slow"
+
+[[guide.end]]
+id = "update_ok"
+severity = "ok"
+title = "Update finished"
+text = "The new firmware was installed or accepted."
+actions = ["Wait for the green LED."]
+
+[[guide.end]]
+id = "update_failed"
+severity = "error"
+title = "Update failed"
+text = "The box keeps its current firmware and retries later."
+actions = ["Check the Wi-Fi is stable. The Diagnosis tab shows why it failed."]
+
+[[guide.end]]
+id = "update_slow"
+severity = "warning"
+title = "Update is taking very long"
+text = "No end of the update was seen in 10 minutes."
+actions = ["Check the Wi-Fi signal; leave the box powered and check again later."]
+
+# =================================================================== power
+[[guide]]
+id = "power"
+title = "LED off"
+summary = "Power switch, heartbeat LED and USB connection."
+recommend = ["led:OFF"]
+start = "switch"
+
+[[guide.step]]
+id = "switch"
+type = "question"
+text = "Is the power switch on the outside of the case set to ON?"
+options = [
+  { label = "It was OFF - I switched it on", next = "boot" },
+  { label = "It is ON", next = "heartbeat" },
+]
+
+[[guide.step]]
+id = "boot"
+type = "wait"
+text = "Waiting for the box to start (up to 30 s)..."
+until_milestone = "app_started"
+timeout_s = 30
+on_ok = "end:was_off"
+on_timeout = "heartbeat"
+
+[[guide.step]]
+id = "heartbeat"
+type = "question"
+text = "Is the small LED next to the RGB LED blinking?"
+options = [
+  { label = "Yes, blinking", next = "end:rgb_led_fault" },
+  { label = "No", next = "end:no_power" },
+]
+
+[[guide.end]]
+id = "was_off"
+severity = "ok"
+title = "Box was switched off"
+text = "It starts normally after switching on."
+actions = ["Run the Quick check again once the LED shows a colour."]
+
+[[guide.end]]
+id = "rgb_led_fault"
+severity = "warning"
+title = "Firmware runs, but the RGB LED stays dark"
+text = "The heartbeat LED shows the firmware is running; the RGB LED or its wiring is faulty."
+actions = ["Use the Diagnosis tab instead of the LED; replace the LED board when convenient."]
+
+[[guide.end]]
+id = "no_power"
+severity = "error"
+title = "Box does not start"
+text = "Neither LED is lit: no power or the firmware does not start."
+actions = [
+  "Check the power supply and cable.",
+  "If the USB port shows up in this tool, re-flash the official firmware (Flash firmware tab, App only).",
+]
+
+# =================================================================== clock
+[[guide]]
+id = "clock"
+title = "Clock not set"
+summary = "Why readings are on hold and when the coin cell matters."
+recommend = ["rtc.clock_not_running", "rtc.lost_after_sync", "kota.rtc_stopped", "kota.rtc_not_ticking", "kota.time_invalid"]
+start = "internet"
+
+[[guide.step]]
+id = "internet"
+type = "question"
+text = "The box clock is not set, so readings are on hold. Will the box have Internet at its installation site?"
+options = [
+  { label = "Yes", next = "end:clock_auto" },
+  { label = "No / not yet", next = "end:clock_offline" },
+]
+
+[[guide.end]]
+id = "clock_auto"
+severity = "info"
+title = "Clock will be set automatically"
+text = "On its first Internet connection the box sets its clock and starts recording."
+actions = ["If the clock is lost again after every power-off, replace the RTC coin cell (inside the case)."]
+
+[[guide.end]]
+id = "clock_offline"
+severity = "error"
+title = "Box will not record data without Internet"
+text = "Without the Internet the clock cannot be set, and the firmware holds all readings until it is."
+actions = [
+  "Give the box Internet access (pair it in Matter).",
+  "Replace the RTC coin cell (inside the case) so the time survives power-offs.",
+]
+
+# ===================================================================== mic
+[[guide]]
+id = "mic"
+title = "Microphone check"
+summary = "Switched-off or silent microphone."
+recommend = ["mic.disabled", "mic.silent", "mic.read_fail"]
+start = "which"
+
+[[guide.step]]
+id = "which"
+type = "route"
+routes = { "mic.disabled" = "switch", "mic.silent" = "clap", "mic.read_fail" = "end:mic_faulty" }
+default = "clap"
+
+[[guide.step]]
+id = "switch"
+type = "question"
+text = "The box reads its microphone switch as OFF. The switch is on the back of the case, just above the power switch (no need to open the box). Should this box measure noise?"
+options = [
+  { label = "Yes - I flipped the microphone switch", next = "switch_verify" },
+  { label = "No - it is meant to be off", next = "end:mic_off_ok" },
+]
+
+[[guide.step]]
+id = "switch_verify"
+type = "wait"
+# The firmware re-reads the switch before every reading (~10 s): no restart needed.
+text = "Waiting for the next microphone reading (up to 30 s)..."
+until = 'MICROPHONE: Read \d+ bytes'
+fail_on = 'Microphone is in shutdown state'
+timeout_s = 30
+on_ok = "end:mic_on"
+on_fail = "flip_back"
+on_timeout = "flip_back"
+
+[[guide.step]]
+id = "flip_back"
+type = "question"
+text = "The box still reads the switch as OFF. Flip the microphone switch to the other position (it may have been ON already)."
+options = [
+  { label = "Done - I flipped it to the other position", next = "switch_verify2" },
+  { label = "Leave it off", next = "end:mic_off_ok" },
+]
+
+[[guide.step]]
+id = "switch_verify2"
+type = "wait"
+text = "Waiting for the next microphone reading (up to 30 s)..."
+until = 'MICROPHONE: Read \d+ bytes'
+fail_on = 'Microphone is in shutdown state'
+timeout_s = 30
+on_ok = "end:mic_on"
+on_fail = "end:mic_switch_faulty"
+on_timeout = "end:mic_switch_faulty"
+
+[[guide.step]]
+id = "clap"
+type = "wait"
+text = "Check the microphone switch (back of the case, above the power switch) is ON. Then clap your hands or speak loudly right next to the box for about 20 seconds..."
+until = 'dB peak: (?!-inf)'
+timeout_s = 45
+on_ok = "end:mic_ok"
+on_timeout = "end:mic_faulty"
+
+[[guide.end]]
+id = "mic_on"
+severity = "ok"
+title = "Microphone is on and recording"
+text = "The firmware reads audio samples again."
+actions = ["Leave the microphone switch in this position."]
+
+[[guide.end]]
+id = "mic_off_ok"
+severity = "info"
+title = "Microphone intentionally off"
+text = "No noise data is recorded for this box; everything else works."
+actions = []
+
+[[guide.end]]
+id = "mic_switch_faulty"
+severity = "warning"
+title = "Microphone switch has no effect"
+text = "The box reads the microphone as OFF in both switch positions (enable line GPIO3)."
+actions = ["Check the switch and its cable to the main board (inside the case); replace the switch if needed."]
+
+[[guide.end]]
+id = "mic_ok"
+severity = "ok"
+title = "Microphone works"
+text = "It picked up sound - the earlier silence was just a very quiet room."
+actions = []
+
+[[guide.end]]
+id = "mic_faulty"
+severity = "error"
+title = "Microphone records nothing"
+text = "Even loud noise next to the box gives no signal, although the switch is on."
+actions = ["Check the microphone board/cable (inside the case); replace the microphone if needed."]

kota_tech/diag/kota.py

@@ -0,0 +1,263 @@
+"""Knowledge about the structured "KOTA:" lines of firmware 1.0.16+.
+
+Firmware source of truth (kota-sensorboard/main):
+  boot_info.cpp  "boot fw=.. build=.. hw=.. mac=.. reset=.. mode=.. commissioned=.. last_restart=.."
+                 "restart reason=.." (W, printed just before a self-restart)
+  status.cpp     "status A -> B [code=N] reason=x", "led color=.. pattern=.. [n=..|period=..ms]",
+                 "led previous_boot status=.. code=..", "led restart_flash color=.."
+  i2c.cpp        "i2c SDA=1 SCL=1 0x39=AS7341 0x68=DS1307(missing) .. [bus=stuck]"
+  ds1307.cpp     "rtc running=1 time=..", "rtc read_failed err=..", "rtc verify running=1 delta=2s ok=1"
+  sd_card.cpp    "sd type=.. size=.. fs=.. free=.. env_keys=A,B buffer_lines=N", "sd mounted=0 [err=..]"
+  main.cpp       "matter fabrics=N window=open|closed qr=MT:.. manual=.."
+  microphone.cpp "mic enabled=0 (GPIO3=1, expected 0)"
+  health.cpp     "health up=60s status=OK wifi=connected rssi=-61 time_valid=1 sd=ok buffer=0
+                  heap=123456 psram=7.8M last_upload=12s|never ota=registered|unregistered|selfcheck"
+
+Error IDs ("[E-SD-03] ...") come from error_ids.csv, a copy of the
+firmware's docs/error_ids.csv (the firmware build generates its IDs from it).
+"""
+
+from __future__ import annotations
+
+import csv
+from dataclasses import dataclass
+from pathlib import Path
+
+ERROR_IDS_PATH = Path(__file__).with_name("error_ids.csv")
+
+# Firmware colour names (status.cpp colors[]) -> engine LED keys.
+LED_COLOURS = {
+    "green": "GREEN", "cyan": "CYAN", "white": "WHITE", "red": "RED",
+    "blue": "BLUE", "purple": "PURPLE", "yellow": "YELLOW", "orange": "ORANGE",
+}
+
+RED_CODES = {1: "BME688", 2: "SEN66", 3: "AS7341", 4: "Microphone", 5: "Flicker sensor", 6: "Self-check"}
+I2C_DEVICES = {"0x39": "AS7341", "0x68": "DS1307", "0x6B": "SEN66", "0x76": "BME688"}
+
+# last_restart values written by kota_restart() that are part of normal
+# operation (button presses, a finished setup, an installed update).
+INTENTIONAL_RESTARTS = {
+    "ota_update", "button_provisioning_abort", "button_wifi_cleared",
+    "button_provisioning_toggle", "provisioning_saved",
+}
+
+MODULES = {
+    "SD": "SD card", "ENV": "ENV.TXT", "INF": "InfluxDB upload", "OTA": "Firmware update",
+    "WIFI": "Wi-Fi", "PROV": "Wi-Fi setup", "MAIN": "Start-up", "STAT": "Status LED", "SPI": "SPI bus",
+    "RTC": "Clock (RTC)", "BME": "BME688", "SEN": "SEN66", "AS": "AS7341", "MIC": "Microphone",
+    "FLK": "Flicker sensor", "DEV": "Device", "GATH": "Sensor readings",
+}
+
+
+@dataclass(frozen=True)
+class ErrorId:
+    id: str
+    module: str
+    severity: str        # error | warning | retired
+    message: str
+    action: str
+
+    @property
+    def module_name(self) -> str:
+        return MODULES.get(self.module, self.module)
+
+
+def load_error_ids(path: Path = ERROR_IDS_PATH) -> dict[str, ErrorId]:
+    if not path.exists():
+        return {}
+    with path.open(encoding="utf-8", newline="") as fh:
+        return {r["id"]: ErrorId(r["id"], r["module"], r["severity"], r["message"], r["action"])
+                for r in csv.DictReader(fh)}
+
+
+def led_for_status(status: str, code: int) -> tuple[str, str]:
+    """(LED key, pattern text) for a status - mirrors Status::pattern_for().
+    Used when the box's own "led" line was not captured (connected mid-run)."""
+    if status == "OK":
+        return "GREEN", "solid"
+    if status == "ERROR":
+        return ("RED", f"{code} pulses") if 1 <= code <= 6 else ("RED", "solid")
+    if status == "OUT_OF_RESOURCES":
+        return "RED", "solid"
+    if status == "UPDATING":
+        return "YELLOW", "blinking"
+    if status == "SELF_CHECK":
+        return "ORANGE", "solid"
+    if status == "CONNECTION_ERROR":
+        return ("PURPLE", "blinking") if code == 1 else ("PURPLE", "solid")
+    if status == "RTC_ERROR":
+        return "BLUE", "2 pulses" if code == 2 else "1 pulse"
+    if status == "SD_ERROR":
+        return "WHITE", "fast blinking"
+    if status == "RESETING":
+        return "WHITE", "solid"
+    if status == "HTTP_SERVER":
+        return "WHITE", "breathing"
+    return "UNKNOWN", ""
+
+
+def pattern_text(fields: dict[str, str]) -> str:
+    """'led color=red pattern=pulses n=2' -> '2 pulses'."""
+    p = fields.get("pattern", "")
+    if p == "pulses":
+        n = fields.get("n", "?")
+        return f"{n} pulse" if n == "1" else f"{n} pulses"
+    if p == "blink":
+        period = fields.get("period", "").removesuffix("ms")
+        fast = period.isdigit() and int(period) <= 500
+        return ("fast blinking" if fast else "blinking") + (f" ({period} ms)" if period else "")
+    if p == "breathe":
+        return "breathing"
+    return p   # solid / off
+
+
+def led_meaning(colour: str, pattern: str) -> str:
+    """Technician meaning of a colour + pattern (firmware diagnostics doc)."""
+    if colour == "GREEN":
+        return "OK"
+    if colour == "CYAN":
+        return "phone connected for pairing" if "fast" in pattern else "waiting to be paired in Matter"
+    if colour == "WHITE":
+        if "fast" in pattern:
+            return "SD card or ENV.TXT error"
+        if "breath" in pattern:
+            return "Wi-Fi setup portal"
+        return "factory reset"
+    if colour == "RED":
+        if "pulse" in pattern:
+            n = int(pattern.split()[0]) if pattern.split()[0].isdigit() else 0
+            return f"{RED_CODES.get(n, 'sensor')} failed"
+        return "internal error / out of memory"
+    if colour == "BLUE":
+        return "I2C bus stuck (sensor cable)" if pattern.startswith("2") else "clock (RTC) not responding"
+    if colour == "PURPLE":
+        return "server rejected the box (check ENV.TXT credentials)" if "blink" in pattern else "no network"
+    if colour == "YELLOW":
+        return "downloading a firmware update"
+    if colour == "ORANGE":
+        return "self-check after an update"
+    return ""
+
+
+# Finding for the current firmware status (Status::set_status). key suffix ->
+# (severity, title, meaning, actions, explained_by). The status finding is
+# grouped under a more specific finding when one explains it.
+_SENSOR_ROOTS = ("sensor.init_failed", "sensor.selfcheck_failed", "kota.i2c_stuck", "kota.sensor_missing",
+                 "sen66.not_ready", "bme688.read_fail", "as7341.read_fail", "mic.read_fail",
+                 "ota.selfcheck_failed")
+_NET_ROOTS = ("matter.not_commissioned", "wifi.disconnected", "wifi.setup_portal", "kota.wifi_down",
+              "net.dns_fail", "net.tls_fail")
+
+
+def status_finding(status: str, code: int) -> tuple[str, str, str, str, tuple[str, ...], tuple[str, ...]] | None:
+    """(key, severity, title, meaning, actions, explained_by) or None for healthy states."""
+    if status == "ERROR":
+        if 1 <= code <= 5:
+            s = RED_CODES[code]
+            return (f"status.error.{code}", "critical", f"{s} fault (LED red, {code} pulses)",
+                    f"The firmware reports the {s} as failed.",
+                    (f"Open the case and check the {s} connector/cable.",
+                     "If several sensors fail: check the shared I2C cable.",
+                     "The box restarts itself after 150 s in this state."), _SENSOR_ROOTS)
+        if code == 6:
+            return ("status.error.6", "error", "Post-update self-check failed (LED red, 6 pulses)",
+                    "The new firmware failed its self-check and rolls back.",
+                    ("Check the sensor named in the log (inside the case), then power-cycle.",), _SENSOR_ROOTS)
+        return ("status.error", "error", "Internal error (LED red)",
+                "The firmware is in its general error state.",
+                ("Save the session log and send it to the firmware team.",
+                 "The box restarts itself after 150 s in this state."), _SENSOR_ROOTS)
+    if status == "OUT_OF_RESOURCES":
+        return ("status.oom", "error", "Firmware ran out of memory (LED red)",
+                "The firmware could not allocate memory; it restarts itself after 30 s.",
+                ("Power-cycle. If it repeats, save the session log for the firmware team.",),
+                ("sys.out_of_resources",))
+    if status == "CONNECTION_ERROR":
+        if code == 1:
+            return ("status.conn.1", "critical", "Server rejected the box (LED purple, blinking)",
+                    "The network works but the server refused the box (HTTP 401/403/404): "
+                    "INFLUX_URL / INFLUX_TOKEN in ENV.TXT are wrong or revoked.",
+                    ("Re-provision the SD card with the current ENV.TXT (SD card is inside the case).",),
+                    ("influx.auth", "influx.not_found"))
+        return ("status.conn", "error", "No connection to the servers (LED purple)",
+                "Uploads or the update check fail: no Wi-Fi, no Internet or the server is unreachable.",
+                ("Check the box is paired/connected to Wi-Fi and the network has Internet.",),
+                _NET_ROOTS + ("influx.buffer_fail", "ota.check_failed", "influx.server_error"))
+    if status == "RTC_ERROR":
+        if code == 2:
+            return ("status.rtc.2", "critical", "I2C bus stuck (LED blue, 2 pulses)",
+                    "SDA or SCL is held low: a shorted or broken sensor cable, or a faulty sensor.",
+                    ("Open the case and check the I2C cable between the boards.",
+                     "Unplug sensors one by one to find the one holding the bus."), ("kota.i2c_stuck",))
+        return ("status.rtc.1", "critical", "Clock chip (RTC) not responding (LED blue, 1 pulse)",
+                "The DS1307 clock does not answer on the I2C bus.",
+                ("Open the case and check the I2C cable/connector between the boards.",
+                 "If the cable is fine: the RTC module is faulty."),
+                ("rtc.init_failed", "kota.rtc_read_failed", "kota.sensor_missing"))
+    if status == "SD_ERROR":
+        return ("status.sd", "critical", "SD card or ENV.TXT error (LED white, fast blinking)",
+                "The SD card cannot be read or ENV.TXT is missing settings.",
+                ("Open the case, re-seat the SD card or re-provision it with the tool.",),
+                ("kota.sd_unmounted", "influx.env_missing", "sd.card_fail", "sd.mount_fail",
+                 "sd.env_open_fail", "influx.init_fail"))
+    if status == "RESETING":
+        return ("status.reset", "warning", "Factory reset in progress (LED white, solid)",
+                "The Matter button was held: the box forgets its Matter network.",
+                ("Pair the box again in the Matter app afterwards.",), ("sys.factory_reset",))
+    if status == "HTTP_SERVER":
+        return ("status.portal", "warning", "Box is in Wi-Fi setup mode (LED white, breathing)",
+                "The box hosts its own Wi-Fi network for configuration.",
+                ("Connect a phone to the box's network and open http://sensorbox.local/,",
+                 "or short-press the Matter button to leave setup mode."), ("wifi.setup_portal",))
+    return None   # OK, UPDATING, SELF_CHECK: covered by milestones / OTA rules
+
+
+# last_restart -> (severity, title, meaning, actions); None = not a fault.
+def restart_finding(reason: str) -> tuple[str, str, str, tuple[str, ...]] | None:
+    if reason in INTENTIONAL_RESTARTS or reason in ("none", "", "-"):
+        return None
+    if reason == "status_watchdog":
+        return ("warning", "Box restarted itself after 150 s in the red error state",
+                "By design the firmware restarts when it stays in the error state (red) for 150 s.",
+                ("Fix the grouped cause; the restarts stop by themselves.",))
+    if reason == "status_oom_watchdog":
+        return ("error", "Box restarted itself because it ran out of memory",
+                "The firmware was out of memory for 30 s and restarted.",
+                ("Save the session log for the firmware team.",))
+    if reason == "provisioning_failed":
+        return ("warning", "Wi-Fi setup portal failed to start",
+                "The setup portal could not start; the box cleared setup mode and restarted.",
+                ("Retry Wi-Fi setup (short button press); restart the device if it persists.",))
+    if reason == "panic":
+        return ("critical", "Firmware crashed (panic) and restarted",
+                "The firmware hit a fatal error.",
+                ("Press Reset & capture to record the crash; save the session log for the firmware team.",))
+    if reason in ("task_wdt", "int_wdt", "wdt"):
+        return ("error", "Firmware froze and was restarted by the watchdog",
+                f"The firmware stopped responding ({reason}); the watchdog restarted it.",
+                ("Save the session log for the firmware team.",))
+    if reason == "brownout":
+        return ("error", "Power supply voltage dropped (brown-out)",
+                "The supply voltage fell too low and the chip reset itself.",
+                ("Check the power supply, cable and connectors.",))
+    if reason == "unknown_sw":
+        return ("warning", "Unexpected software restart",
+                "The firmware restarted without recording a reason.",
+                ("Watch whether it repeats; save the session log for the firmware team.",))
+    return ("warning", f"Box restarted itself ({reason})",
+            f"The firmware recorded the restart reason '{reason}'.",
+            ("Save the session log for the firmware team if it repeats.",))
+
+
+def parse_size_gb(value: str) -> float | None:
+    """'7.3GB' -> 7.3 (sd_card.cpp format_gb)."""
+    v = value.upper().removesuffix("GB")
+    try:
+        return float(v)
+    except ValueError:
+        return None
+
+
+def parse_seconds(value: str) -> int | None:
+    v = value.removesuffix("s")
+    return int(v) if v.lstrip("-").isdigit() else None

kota_tech/diag/rules.toml

@@ -8,6 +8,9 @@
 # Fields:
 #   id           unique, "<category>.<name>"
 #   pattern      Python regex (search). Named groups can be used in `title`.
+#                Matched against the line with its error ID ("[E-SD-03] ")
+#                removed. Rules without a pattern ("kota.*") are raised by
+#                the engine from the structured KOTA: lines (diag/kota.py).
 #   severity     critical | error | warning | info | ignore
 #                ignore = never shown (benign ESP_LOGE lines, LED-only rules)
 #   title        short technician-facing headline
@@ -72,6 +75,13 @@ severity = "ignore"
 milestone = "wifi_connected"
 clears = ["matter.not_commissioned", "wifi.disconnected"]
 
+[[rule]]
+id = "matter.commissioned"
+pattern = 'MAIN: Commissioning complete|MAIN: Fabric is committed'
+severity = "ignore"
+milestone = "matter_commissioned"
+clears = ["matter.not_commissioned", "matter.commissioning_failed"]
+
 [[rule]]
 id = "net.time_synced"
 pattern = 'SNTP: Time synchronized'
@@ -114,7 +124,7 @@ led_from = "PURPLE"
 
 [[rule]]
 id = "benign.mac"
-pattern = 'ID: Device MAC address'
+pattern = 'Device MAC address'
 severity = "ignore"
 
 [[rule]]
@@ -127,6 +137,14 @@ id = "benign.zcl"
 pattern = 'chip\[ZCL\]: WRITE ERR|data_model: Cluster cannot be NULL'
 severity = "ignore"
 
+[[rule]]
+id = "benign.wifi_start"
+# Harmless Wi-Fi noise seen on every 1.0.16 boot: Matter asks for a connect
+# while the station is already connecting, and an unpaired box polls a
+# network it does not have yet (matter.not_commissioned covers that case).
+pattern = 'wifi:sta is connecting, return error|esp_wifi_connect\(\) failed: ESP_ERR_WIFI_CONN|Failed to get configured network when updating network status'
+severity = "ignore"
+
 [[rule]]
 id = "benign.connect_chain"
 # Transport-level echo of a failure that a more specific rule reports.
@@ -215,7 +233,7 @@ id = "influx.buffer_fail"
 pattern = 'Failed to write chunk with \d+ retries to Influx|MAIN: Failed to flush Influx buffer'
 severity = "error"
 title = "Measurements cannot be uploaded to InfluxDB"
-meaning = "Uploads keep failing, so readings are stored on the SD card and sent later. The LED turns purple and the box restarts itself after about 2.5 minutes in this state."
+meaning = "Uploads keep failing, so readings are stored on the SD card and sent later. The LED turns purple (firmware v1.0 also restarts itself after about 2.5 minutes in this state)."
 actions = [
   "Fix the network problem first (see the finding this is grouped under).",
   "Buffered data is uploaded automatically once the connection works.",
@@ -333,6 +351,7 @@ actions = [
   "Open the case and check the I2C cable/connector between the boards.",
   "If the cable is fine: the RTC module is faulty.",
 ]
+explained_by = ["kota.i2c_stuck"]
 led = "BLUE"
 
 [[rule]]
@@ -346,6 +365,7 @@ actions = [
   "Give the box Internet access: the clock is set automatically on the first connection.",
   "If this comes back after every power-off: replace the RTC coin cell (inside the case).",
 ]
+explained_by = ["kota.rtc_stopped"]
 
 [[rule]]
 id = "i2c.errors"
@@ -355,6 +375,7 @@ min_count = 2
 title = "I2C bus communication errors"
 meaning = "Sensors are not answering reliably on the I2C bus: loose connector, damaged cable, or a failing sensor."
 actions = ["Open the case and check the I2C cable/connectors between the boards."]
+explained_by = ["kota.i2c_stuck", "kota.sensor_missing"]
 
 # ------------------------------------------------------------------ sensors
 
@@ -369,6 +390,7 @@ actions = [
   "Open the case and check the {sensor} connector/cable.",
   "If several sensors fail in turn: check the shared I2C cable.",
 ]
+explained_by = ["kota.i2c_stuck", "kota.sensor_missing"]
 led = "RED"
 
 [[rule]]
@@ -551,8 +573,8 @@ id = "mic.disabled"
 pattern = 'MICROPHONE: Microphone is in shutdown state'
 severity = "info"
 title = "Microphone is switched off - no noise measurements"
-meaning = "The firmware reads the microphone enable line (GPIO3) as 'off', which it treats as disabled on purpose. Noise levels are not recorded."
-actions = ["If this box should measure noise: check the microphone enable switch/jumper and its wiring (inside the case)."]
+meaning = "The microphone switch on the back of the case (just above the power switch) is OFF, so noise levels are not recorded."
+actions = ["If this box should measure noise: flip the microphone switch (back of the case, above the power switch). No restart needed - it is picked up within about 10 s."]
 
 [[rule]]
 id = "gather.empty_reading"
@@ -563,3 +585,148 @@ title = "A sensor returned no data"
 meaning = "One of the sensors skipped its reading; the preceding log lines name the sensor."
 actions = ["Check the log lines just before this message for the sensor name."]
 explained_by = ["mic.disabled", "mic.read_fail", "bme688.read_fail", "as7341.read_fail", "rtc.clock_not_running"]
+
+# ------------------------------------------------ structured KOTA: lines
+# Firmware 1.0.16+ reports its state as "KOTA: <record> key=value ..." lines.
+# These rules have no pattern: the engine raises them from the parsed fields
+# (see diag/kota.py for the line formats). Named values in {braces} come
+# from the line's fields.
+
+[[rule]]
+id = "kota.i2c_stuck"
+severity = "critical"
+title = "I2C bus stuck (SDA={sda}, SCL={scl})"
+meaning = "A data line of the sensor bus is held low before any sensor is used: a shorted or broken sensor cable, or a faulty sensor. LED blue, 2 pulses."
+actions = [
+  "Open the case and check the I2C cable between the boards.",
+  "Unplug the sensors one by one to find the one holding the bus.",
+]
+
+[[rule]]
+id = "kota.sensor_missing"
+split_by = "sensor"
+severity = "error"
+title = "{sensor} does not answer on the I2C bus"
+meaning = "The start-up scan did not find the {sensor} at address {addr}. The other sensors answer, so the bus itself works: the {sensor} cable, connector or the sensor is faulty."
+actions = [
+  "Open the case and re-seat the {sensor} cable/connector.",
+  "If it is still missing after a restart: replace the {sensor}.",
+]
+explained_by = ["kota.i2c_stuck"]
+
+[[rule]]
+id = "kota.rtc_read_failed"
+severity = "critical"
+title = "Clock chip (RTC) cannot be read ({err})"
+meaning = "The DS1307 clock does not answer. It is on the shared I2C bus, so a loose cable also causes this."
+actions = [
+  "Open the case and check the I2C cable/connector between the boards.",
+  "If the cable is fine: replace the RTC module.",
+]
+explained_by = ["kota.i2c_stuck", "kota.sensor_missing"]
+
+[[rule]]
+id = "kota.rtc_stopped"
+severity = "warning"
+title = "Clock chip was stopped at start-up (time {time})"
+meaning = "The RTC answers but its clock was not running - typical after its coin cell was removed or is empty. It is set again from the Internet once the box is online; until then readings are held."
+actions = [
+  "Give the box Internet access: the clock is set automatically.",
+  "If this comes back after every power-off: replace the RTC coin cell (inside the case).",
+]
+
+[[rule]]
+id = "kota.rtc_not_ticking"
+severity = "error"
+title = "Clock chip does not keep time"
+meaning = "The clock was set from the Internet, but 2 s later it had not advanced correctly (running={running}, delta={delta}). The RTC module or its crystal is faulty."
+actions = ["Replace the RTC module (inside the case)."]
+
+[[rule]]
+id = "kota.sd_unmounted"
+severity = "critical"
+title = "SD card not mounted ({err})"
+meaning = "The firmware cannot use the SD card: missing, not seated, not FAT32 or damaged. Without it the box cannot read ENV.TXT. LED white, fast blinking."
+actions = [
+  "Open the case and re-seat the SD card.",
+  "Re-provision the card with the tool (FAT32, MBR) or try a freshly provisioned card.",
+]
+
+[[rule]]
+id = "kota.sd_not_fat32"
+severity = "warning"
+title = "SD card file system is {fs}, not FAT32"
+meaning = "The card works, but the provisioning standard is FAT32."
+actions = ["Re-provision the card with the tool when convenient."]
+
+[[rule]]
+id = "kota.sd_full"
+severity = "warning"
+title = "SD card is almost full ({free} free)"
+meaning = "Offline readings may soon not be stored."
+actions = ["Check the buffered readings upload (Internet access), or replace the card."]
+
+[[rule]]
+id = "kota.buffer_backlog"
+severity = "warning"
+title = "{lines} readings are waiting on the SD card to be uploaded"
+meaning = "The box stored readings while it could not upload them. They are sent automatically once the connection works."
+actions = ["Fix the connection problem if there is one; watch the health line: the buffer should shrink."]
+explained_by = ["kota.wifi_down", "matter.not_commissioned", "status.conn", "status.conn.1", "net.dns_fail", "influx.auth"]
+
+[[rule]]
+id = "kota.wifi_down"
+severity = "error"
+min_count = 2
+title = "Box has no Wi-Fi connection"
+meaning = "The periodic health report says Wi-Fi is disconnected, so the box cannot upload data or receive updates."
+actions = [
+  "Check the site Wi-Fi is on, 2.4 GHz and in range.",
+  "Matter boxes: check the box is still paired in the Matter app. Wi-Fi-from-SD boxes: check SSID/PASSWORD in ENV.TXT.",
+]
+explained_by = ["matter.not_commissioned", "wifi.setup_portal", "wifi.disconnected"]
+
+[[rule]]
+id = "kota.weak_wifi"
+severity = "warning"
+title = "Weak Wi-Fi signal ({rssi} dBm)"
+meaning = "The connection works but the signal is weak; uploads may fail intermittently. Below about -75 dBm is unreliable."
+actions = ["Move the box or the access point closer, or add a repeater."]
+
+[[rule]]
+id = "kota.time_invalid"
+severity = "warning"
+title = "Box has no valid time - readings are on hold"
+meaning = "Readings are only stored with a valid timestamp. The time comes from the RTC or from the Internet."
+actions = [
+  "Give the box Internet access so it can set its clock.",
+  "If it is online and this persists: check the RTC findings.",
+]
+explained_by = ["kota.wifi_down", "matter.not_commissioned", "kota.rtc_not_ticking", "kota.rtc_read_failed", "kota.rtc_stopped", "rtc.clock_not_running", "net.dns_fail"]
+
+[[rule]]
+id = "kota.no_upload"
+severity = "error"
+title = "Connected to Wi-Fi, but no data uploaded yet (5+ min)"
+meaning = "The box has Wi-Fi but no upload to InfluxDB has succeeded yet."
+actions = [
+  "Check the network has Internet (open a website on a phone on the same Wi-Fi).",
+  "Check INFLUX_URL / INFLUX_TOKEN in ENV.TXT (re-provision the SD card).",
+]
+explained_by = ["kota.time_invalid", "influx.auth", "influx.not_found", "status.conn.1", "net.dns_fail", "net.tls_fail", "influx.server_error"]
+
+[[rule]]
+id = "kota.low_heap"
+severity = "warning"
+title = "Firmware memory is low ({heap} bytes free)"
+meaning = "Internal memory is running low; the firmware may fail to start tasks and restart."
+actions = ["Save the session log for the firmware team."]
+
+[[rule]]
+id = "kota.ota_unregistered"
+severity = "warning"
+min_count = 3
+title = "Online, but not registered for firmware updates"
+meaning = "The box has Wi-Fi but is still not registered with the update server, so it will not receive new firmware."
+actions = ["Check the network allows HTTPS to bin.kota-app.com; registration is retried automatically."]
+explained_by = ["ota.registration_failed", "net.dns_fail", "net.tls_fail"]

kota_tech/flash/image.py

@@ -0,0 +1,260 @@
+"""Firmware images: validation, integrity, layout and the firmware folder.
+
+The tool flashes ONLY the .bin files in its own firmware/ folder (next to
+kota_tech/). There is no import and no per-user library: to offer a build,
+the firmware team puts the file into that folder. Images are listed by the
+compile date stored in the firmware itself (ESP-IDF app descriptor), newest
+first, so the file name does not matter.
+
+Two kinds:
+  * merged - bootloader at 0x0 + partition table + app (merged-binary.bin);
+             App-only or Full flashing;
+  * app    - the application binary only (build/kota-sensorboard.bin);
+             App-only flashing, laid out like a merged image in the folder.
+
+Every image is checked structurally (ESP32-S3, kota-sensorboard app
+descriptor, segment checksum and the appended SHA-256) so a truncated or
+corrupted file is refused before anything is written.
+"""
+
+from __future__ import annotations
+
+import datetime as dt
+import hashlib
+import struct
+from dataclasses import dataclass
+from pathlib import Path
+
+FIRMWARE_DIR = Path(__file__).resolve().parents[2] / "firmware"
+
+PT_OFFSET = 0x8000
+PT_SIZE = 0xC00
+ESP32S3_CHIP_ID = 9
+IMAGE_MAGIC = 0xE9
+APP_DESC_MAGIC = 0xABCD5432
+FLASH_SIZES = {0: "1MB", 1: "2MB", 2: "4MB", 3: "8MB", 4: "16MB", 5: "32MB"}
+_MONTHS = {m: i for i, m in enumerate(
+    ["Jan", "Feb", "Mar", "Apr", "May", "Jun", "Jul", "Aug", "Sep", "Oct", "Nov", "Dec"], 1)}
+
+
+class ImageError(ValueError):
+    pass
+
+
+@dataclass(frozen=True)
+class Partition:
+    label: str
+    type: int
+    subtype: int
+    offset: int
+    size: int
+
+
+@dataclass(frozen=True)
+class AppInfo:
+    project: str
+    version: str
+    built: str          # "Sep 28 2026 15:07:57" as in the app descriptor
+    idf: str
+    elf_sha: str        # hex
+
+    @property
+    def built_at(self) -> dt.datetime | None:
+        try:
+            mon, day, year, hms = self.built.split()
+            h, m, s = (int(x) for x in hms.split(":"))
+            return dt.datetime(int(year), _MONTHS[mon], int(day), h, m, s)
+        except (ValueError, KeyError):
+            return None
+
+    @property
+    def compiled(self) -> str:
+        """'2026-09-28 15:07' (ISO-like, sortable) or the raw descriptor text."""
+        t = self.built_at
+        return t.strftime("%Y-%m-%d %H:%M") if t else self.built
+
+
+@dataclass(frozen=True)
+class FirmwareImage:
+    path: Path
+    kind: str                        # "merged" | "app"
+    sha256: str
+    flash_size: str
+    partitions: tuple[Partition, ...]
+    partition_table: bytes           # expected table on the box
+    app_offset: int                  # where the app starts inside the file
+    app_length: int                  # exact app image length (from its structure)
+    app: AppInfo
+
+    @property
+    def name(self) -> str:
+        return self.path.name
+
+    @property
+    def data(self) -> bytes:
+        return self.path.read_bytes()
+
+    def partition(self, label: str) -> Partition:
+        for p in self.partitions:
+            if p.label == label:
+                return p
+        raise ImageError(f"partition {label!r} not in image")
+
+    def app_bytes(self) -> bytes:
+        return self.data[self.app_offset:self.app_offset + self.app_length]
+
+    def blank_otadata(self) -> bytes:
+        """Erased otadata: the bootloader then boots ota_0."""
+        return b"\xff" * self.partition("otadata").size
+
+    def label(self) -> str:
+        """Choice text: compile date first (that is what the technician picks by)."""
+        kind = "" if self.kind == "merged" else ", app only"
+        return f"Compiled {self.app.compiled}  -  v{self.app.version} [{self.app.elf_sha[:8]}]{kind}  ({self.name})"
+
+
+# ---------------------------------------------------------------- parsing
+
+def parse_partition_table(raw: bytes) -> tuple[Partition, ...]:
+    parts = []
+    for i in range(0, len(raw) - 31, 32):
+        entry = raw[i:i + 32]
+        magic = entry[:2]
+        if magic == b"\xaa\x50":
+            _, ptype, sub, off, size = struct.unpack_from("<HBBII", entry)
+            label = entry[12:28].split(b"\0")[0].decode("ascii", "replace")
+            parts.append(Partition(label, ptype, sub, off, size))
+        elif magic in (b"\xeb\xeb", b"\xff\xff"):   # MD5 entry / end
+            break
+        else:
+            raise ImageError(f"corrupt partition table entry at 0x{PT_OFFSET + i:x}")
+    return tuple(parts)
+
+
+def app_image_length(data: bytes, offset: int = 0) -> int:
+    """Validate an ESP app image at `offset`; return its exact length.
+
+    Checks the segment checksum and, when the header says so, the appended
+    SHA-256 - the same checks the bootloader performs before booting it.
+    """
+    if len(data) < offset + 24 or data[offset] != IMAGE_MAGIC:
+        raise ImageError(f"no firmware image at 0x{offset:x}")
+    segments = data[offset + 1]
+    chip_id = struct.unpack_from("<H", data, offset + 12)[0]
+    if chip_id != ESP32S3_CHIP_ID:
+        raise ImageError(f"image is for chip id {chip_id}, not ESP32-S3")
+    hash_appended = data[offset + 23] == 1
+    pos, checksum = offset + 24, 0xEF
+    for _ in range(segments):
+        if pos + 8 > len(data):
+            raise ImageError("image is truncated (segment header missing)")
+        _, seg_len = struct.unpack_from("<II", data, pos)
+        pos += 8
+        if pos + seg_len > len(data):
+            raise ImageError("image is truncated (segment data missing)")
+        for b in data[pos:pos + seg_len]:
+            checksum ^= b
+        pos += seg_len
+    pos += 15 - ((pos - offset) % 16)          # pad so the checksum ends a 16-byte block
+    if pos >= len(data) or data[pos] != checksum:
+        raise ImageError("image checksum is wrong - the file is corrupted")
+    pos += 1
+    if hash_appended:
+        if pos + 32 > len(data):
+            raise ImageError("image is truncated (SHA-256 missing)")
+        if hashlib.sha256(data[offset:pos]).digest() != data[pos:pos + 32]:
+            raise ImageError("image SHA-256 does not match its content - the file is corrupted")
+        pos += 32
+    return pos - offset
+
+
+def _app_info(data: bytes, offset: int) -> AppInfo:
+    d = data[offset + 0x20:offset + 0x20 + 256]
+    if len(d) < 256 or struct.unpack_from("<I", d)[0] != APP_DESC_MAGIC:
+        raise ImageError("firmware has no ESP-IDF app descriptor")
+    s = lambda o, n: d[o:o + n].split(b"\0")[0].decode("ascii", "replace")
+    info = AppInfo(project=s(48, 32), version=s(16, 32), built=f"{s(96, 16)} {s(80, 16)}",
+                   idf=s(112, 32), elf_sha=d[144:176].hex())
+    if info.project != "kota-sensorboard":
+        raise ImageError(f"firmware is {info.project!r}, not kota-sensorboard")
+    return info
+
+
+
+def inspect_image(path: Path, reference: FirmwareImage | None = None) -> FirmwareImage:
+    """Validate a merged or app-only image. App-only images need a `reference`
+    (a merged image) that provides the flash layout."""
+    data = path.read_bytes()
+    if len(data) >= PT_OFFSET + PT_SIZE and data[0] == IMAGE_MAGIC and data[PT_OFFSET:PT_OFFSET + 2] == b"\xaa\x50":
+        app_image_length(data, 0)              # bootloader must be intact
+        table = data[PT_OFFSET:PT_OFFSET + PT_SIZE]
+        parts = parse_partition_table(table)
+        labels = {p.label for p in parts}
+        for need in ("nvs", "otadata", "ota_0"):
+            if need not in labels:
+                raise ImageError(f"partition table has no {need!r} partition")
+        ota0 = next(p for p in parts if p.label == "ota_0")
+        kind, app_off, flash_size = "merged", ota0.offset, FLASH_SIZES.get(data[3] >> 4, "?")
+    elif data[:1] == bytes([IMAGE_MAGIC]):
+        if reference is None:
+            raise ImageError("app-only file, but there is no complete (merged) image in the folder "
+                             "to take the flash layout from")
+        kind, app_off = "app", 0
+        parts, table, flash_size = reference.partitions, reference.partition_table, reference.flash_size
+        ota0 = next(p for p in parts if p.label == "ota_0")
+    else:
+        raise ImageError("not an ESP32 firmware file")
+    length = app_image_length(data, app_off)
+    if length > ota0.size:
+        raise ImageError(f"firmware ({length} bytes) does not fit the ota_0 partition ({ota0.size} bytes)")
+    app = _app_info(data, app_off)
+    return FirmwareImage(path, kind, hashlib.sha256(data).hexdigest(),
+                         flash_size, parts, table, app_off, length, app)
+
+
+# ------------------------------------------------------------- catalogue
+
+def folder_images(folder: Path = FIRMWARE_DIR) -> tuple[list[FirmwareImage], list[str]]:
+    """(valid images newest-compiled first, problems) for the .bin files in `folder`.
+
+    A broken or foreign file is reported, never offered. The same build
+    under two file names is offered once.
+    """
+    if not folder.is_dir():
+        return [], [f"firmware folder not found: {folder}"]
+    files = sorted(p for p in folder.iterdir() if p.is_file() and p.suffix.lower() == ".bin")
+    merged: list[FirmwareImage] = []
+    app_only: list[Path] = []
+    problems: list[str] = []
+    for f in files:
+        try:
+            merged.append(inspect_image(f))
+        except ImageError as exc:
+            if "app-only" in str(exc):
+                app_only.append(f)
+            else:
+                problems.append(f"{f.name}: {exc}")
+        except OSError as exc:
+            problems.append(f"{f.name}: cannot read ({exc})")
+    merged.sort(key=_newest_first)
+    reference = merged[0] if merged else None
+    images = list(merged)
+    for f in app_only:
+        try:
+            images.append(inspect_image(f, reference))
+        except (ImageError, OSError) as exc:
+            problems.append(f"{f.name}: {exc}")
+    images.sort(key=_newest_first)
+    unique: dict[str, FirmwareImage] = {}
+    for img in images:
+        if img.sha256 in unique:
+            problems.append(f"{img.name}: same file as {unique[img.sha256].name} (listed once)")
+        else:
+            unique[img.sha256] = img
+    return list(unique.values()), problems
+
+
+def _newest_first(img: FirmwareImage) -> tuple:
+    # Unknown compile dates last; merged before app-only for the same date.
+    t = img.app.built_at
+    return (t is None, -t.timestamp() if t else 0.0, img.kind != "merged", img.name)

kota_tech/flash/plan.py

@@ -0,0 +1,104 @@
+"""Flash plans: which esptool steps run, in which order.
+
+App-only (default, repairs): check the box has the same partition table,
+then write the app to ota_0 and erase otadata so ota_0 boots. NVS is kept:
+Matter pairing, OTA registration and Wi-Fi survive.
+
+Full (new or wiped boards): write the whole factory image at 0x0, the same
+as the factory flash_all.bat. This erases NVS: pairing and OTA registration
+are lost.
+"""
+
+from __future__ import annotations
+
+import enum
+from dataclasses import dataclass, field
+from pathlib import Path
+
+from .image import PT_OFFSET, PT_SIZE, FirmwareImage
+
+BAUD = "460800"
+
+
+class Mode(str, enum.Enum):
+    APP_ONLY = "app_only"
+    FULL = "full"
+
+
+@dataclass
+class Step:
+    kind: str                  # "backup" | "read_pt" | "write"
+    title: str
+    args: list[str]            # esptool arguments (no interpreter prefix)
+    est_s: int                 # rough duration for the UI
+    output: Path | None = None # file produced by the step (backup / table)
+
+
+@dataclass
+class Plan:
+    mode: Mode
+    image: FirmwareImage
+    port: str
+    steps: list[Step] = field(default_factory=list)
+    workdir: Path | None = None
+
+    def summary(self) -> list[str]:
+        return [f"{i}. {s.title} (~{_dur(s.est_s)})" for i, s in enumerate(self.steps, 1)]
+
+
+def _dur(s: int) -> str:
+    return f"{s // 60} min" if s >= 90 else f"{s} s"
+
+
+def _common(port: str, after: str) -> list[str]:
+    return ["--chip", "esp32s3", "--port", port, "--baud", BAUD,
+            "--before", "default_reset", "--after", after]
+
+
+def build_plan(image: FirmwareImage, mode: Mode, port: str, workdir: Path,
+               backup_to: Path | None = None) -> Plan:
+    workdir.mkdir(parents=True, exist_ok=True)
+    plan = Plan(mode, image, port, workdir=workdir)
+    if backup_to is not None:
+        size = {"4MB": "0x400000", "8MB": "0x800000", "16MB": "0x1000000"}.get(image.flash_size, "0x800000")
+        plan.steps.append(Step(
+            "backup", f"Back up the box's complete flash to {backup_to.name}",
+            _common(port, "no_reset") + ["read_flash", "0", size, str(backup_to)],
+            est_s=200 if size == "0x800000" else 100, output=backup_to))
+
+    write_opts = ["write_flash", "--flash_mode", "keep", "--flash_freq", "keep", "--flash_size", "keep"]
+    if mode == Mode.APP_ONLY:
+        pt_file = workdir / "box_partition_table.bin"
+        plan.steps.append(Step(
+            "read_pt", "Check the box has the same partition layout",
+            _common(port, "no_reset") + ["read_flash", hex(PT_OFFSET), hex(PT_SIZE), str(pt_file)],
+            est_s=5, output=pt_file))
+        app_file = workdir / "app_ota0.bin"
+        ota_file = workdir / "otadata_blank.bin"
+        app_file.write_bytes(image.app_bytes())
+        ota_file.write_bytes(image.blank_otadata())
+        otadata, ota0 = image.partition("otadata"), image.partition("ota_0")
+        plan.steps.append(Step(
+            "write", "Write the firmware app (keeps pairing, OTA registration, settings)",
+            _common(port, "hard_reset") + write_opts + [
+                hex(otadata.offset), str(ota_file), hex(ota0.offset), str(app_file)],
+            est_s=20))
+    else:
+        if image.kind != "merged":
+            raise ValueError("Full mode needs a complete image (bootloader + partition table + app); "
+                             "this file contains the app only - use App-only mode.")
+        plan.steps.append(Step(
+            "write", "Write the complete image (erases pairing and OTA registration)",
+            _common(port, "hard_reset") + write_opts + ["0x0", str(image.path)],
+            est_s=25))
+    return plan
+
+
+def check_partition_table(box_table: bytes, image: FirmwareImage) -> str | None:
+    """None if App-only is safe, otherwise the reason it is not."""
+    if box_table.strip(b"\xff") == b"":
+        return "The box has no partition table (blank or erased chip). Use Full mode."
+    if box_table != image.partition_table:
+        return ("The box uses a different partition layout than this image. "
+                "App-only could leave it unbootable - use Full mode.")
+    return None

kota_tech/flash/runner.py

@@ -0,0 +1,118 @@
+"""Runs a flash plan: one esptool subprocess per step, in a background thread.
+
+A subprocess (instead of calling esptool in-process) keeps esptool's
+stdout/sys.exit handling away from the GUI and lets the tool read progress
+line by line. Callbacks are invoked from the worker thread.
+"""
+
+from __future__ import annotations
+
+import re
+import subprocess
+import sys
+import threading
+from collections.abc import Callable
+from dataclasses import dataclass
+
+from .plan import Plan, check_partition_table
+
+_PROGRESS = re.compile(r"\((\d{1,3}) ?%\)")
+
+# esptool output -> technician-facing hint
+HINTS = [
+    (re.compile(r"could not open port|Access is denied|PermissionError|Resource busy", re.I),
+     "The USB port is in use. Close other programs that use the sensorbox port (serial monitors, Arduino IDE) and try again."),
+    (re.compile(r"Failed to connect to ESP32-S3|No serial data received|Wrong boot mode", re.I),
+     "The box did not enter flashing mode by itself. Open the case, hold the BOOT button, press and release RESET, "
+     "release BOOT, then press Start again."),
+    (re.compile(r"device reports readiness to read but returned no data|The port disappeared|device disconnected", re.I),
+     "The USB connection dropped. Use a short data-capable USB cable directly on the laptop (no hub) and try again."),
+    (re.compile(r"Invalid head of packet|timed out", re.I),
+     "Communication errors. Try another USB cable or port."),
+]
+
+
+@dataclass
+class Result:
+    ok: bool
+    message: str
+    hint: str = ""
+    failed_step: int | None = None
+
+
+class FlashRunner:
+    def __init__(self, plan: Plan,
+                 on_step: Callable[[int, str], None],
+                 on_progress: Callable[[int], None],
+                 on_output: Callable[[str], None],
+                 on_done: Callable[[Result], None],
+                 esptool_cmd: list[str] | None = None):
+        self.plan = plan
+        self._on_step, self._on_progress = on_step, on_progress
+        self._on_output, self._on_done = on_output, on_done
+        self._cmd = esptool_cmd or [sys.executable, "-m", "esptool"]
+        self._thread: threading.Thread | None = None
+
+    def start(self) -> None:
+        self._thread = threading.Thread(target=self._run, name="flash", daemon=True)
+        self._thread.start()
+
+    def join(self, timeout: float | None = None) -> None:
+        if self._thread:
+            self._thread.join(timeout)
+
+    def _run(self) -> None:
+        try:
+            self._on_done(self._execute())
+        except Exception as exc:  # never leave the UI waiting
+            self._on_done(Result(False, f"Internal error: {exc}"))
+
+    def _execute(self) -> Result:
+        for i, step in enumerate(self.plan.steps):
+            self._on_step(i, step.title)
+            self._on_progress(0)
+            code, output = self._esptool(step.args)
+            if code != 0:
+                return Result(False, f"Step {i + 1} failed: {step.title}", _hint(output), i)
+            if step.kind == "read_pt":
+                problem = check_partition_table(step.output.read_bytes(), self.plan.image)
+                if problem:
+                    return Result(False, problem, failed_step=i)
+            self._on_progress(100)
+        return Result(True, "Firmware written and verified by esptool.")
+
+    def _esptool(self, args: list[str]) -> tuple[int, str]:
+        cmd = self._cmd + args
+        self._on_output("$ esptool " + " ".join(args))
+        flags = subprocess.CREATE_NO_WINDOW if sys.platform == "win32" else 0
+        proc = subprocess.Popen(cmd, stdout=subprocess.PIPE, stderr=subprocess.STDOUT,
+                                creationflags=flags)
+        collected: list[str] = []
+        buf = b""
+        assert proc.stdout is not None
+        while chunk := proc.stdout.read1(4096):   # returns as soon as bytes arrive
+            buf += chunk
+            # esptool redraws progress with '\r'; treat it as a line break.
+            *lines, buf = re.split(rb"[\r\n]", buf)
+            for raw in lines:
+                self._line(raw, collected)
+        if buf:
+            self._line(buf, collected)
+        return proc.wait(), "\n".join(collected)
+
+    def _line(self, raw: bytes, collected: list[str]) -> None:
+        text = raw.decode("utf-8", "replace").strip()
+        if not text:
+            return
+        collected.append(text)
+        if m := _PROGRESS.search(text):
+            self._on_progress(min(int(m.group(1)), 100))
+            return   # progress lines are not worth listing one by one
+        self._on_output(text)
+
+
+def _hint(output: str) -> str:
+    for pattern, hint in HINTS:
+        if pattern.search(output):
+            return hint
+    return "See the esptool output below. Save it and send it to the firmware team if the problem repeats."

kota_tech/matter/payload.py

@@ -0,0 +1,113 @@
+"""Matter onboarding payloads: the "MT:..." QR string and the 11-digit manual code.
+
+Implements the Matter spec (5.1.3 QR payload, 5.1.4 manual pairing code):
+bit fields packed LSB-first, Base38 in 3-byte chunks, Verhoeff check digit.
+
+The sensorbox firmware uses the Matter SDK example commissionable data
+(CONFIG_EXAMPLE_COMMISSIONABLE_DATA_PROVIDER): every v1.0 box advertises
+VID 0xFFF1 / PID 0x8000 / discriminator 3840 with passcode 20202021, which is
+exactly the sticker (QR "MT:Y.K9042C00KA0648G00", manual 3497-011-2332).
+VID/PID/discriminator are taken from the box's own log when available; the
+passcode is never logged, so the known default is used.
+"""
+
+from __future__ import annotations
+
+import re
+from dataclasses import dataclass
+
+BASE38 = "0123456789ABCDEFGHIJKLMNOPQRSTUVWXYZ-."
+RENDEZVOUS_BLE = 1 << 1
+DEFAULT_PASSCODE = 20202021          # Matter SDK test passcode used by the v1.0 firmware
+DEFAULT = dict(vendor_id=0xFFF1, product_id=0x8000, discriminator=3840)
+
+# chip[DIS]: Advertise commission parameter vendorID=65521 productID=32768 discriminator=3840/15 cm=1 cp=0
+_ADVERTISE = re.compile(r"vendorID=(\d+) productID=(\d+) discriminator=(\d+)")
+
+
+@dataclass(frozen=True)
+class SetupPayload:
+    vendor_id: int = DEFAULT["vendor_id"]
+    product_id: int = DEFAULT["product_id"]
+    discriminator: int = DEFAULT["discriminator"]
+    passcode: int = DEFAULT_PASSCODE
+    rendezvous: int = RENDEZVOUS_BLE
+    flow: int = 0                     # standard commissioning flow
+    version: int = 0
+    from_log: bool = False            # VID/PID/discriminator read from this box's log
+    qr: str | None = None             # exact payload reported by the box ("KOTA: matter qr=MT:...")
+    manual: str | None = None         # exact 11-digit manual code reported by the box
+
+    @property
+    def from_box(self) -> bool:
+        return self.qr is not None
+
+    def qr_text(self) -> str:
+        if self.qr:
+            return self.qr
+        fields = [(self.version, 3), (self.vendor_id, 16), (self.product_id, 16), (self.flow, 2),
+                  (self.rendezvous, 8), (self.discriminator, 12), (self.passcode, 27), (0, 4)]
+        value, shift = 0, 0
+        for v, bits in fields:
+            if not 0 <= v < (1 << bits):
+                raise ValueError(f"field value {v} does not fit in {bits} bits")
+            value |= v << shift
+            shift += bits
+        return "MT:" + _base38(value.to_bytes(shift // 8, "little"))
+
+    def manual_code(self) -> str:
+        if self.manual:
+            return self.manual
+        short = self.discriminator >> 8                       # upper 4 bits
+        chunk1 = short >> 2                                   # vid_pid_present = 0
+        chunk2 = ((short & 0x3) << 14) | (self.passcode & 0x3FFF)
+        chunk3 = self.passcode >> 14
+        digits = f"{chunk1}{chunk2:05d}{chunk3:04d}"
+        return digits + str(verhoeff_check(digits))
+
+    def manual_code_pretty(self) -> str:
+        c = self.manual_code()
+        return f"{c[:4]}-{c[4:7]}-{c[7:]}"
+
+
+def _base38(data: bytes) -> str:
+    out = []
+    for i in range(0, len(data), 3):
+        chunk = data[i:i + 3]
+        value = int.from_bytes(chunk, "little")
+        for _ in range({3: 5, 2: 4, 1: 2}[len(chunk)]):
+            value, rem = divmod(value, 38)
+            out.append(BASE38[rem])
+    return "".join(out)
+
+
+_D = [[0, 1, 2, 3, 4, 5, 6, 7, 8, 9], [1, 2, 3, 4, 0, 6, 7, 8, 9, 5], [2, 3, 4, 0, 1, 7, 8, 9, 5, 6],
+      [3, 4, 0, 1, 2, 8, 9, 5, 6, 7], [4, 0, 1, 2, 3, 9, 5, 6, 7, 8], [5, 9, 8, 7, 6, 0, 4, 3, 2, 1],
+      [6, 5, 9, 8, 7, 1, 0, 4, 3, 2], [7, 6, 5, 9, 8, 2, 1, 0, 4, 3], [8, 7, 6, 5, 9, 3, 2, 1, 0, 4],
+      [9, 8, 7, 6, 5, 4, 3, 2, 1, 0]]
+_P = [[0, 1, 2, 3, 4, 5, 6, 7, 8, 9], [1, 5, 7, 6, 2, 8, 3, 0, 9, 4], [5, 8, 0, 3, 7, 9, 6, 1, 4, 2],
+      [8, 9, 1, 6, 0, 4, 3, 5, 2, 7], [9, 4, 5, 3, 1, 2, 6, 8, 7, 0], [4, 2, 8, 6, 5, 7, 3, 9, 0, 1],
+      [2, 7, 9, 3, 8, 0, 6, 4, 1, 5], [7, 0, 4, 6, 9, 1, 3, 2, 5, 8]]
+_INV = [0, 4, 3, 2, 1, 5, 6, 7, 8, 9]
+
+
+def verhoeff_check(digits: str) -> int:
+    c = 0
+    for i, d in enumerate(reversed(digits)):
+        c = _D[c][_P[(i + 1) % 8][int(d)]]
+    return _INV[c]
+
+
+def payload_from_log(lines: list[str], qr: str | None = None, manual: str | None = None) -> SetupPayload:
+    """Firmware 1.0.16+ reports its exact QR payload and manual code
+    ("KOTA: matter ... qr=MT:... manual=..."); older firmware: use the
+    advertised VID/PID/discriminator if seen; defaults otherwise."""
+    base = SetupPayload()
+    for text in reversed(lines):
+        if m := _ADVERTISE.search(text):
+            base = SetupPayload(int(m.group(1)), int(m.group(2)), int(m.group(3)), from_log=True)
+            break
+    if qr:
+        return SetupPayload(base.vendor_id, base.product_id, base.discriminator, from_log=True,
+                            qr=qr, manual=manual if manual and manual.isdigit() else None)
+    return base

kota_tech/sd/disks.py

@@ -0,0 +1,128 @@
+"""Find SD cards (removable disks) on Windows and macOS.
+
+Safety first: only USB/SD/MMC-attached disks that are not the system or
+boot disk and not larger than MAX_CARD_BYTES are ever offered. Parsers are
+pure functions over the OS tool output so they can be tested without
+hardware.
+"""
+
+from __future__ import annotations
+
+import json
+import plistlib
+import subprocess
+import sys
+from dataclasses import dataclass, field
+
+MAX_CARD_BYTES = 256 * 1024**3         # larger "removable" disks are probably not SD cards
+CARD_BUSES = {"USB", "SD", "MMC"}
+
+
+@dataclass
+class Volume:
+    mount: str           # "E:\\" on Windows, "/Volumes/KOTA" on macOS ("" if not mounted)
+    filesystem: str      # "FAT32", "exFAT", "MS-DOS FAT32", ...
+    label: str
+
+
+@dataclass
+class Disk:
+    id: str              # Windows disk number / macOS "/dev/disk4"
+    name: str
+    size: int
+    bus: str
+    volumes: list[Volume] = field(default_factory=list)
+    has_media: bool = True
+
+    @property
+    def size_text(self) -> str:
+        return f"{self.size / 1e9:.1f} GB" if self.size else "no card"
+
+    @property
+    def label(self) -> str:
+        vols = ", ".join(f"{v.mount or '-'} {v.filesystem} '{v.label}'" for v in self.volumes) or "no volume"
+        return f"Disk {self.id}: {self.name} - {self.size_text} ({self.bus}) - {vols}"
+
+
+# ------------------------------------------------------------------ Windows
+
+WIN_LIST_PS = r"""
+$ErrorActionPreference = 'SilentlyContinue'
+# Filter by bus BEFORE touching partitions: querying volumes of every
+# internal disk made this take >30 s on a machine with several HDDs.
+$out = @(Get-Disk | Where-Object { -not $_.IsSystem -and -not $_.IsBoot -and
+                                   @('USB','SD','MMC') -contains [string]$_.BusType } | ForEach-Object {
+  $d = $_
+  $vols = @(Get-Partition -DiskNumber $d.Number | ForEach-Object {
+      $v = $_ | Get-Volume
+      [pscustomobject]@{ DriveLetter = [string]$_.DriveLetter; FileSystem = [string]$v.FileSystem; Label = [string]$v.FileSystemLabel }
+  })
+  [pscustomobject]@{ Number = $d.Number; FriendlyName = $d.FriendlyName; Size = [int64]$d.Size;
+                     BusType = [string]$d.BusType; Volumes = $vols }
+})
+ConvertTo-Json -InputObject $out -Depth 4 -Compress
+"""
+
+
+def parse_windows(json_text: str) -> list[Disk]:
+    data = json.loads(json_text or "[]")
+    if isinstance(data, dict):     # ConvertTo-Json quirk for one element
+        data = [data]
+    disks = []
+    for d in data:
+        if str(d.get("BusType")) not in CARD_BUSES:
+            continue
+        vols = d.get("Volumes") or []
+        if isinstance(vols, dict):
+            vols = [vols]
+        volumes = [Volume(f"{v['DriveLetter']}:\\" if v.get("DriveLetter") and v["DriveLetter"] not in ("\x00", "") else "",
+                          v.get("FileSystem") or "", v.get("Label") or "") for v in vols]
+        size = int(d.get("Size") or 0)
+        disks.append(Disk(str(d["Number"]), d.get("FriendlyName") or "Disk", size, str(d["BusType"]),
+                          [v for v in volumes if v.mount or v.filesystem], has_media=size > 0))
+    return disks
+
+
+# -------------------------------------------------------------------- macOS
+
+def parse_macos(list_plist: bytes, infos: dict[str, bytes]) -> list[Disk]:
+    """`diskutil list -plist physical` + `diskutil info -plist <disk>` for each."""
+    listing = plistlib.loads(list_plist)
+    disks = []
+    for entry in listing.get("AllDisksAndPartitions", []):
+        ident = entry.get("DeviceIdentifier", "")
+        info = plistlib.loads(infos[ident]) if ident in infos else {}
+        protocol = str(info.get("BusProtocol", ""))
+        removable = bool(info.get("RemovableMedia") or info.get("Removable") or info.get("Ejectable"))
+        internal = bool(info.get("Internal", True))
+        is_root = any(p.get("MountPoint") == "/" for p in entry.get("Partitions", []) + entry.get("APFSVolumes", []))
+        if ident == "disk0" or is_root or not (removable or not internal or protocol in ("USB", "Secure Digital", "SD")):
+            continue
+        vols = [Volume(p.get("MountPoint", ""), p.get("Content", ""), p.get("VolumeName", ""))
+                for p in entry.get("Partitions", [])]
+        size = int(entry.get("Size") or info.get("TotalSize") or 0)
+        bus = "SD" if "Secure Digital" in protocol or protocol == "SD" else (protocol or "USB")
+        disks.append(Disk(f"/dev/{ident}", info.get("MediaName", "Disk"), size, bus, vols, has_media=size > 0))
+    return disks
+
+
+# ------------------------------------------------------------------ public
+
+def list_cards() -> tuple[list[Disk], list[Disk]]:
+    """(cards that may be formatted, readers/disks shown but not offered)."""
+    if sys.platform == "win32":
+        # Driver-level listing (milliseconds, 1.5 s worst case) instead of
+        # Get-Disk/WMI, which stalled 5-21 s on an empty card-reader slot.
+        from .win_disks import list_disks
+        disks = list_disks(CARD_BUSES)
+    elif sys.platform == "darwin":
+        lst = subprocess.run(["diskutil", "list", "-plist", "physical"], capture_output=True, timeout=30).stdout
+        infos = {}
+        for e in plistlib.loads(lst).get("AllDisksAndPartitions", []):
+            ident = e.get("DeviceIdentifier", "")
+            infos[ident] = subprocess.run(["diskutil", "info", "-plist", ident], capture_output=True, timeout=30).stdout
+        disks = parse_macos(lst, infos)
+    else:
+        return [], []
+    ok = [d for d in disks if d.has_media and 0 < d.size <= MAX_CARD_BYTES]
+    return ok, [d for d in disks if d not in ok]

kota_tech/sd/envfile.py

@@ -0,0 +1,151 @@
+"""ENV.TXT for the sensorbox SD card.
+
+Parsing mirrors EnvironmentService::read_env_var in the firmware exactly:
+lines read with a 512-byte buffer, split at the FIRST '=', key compared
+verbatim (no trimming), CR/LF removed from the value only, first match wins.
+So the checks below report what would actually break a box - e.g. a UTF-8
+BOM (Windows Notepad) hides the first key, and "KEY = value" is not "KEY".
+
+The firmware FAT driver has no long-file-name support: the file must be
+the 8.3 name ENV.TXT (case-insensitive) in the card root.
+"""
+
+from __future__ import annotations
+
+import re
+from dataclasses import dataclass
+from pathlib import Path
+
+ENV_NAME = "ENV.TXT"
+BUFFER_NAME = "BUFFER.TXT"          # offline measurements waiting for upload
+LINE_BUF = 512                      # char line[512] in the firmware
+REQUIRED = ("INFLUX_URL", "INFLUX_TOKEN")
+OPTIONAL = ("SSID", "PASSWORD")
+_BOM = b"\xef\xbb\xbf"
+
+
+@dataclass
+class Issue:
+    level: str          # "error" | "warning" | "info"
+    text: str
+
+
+@dataclass
+class EnvConfig:
+    influx_url: str = ""
+    influx_token: str = ""
+    ssid: str = ""
+    password: str = ""
+
+    @property
+    def local_wifi(self) -> bool:
+        return bool(self.ssid or self.password)
+
+    def lines(self) -> list[tuple[str, str]]:
+        out = [("INFLUX_TOKEN", self.influx_token), ("INFLUX_URL", self.influx_url)]
+        if self.local_wifi:
+            out += [("SSID", self.ssid), ("PASSWORD", self.password)]
+        return out
+
+    def render(self) -> bytes:
+        # LF only, no BOM, no quoting: exactly what the firmware parser expects.
+        return "".join(f"{k}={v}\n" for k, v in self.lines()).encode("utf-8")
+
+    def problems(self) -> list[Issue]:
+        issues: list[Issue] = []
+        for key, value in self.lines():
+            if any(c in value for c in "\r\n"):
+                issues.append(Issue("error", f"{key} contains a line break."))
+            if value != value.strip():
+                issues.append(Issue("error", f"{key} starts or ends with a space; the box would use the space too."))
+            if len(f"{key}={value}".encode()) >= LINE_BUF - 1:
+                issues.append(Issue("error", f"{key} is too long for the box (max {LINE_BUF - 2} bytes per line)."))
+        url = self.influx_url.strip()
+        if not url:
+            issues.append(Issue("error", "INFLUX_URL is empty."))
+        elif not re.match(r"^https?://", url):
+            issues.append(Issue("error", "INFLUX_URL must start with https://"))
+        elif not ("/api/v2/write" in url and "bucket=" in url and "org=" in url):
+            issues.append(Issue("error", "INFLUX_URL must be a write URL: .../api/v2/write?bucket=...&org=..."))
+        elif url.startswith("http://"):
+            issues.append(Issue("warning", "INFLUX_URL uses http:// (unencrypted)."))
+        if not self.influx_token:
+            issues.append(Issue("error", "INFLUX_TOKEN is empty."))
+        elif re.search(r"\s", self.influx_token):
+            issues.append(Issue("error", "INFLUX_TOKEN contains spaces."))
+        elif len(self.influx_token) < 20:
+            issues.append(Issue("warning", "INFLUX_TOKEN looks too short."))
+        if self.local_wifi:
+            if not self.ssid or not self.password:
+                issues.append(Issue("error", "Wi-Fi needs both SSID and PASSWORD (the box ignores one without the other)."))
+            if len(self.ssid.encode()) > 32:
+                issues.append(Issue("error", "SSID is longer than 32 bytes."))
+            pw = self.password
+            if pw and not (8 <= len(pw) <= 63 or re.fullmatch(r"[0-9A-Fa-f]{64}", pw)):
+                issues.append(Issue("error", "Wi-Fi PASSWORD must be 8-63 characters (WPA2)."))
+        return issues
+
+
+@dataclass
+class EnvCheck:
+    values: dict[str, str]
+    issues: list[Issue]
+
+    @property
+    def ok(self) -> bool:
+        return not any(i.level == "error" for i in self.issues)
+
+    def masked(self) -> dict[str, str]:
+        out = {}
+        for k, v in self.values.items():
+            out[k] = (v[:4] + "..." + v[-4:] if len(v) > 12 else "***") if k in ("INFLUX_TOKEN", "PASSWORD") else v
+        return out
+
+
+def parse_env(raw: bytes) -> EnvCheck:
+    """Read ENV.TXT the way the firmware does and report what it would see."""
+    issues: list[Issue] = []
+    if raw.startswith(_BOM):
+        issues.append(Issue("error", "File starts with a UTF-8 BOM (saved by Notepad?): the box cannot read the first key. "
+                                     "Re-write the card with the tool."))
+    text = raw.decode("utf-8", errors="replace")
+    values: dict[str, str] = {}
+    for n, line in enumerate(text.split("\n"), 1):
+        if len(line.encode()) >= LINE_BUF - 1:
+            issues.append(Issue("error", f"Line {n} is longer than the box can read."))
+        if "=" not in line:
+            continue
+        key, value = line.split("=", 1)
+        value = value.replace("\r", "")
+        if key != key.strip():
+            issues.append(Issue("error", f"Line {n}: spaces around the key '{key.strip()}' - the box will not find it."))
+        if key in values:
+            issues.append(Issue("warning", f"{key} appears twice; the box uses the first one."))
+            continue
+        values[key] = value
+    for key in REQUIRED:
+        if key not in values:
+            issues.append(Issue("error", f"{key} is missing - the box stops at start-up (white LED)."))
+        elif not values[key]:
+            issues.append(Issue("error", f"{key} is empty."))
+    if values.get("HTTP_SERVER") == "true":
+        issues.append(Issue("warning", "HTTP_SERVER=true: a box with newer firmware starts in Wi-Fi setup mode."))
+    if bool(values.get("SSID")) != bool(values.get("PASSWORD")):
+        issues.append(Issue("warning", "Only one of SSID / PASSWORD is set; the box ignores Wi-Fi settings."))
+    elif values.get("SSID"):
+        issues.append(Issue("info", "Wi-Fi settings present: newer firmware uses this Wi-Fi instead of Matter "
+                                    "(the factory v1.0 firmware ignores them)."))
+    return EnvCheck(values, issues)
+
+
+def load_template(path: Path) -> EnvConfig:
+    """Settings from an existing ENV.TXT (e.g. 002-SD_card_format/ENV.txt)."""
+    v = parse_env(path.read_bytes()).values
+    return EnvConfig(v.get("INFLUX_URL", ""), v.get("INFLUX_TOKEN", ""), v.get("SSID", ""), v.get("PASSWORD", ""))
+
+
+def find_case_insensitive(root: Path, name: str) -> Path | None:
+    for p in root.iterdir() if root.is_dir() else ():
+        if p.is_file() and p.name.lower() == name.lower():
+            return p
+    return None

kota_tech/sd/fat32.py

@@ -0,0 +1,135 @@
+"""FAT32 + MBR layout for an SD card, as raw byte writes (no OS formatter).
+
+Follows the Microsoft FAT specification (fatgen103): BPB at sector 0,
+FSInfo at 1, backup boot sector at 6, two FATs, root directory in cluster 2
+holding the volume label. Cluster sizes follow Windows' defaults. The
+partition starts at 1 MiB (SD erase-block friendly), MBR type 0x0C
+(FAT32 LBA), which is what the firmware's FatFs expects.
+
+Pure functions: the result is a list of (offset, bytes) writes plus zero
+ranges relative to the start of the DISK, so it can be tested on a buffer.
+"""
+
+from __future__ import annotations
+
+import math
+import struct
+from dataclasses import dataclass
+
+PART_START = 1024 * 1024
+FAT32_MAX_BYTES = 32 * 1024**3        # Windows convention, and all the box needs
+MIN_CLUSTERS, MAX_CLUSTERS = 65525, 0x0FFFFFF5
+RESERVED = 32
+NUM_FATS = 2
+MEDIA = 0xF8
+
+
+@dataclass(frozen=True)
+class Fat32Layout:
+    bytes_per_sector: int
+    part_start: int            # bytes from disk start
+    part_sectors: int
+    sectors_per_cluster: int
+    fat_sectors: int
+    clusters: int
+
+    @property
+    def data_start(self) -> int:      # sectors from partition start
+        return RESERVED + NUM_FATS * self.fat_sectors
+
+
+def _spc(sectors: int, bps: int) -> int:
+    size = sectors * bps
+    for limit, cluster in ((260 * 1024**2, 512), (8 * 1024**3, 4096), (16 * 1024**3, 8192),
+                           (32 * 1024**3, 16384)):
+        if size <= limit:
+            return max(1, cluster // bps)
+    return max(1, 32768 // bps)
+
+
+def plan(disk_bytes: int, bps: int = 512) -> Fat32Layout:
+    part_bytes = min(disk_bytes - PART_START, FAT32_MAX_BYTES)
+    part_bytes -= part_bytes % (1024 * 1024)                # whole MiB
+    sectors = part_bytes // bps
+    if sectors <= 0:
+        raise ValueError("card is too small")
+    spc = _spc(sectors, bps)
+    fat = 1
+    for _ in range(20):                                     # converge FAT size <-> cluster count
+        clusters = (sectors - RESERVED - NUM_FATS * fat) // spc
+        need = math.ceil((clusters + 2) * 4 / bps)
+        if need == fat:
+            break
+        fat = need
+    clusters = (sectors - RESERVED - NUM_FATS * fat) // spc
+    if not MIN_CLUSTERS <= clusters < MAX_CLUSTERS:
+        raise ValueError(f"card size gives {clusters} clusters - not valid for FAT32")
+    return Fat32Layout(bps, PART_START, sectors, spc, fat, clusters)
+
+
+def _boot_sector(lay: Fat32Layout, label: bytes, vol_id: int) -> bytes:
+    bps = lay.bytes_per_sector
+    b = bytearray(bps)
+    b[0:3] = b"\xEB\x58\x90"
+    b[3:11] = b"MSWIN4.1"
+    struct.pack_into("<HBHBHHBHHHII", b, 11, bps, lay.sectors_per_cluster, RESERVED, NUM_FATS, 0, 0,
+                     MEDIA, 0, 63, 255, lay.part_start // bps, lay.part_sectors)
+    struct.pack_into("<IHHIHH", b, 36, lay.fat_sectors, 0, 0, 2, 1, 6)
+    struct.pack_into("<BBBI", b, 64, 0x80, 0, 0x29, vol_id)
+    b[71:82] = label
+    b[82:90] = b"FAT32   "
+    b[90:93] = b"\xF4\xEB\xFD"                              # not bootable: hlt loop
+    b[510:512] = b"\x55\xAA"
+    return bytes(b)
+
+
+def _fsinfo(lay: Fat32Layout) -> bytes:
+    b = bytearray(lay.bytes_per_sector)
+    struct.pack_into("<I", b, 0, 0x41615252)
+    struct.pack_into("<III", b, 484, 0x61417272, lay.clusters - 1, 3)   # root uses cluster 2
+    struct.pack_into("<I", b, 508, 0xAA550000)
+    return bytes(b)
+
+
+def mbr(lay: Fat32Layout, signature: int) -> bytes:
+    b = bytearray(512)
+    struct.pack_into("<I", b, 0x1B8, signature)
+    entry = struct.pack("<B3sB3sII", 0x00, b"\xFE\xFF\xFF", 0x0C, b"\xFE\xFF\xFF",
+                        lay.part_start // lay.bytes_per_sector, lay.part_sectors)
+    b[0x1BE:0x1BE + 16] = entry
+    b[510:512] = b"\x55\xAA"
+    return bytes(b[:512]) + bytes(lay.bytes_per_sector - 512)
+
+
+def volume_label(text: str) -> bytes:
+    label = text.upper().encode("ascii", "replace")[:11]
+    return label.ljust(11, b" ")
+
+
+def build(lay: Fat32Layout, label: str, vol_id: int, disk_signature: int,
+          disk_bytes: int) -> tuple[list[tuple[int, int]], list[tuple[int, bytes]]]:
+    """(zero ranges, writes) in disk byte offsets; apply zero ranges first."""
+    bps, p = lay.bytes_per_sector, lay.part_start
+    lab = volume_label(label)
+    fat_bytes = lay.fat_sectors * bps
+    fat1 = p + RESERVED * bps
+    fat2 = fat1 + fat_bytes
+    root = p + lay.data_start * bps
+    cluster = lay.sectors_per_cluster * bps
+    zeros = [
+        (0, PART_START),                                   # old MBR / GPT header and gap
+        (disk_bytes - PART_START, PART_START),             # backup GPT at the end of the disk
+        (p, RESERVED * bps),                               # reserved region
+        (fat1, NUM_FATS * fat_bytes),                      # both FATs
+        (root, cluster),                                   # root directory cluster
+    ]
+    boot, info = _boot_sector(lay, lab, vol_id), _fsinfo(lay)
+    first_fat = struct.pack("<III", 0x0FFFFF00 | MEDIA, 0x0FFFFFFF, 0x0FFFFFFF)
+    label_entry = lab + bytes([0x08]) + bytes(20)          # 32-byte volume-label directory entry
+    writes = [
+        (p, boot), (p + bps, info), (p + 6 * bps, boot), (p + 7 * bps, info),
+        (fat1, first_fat), (fat2, first_fat),
+        (root, label_entry),
+        (0, mbr(lay, disk_signature)),                     # last: the partition appears only now
+    ]
+    return zeros, writes

kota_tech/sd/provision.py

@@ -0,0 +1,261 @@
+"""Format an SD card for the sensorbox and write / check ENV.TXT.
+
+Card format required by the firmware: MBR partition table, FAT32 (its FAT
+driver has no exFAT and no long file names), ENV.TXT in the root.
+
+Windows: formatting needs administrator rights, so kota_tech.sd.win_format
+runs elevated (UAC prompt). It re-checks the disk (number, size, bus, not the
+Windows drive) right before erasing it, so a card swapped after the
+technician confirmed is not touched, and it writes MBR + FAT32 itself
+(no Storage cmdlets, which stalled on empty card-reader slots). Larger cards
+get a 32 GB FAT32 partition (Windows convention; plenty for the box).
+macOS: `diskutil eraseDisk FAT32 KOTA MBRFormat` (same as format_sd.sh).
+"""
+
+from __future__ import annotations
+
+import json
+import os
+import plistlib
+import subprocess
+import sys
+import time
+import uuid
+from dataclasses import dataclass, field
+from pathlib import Path
+
+from .disks import Disk
+from .envfile import BUFFER_NAME, ENV_NAME, EnvCheck, EnvConfig, find_case_insensitive, parse_env
+
+VOLUME_LABEL = "KOTA"
+
+
+@dataclass
+class Outcome:
+    ok: bool
+    message: str
+    mount: str = ""
+    log: list[str] = field(default_factory=list)
+
+
+@dataclass
+class CardReport:
+    mount: str
+    filesystem: str
+    env: EnvCheck | None
+    buffered_lines: int | None      # measurements waiting on the card for upload
+    problems: list[str]
+
+
+# ----------------------------------------------------------------- Windows
+
+WORK_ROOT = Path.home() / "KotaTechnicianTool" / "tmp"
+
+
+def _workdir() -> Path:
+    # Not tempfile.mkdtemp(): on Windows it creates an owner-only folder, and a
+    # file written there by the ELEVATED script is then unreadable for this
+    # (non-elevated) process. A normally inherited ACL works for both.
+    work = WORK_ROOT / f"sd_{uuid.uuid4().hex[:10]}"
+    work.mkdir(parents=True, exist_ok=False)
+    return work
+
+
+def win_format_command(disk: Disk, result: Path) -> tuple[str, str, str]:
+    """(program, parameters, working dir) for the elevated helper."""
+    root = Path(__file__).resolve().parents[2]            # the version folder holding kota_tech/
+    params = f'-m kota_tech.sd.win_format --disk {int(disk.id)} --size {int(disk.size)} ' \
+             f'--label {VOLUME_LABEL} --result "{result}"'
+    return sys.executable, params, str(root)
+
+
+def _run_elevated(program: str, params: str, cwd: str, timeout_s: int = 300) -> int | None:
+    """ShellExecuteEx 'runas' + wait. None if the technician refused the UAC prompt."""
+    import ctypes
+    from ctypes import wintypes
+
+    class SHELLEXECUTEINFOW(ctypes.Structure):
+        _fields_ = [("cbSize", wintypes.DWORD), ("fMask", ctypes.c_ulong), ("hwnd", wintypes.HWND),
+                    ("lpVerb", wintypes.LPCWSTR), ("lpFile", wintypes.LPCWSTR), ("lpParameters", wintypes.LPCWSTR),
+                    ("lpDirectory", wintypes.LPCWSTR), ("nShow", ctypes.c_int), ("hInstApp", wintypes.HINSTANCE),
+                    ("lpIDList", ctypes.c_void_p), ("lpClass", wintypes.LPCWSTR), ("hkeyClass", wintypes.HKEY),
+                    ("dwHotKey", wintypes.DWORD), ("hIconOrMonitor", wintypes.HANDLE), ("hProcess", wintypes.HANDLE)]
+
+    SEE_MASK_NOCLOSEPROCESS, SW_HIDE = 0x40, 0
+    info = SHELLEXECUTEINFOW(cbSize=ctypes.sizeof(SHELLEXECUTEINFOW), fMask=SEE_MASK_NOCLOSEPROCESS,
+                             lpVerb="runas", lpFile=program, lpParameters=params, lpDirectory=cwd, nShow=SW_HIDE)
+    shell32 = ctypes.WinDLL("shell32", use_last_error=True)
+    k32 = ctypes.WinDLL("kernel32", use_last_error=True)
+    if not shell32.ShellExecuteExW(ctypes.byref(info)):
+        return None                                            # ERROR_CANCELLED (1223) or failure
+    k32.WaitForSingleObject(info.hProcess, timeout_s * 1000)
+    code = wintypes.DWORD()
+    k32.GetExitCodeProcess(info.hProcess, ctypes.byref(code))
+    k32.CloseHandle(info.hProcess)
+    return code.value
+
+
+def _format_windows(disk: Disk, log: list[str]) -> Outcome:
+    result = _workdir() / "result.json"
+    log.append("Asking Windows for administrator rights to format the card (UAC prompt)...")
+    t = time.perf_counter()
+    code = _run_elevated(*win_format_command(disk, result))
+    if code is None:
+        return Outcome(False, "Administrator permission was refused - the card was not formatted.", log=log)
+    try:
+        res = json.loads(result.read_text(encoding="utf-8"))
+    except (OSError, ValueError) as exc:
+        return Outcome(False, f"The formatter did not report back ({exc.__class__.__name__}, exit {code}). "
+                              "Check the card with 'Check card'.", log=log)
+    steps = ", ".join(f"{k} {v:.1f} s" for k, v in res.get("timings", {}).items())
+    log.append(f"{res.get('message', '')} ({time.perf_counter() - t:.1f} s incl. permission prompt; {steps})")
+    return Outcome(bool(res.get("ok")), res.get("message", ""), res.get("drive", ""), log)
+
+
+def _eject_windows(mount: str) -> bool:
+    """Flush, lock, dismount and eject the card - what 'Safely Remove' does.
+
+    Not Shell.Application InvokeVerb('Eject'): it fails silently because the
+    verb is named 'E&ject' (and is localised on non-English Windows).
+    """
+    import ctypes
+    from ctypes import wintypes
+
+    k32 = ctypes.WinDLL("kernel32", use_last_error=True)
+    k32.CreateFileW.restype = wintypes.HANDLE
+    k32.CreateFileW.argtypes = [wintypes.LPCWSTR, wintypes.DWORD, wintypes.DWORD, wintypes.LPVOID,
+                                wintypes.DWORD, wintypes.DWORD, wintypes.HANDLE]
+    k32.DeviceIoControl.argtypes = [wintypes.HANDLE, wintypes.DWORD, wintypes.LPVOID, wintypes.DWORD,
+                                    wintypes.LPVOID, wintypes.DWORD, ctypes.POINTER(wintypes.DWORD), wintypes.LPVOID]
+    GENERIC_RW, SHARE_RW, OPEN_EXISTING = 0xC0000000, 0x3, 3
+    FSCTL_LOCK_VOLUME, FSCTL_DISMOUNT_VOLUME = 0x00090018, 0x00090020
+    IOCTL_STORAGE_MEDIA_REMOVAL, IOCTL_STORAGE_EJECT_MEDIA = 0x002D4804, 0x002D4808
+    handle = k32.CreateFileW(f"\\\\.\\{mount[0]}:", GENERIC_RW, SHARE_RW, None, OPEN_EXISTING, 0, None)
+    if handle in (None, wintypes.HANDLE(-1).value):
+        return False
+    ret = wintypes.DWORD()
+
+    def ioctl(code: int, buf=None, size: int = 0) -> bool:
+        return bool(k32.DeviceIoControl(handle, code, buf, size, None, 0, ctypes.byref(ret), None))
+
+    try:
+        k32.FlushFileBuffers(handle)
+        for _ in range(10):                       # Explorer/indexer may hold it briefly
+            if ioctl(FSCTL_LOCK_VOLUME):
+                break
+            time.sleep(0.5)
+        else:
+            return False
+        if not ioctl(FSCTL_DISMOUNT_VOLUME):
+            return False
+        allow = ctypes.c_bool(False)              # PREVENT_MEDIA_REMOVAL{FALSE}
+        ioctl(IOCTL_STORAGE_MEDIA_REMOVAL, ctypes.byref(allow), 1)
+        ioctl(IOCTL_STORAGE_EJECT_MEDIA)          # card readers may not support it; dismount suffices
+        return True
+    finally:
+        k32.CloseHandle(handle)
+
+
+# ------------------------------------------------------------------- macOS
+
+def _format_macos(disk: Disk, log: list[str]) -> Outcome:
+    log.append(f"diskutil eraseDisk FAT32 {VOLUME_LABEL} MBRFormat {disk.id}")
+    proc = subprocess.run(["diskutil", "eraseDisk", "FAT32", VOLUME_LABEL, "MBRFormat", disk.id],
+                          capture_output=True, text=True, timeout=600)
+    log += [l for l in proc.stdout.splitlines() if l.strip()]
+    if proc.returncode != 0:
+        return Outcome(False, "Formatting failed: " + (proc.stderr.strip() or proc.stdout.strip()[-200:])
+                       + " (is the card's write-protect switch on?)", log=log)
+    part = f"{disk.id}s1"
+    for _ in range(20):   # wait for the volume to mount
+        info = plistlib.loads(subprocess.run(["diskutil", "info", "-plist", part], capture_output=True).stdout or b"<plist><dict/></plist>")
+        if info.get("MountPoint"):
+            return Outcome(True, "Formatted FAT32 (MBR).", info["MountPoint"], log)
+        time.sleep(0.5)
+    return Outcome(False, "Formatted, but the card did not mount.", log=log)
+
+
+def _eject_macos(disk_id: str) -> bool:
+    return subprocess.run(["diskutil", "eject", disk_id], capture_output=True, timeout=60).returncode == 0
+
+
+# ------------------------------------------------------------------ common
+
+def write_env(mount: str, env: EnvConfig) -> Outcome:
+    """Write ENV.TXT (8.3 name, LF, no BOM), keep other files (buffered data), read back."""
+    problems = [i.text for i in env.problems() if i.level == "error"]
+    if problems:
+        return Outcome(False, "Settings are not valid: " + " ".join(problems))
+    root = Path(mount)
+    if not root.is_dir():
+        return Outcome(False, f"Card not found at {mount}.")
+    old = find_case_insensitive(root, ENV_NAME)
+    if old is not None and old.name != ENV_NAME:
+        old.unlink()                                   # replace env.txt / Env.txt variants
+    target = root / ENV_NAME
+    data = env.render()
+    with open(target, "wb") as fh:
+        fh.write(data)
+        fh.flush()
+        os.fsync(fh.fileno())
+    if target.read_bytes() != data:
+        return Outcome(False, "ENV.TXT read-back does not match - the card may be faulty.")
+    check = parse_env(target.read_bytes())
+    if not check.ok:
+        return Outcome(False, "ENV.TXT was written but does not validate: "
+                       + " ".join(i.text for i in check.issues if i.level == "error"))
+    return Outcome(True, f"ENV.TXT written and verified on {mount}.", mount)
+
+
+def format_and_write(disk: Disk, env: EnvConfig, eject_card: bool = True) -> Outcome:
+    problems = [i.text for i in env.problems() if i.level == "error"]
+    if problems:
+        return Outcome(False, "Settings are not valid: " + " ".join(problems))
+    log: list[str] = []
+    if sys.platform == "win32":
+        fmt = _format_windows(disk, log)
+    elif sys.platform == "darwin":
+        fmt = _format_macos(disk, log)
+    else:
+        return Outcome(False, "SD provisioning is supported on Windows and macOS only.")
+    if not fmt.ok:
+        return fmt
+    wr = write_env(fmt.mount, env)
+    log.append(wr.message)
+    if not wr.ok:
+        return Outcome(False, wr.message, fmt.mount, log)
+    if eject_card:
+        log.append("Card ejected - you can remove it." if eject(fmt.mount, disk) else
+                   "Could not eject the card automatically - use 'Safely remove' before pulling it out.")
+    return Outcome(True, "Card ready: formatted FAT32 and ENV.TXT verified.", fmt.mount, log)
+
+
+def eject(mount: str, disk: Disk | None = None) -> bool:
+    """True if the card was dismounted and can be pulled out safely."""
+    if sys.platform == "win32":
+        return _eject_windows(mount)
+    if sys.platform == "darwin" and disk is not None:
+        return _eject_macos(disk.id)
+    return False
+
+
+def check_card(mount: str, filesystem: str = "") -> CardReport:
+    """What the box would find on this card (values masked in the UI)."""
+    root = Path(mount)
+    problems: list[str] = []
+    # Windows says "FAT32"; macOS diskutil says "DOS_FAT_32" / "Windows_FAT_32" / "MS-DOS FAT32".
+    fs = filesystem.upper().replace("_", "").replace(" ", "")
+    if fs and "FAT32" not in fs and fs not in ("FAT", "MSDOS"):
+        problems.append(f"File system is {filesystem}; the box needs FAT32 - re-format the card.")
+    env_file = find_case_insensitive(root, ENV_NAME)
+    env = parse_env(env_file.read_bytes()) if env_file else None
+    if env_file is None:
+        problems.append("No ENV.TXT on the card - the box stops at start-up (white LED).")
+    elif len(env_file.name.split(".")[0]) > 8:
+        problems.append("ENV.TXT has a long name variant; use exactly ENV.TXT.")
+    buf = find_case_insensitive(root, BUFFER_NAME)
+    lines = None
+    if buf is not None:
+        with open(buf, "rb") as fh:
+            lines = sum(1 for ln in fh if ln.strip())
+    return CardReport(mount, filesystem, env, lines, problems)

kota_tech/sd/win_disks.py

@@ -0,0 +1,161 @@
+"""Fast Windows card discovery straight from the storage drivers (ctypes).
+
+Why not Get-Disk / WMI: every fresh PowerShell/WMI query enumerates ALL
+disks, which wakes sleeping hard drives - measured 1.6 to 21 s per listing
+on a PC with two SATA HDDs, freezing the UI each time. Here each physical
+drive is opened with access 0 (no admin needed, no I/O to the medium) and
+only its cached device descriptor is read; size and volumes are queried only
+for USB/SD/MMC disks. A full listing takes milliseconds.
+"""
+
+from __future__ import annotations
+
+import concurrent.futures
+import ctypes
+import string
+from ctypes import wintypes
+
+from .disks import Disk, Volume
+
+IOCTL_STORAGE_QUERY_PROPERTY = 0x002D1400
+IOCTL_STORAGE_GET_DEVICE_NUMBER = 0x002D1080
+IOCTL_DISK_GET_DRIVE_GEOMETRY_EX = 0x000700A0
+BUS_TYPES = {1: "SCSI", 2: "ATAPI", 3: "ATA", 4: "1394", 7: "USB", 8: "RAID", 10: "SAS", 11: "SATA",
+             12: "SD", 13: "MMC", 14: "Virtual", 15: "FileBackedVirtual", 17: "NVMe", 18: "SCM", 19: "UFS"}
+SHARE_RW, OPEN_EXISTING = 0x3, 3
+DRIVE_REMOVABLE, DRIVE_FIXED = 2, 3
+MAX_DRIVES = 32
+
+_k32 = ctypes.WinDLL("kernel32", use_last_error=True)
+_k32.CreateFileW.restype = wintypes.HANDLE
+_k32.CreateFileW.argtypes = [wintypes.LPCWSTR, wintypes.DWORD, wintypes.DWORD, wintypes.LPVOID,
+                             wintypes.DWORD, wintypes.DWORD, wintypes.HANDLE]
+_k32.DeviceIoControl.argtypes = [wintypes.HANDLE, wintypes.DWORD, wintypes.LPVOID, wintypes.DWORD,
+                                 wintypes.LPVOID, wintypes.DWORD, ctypes.POINTER(wintypes.DWORD), wintypes.LPVOID]
+_k32.GetDriveTypeW.argtypes = [wintypes.LPCWSTR]
+_k32.GetVolumeInformationW.argtypes = [wintypes.LPCWSTR, wintypes.LPWSTR, wintypes.DWORD,
+                                       ctypes.POINTER(wintypes.DWORD), ctypes.POINTER(wintypes.DWORD),
+                                       ctypes.POINTER(wintypes.DWORD), wintypes.LPWSTR, wintypes.DWORD]
+_INVALID = wintypes.HANDLE(-1).value
+
+
+class _Query(ctypes.Structure):          # STORAGE_PROPERTY_QUERY (StorageDeviceProperty, standard)
+    _fields_ = [("PropertyId", wintypes.DWORD), ("QueryType", wintypes.DWORD), ("Extra", ctypes.c_ubyte * 4)]
+
+
+class _DevNumber(ctypes.Structure):      # STORAGE_DEVICE_NUMBER
+    _fields_ = [("DeviceType", wintypes.DWORD), ("DeviceNumber", wintypes.DWORD),
+                ("PartitionNumber", wintypes.DWORD)]
+
+
+def _open(path: str):
+    h = _k32.CreateFileW(path, 0, SHARE_RW, None, OPEN_EXISTING, 0, None)
+    return None if h in (None, _INVALID) else h
+
+
+def _ioctl(h, code: int, inbuf=None, insize: int = 0, outsize: int = 1024) -> bytes | None:
+    out = ctypes.create_string_buffer(outsize)
+    got = wintypes.DWORD()
+    ok = _k32.DeviceIoControl(h, code, inbuf, insize, out, outsize, ctypes.byref(got), None)
+    return out.raw[:got.value] if ok else None
+
+
+def _descriptor(h) -> tuple[str, str] | None:
+    """(bus, "vendor product") from STORAGE_DEVICE_DESCRIPTOR - served from the driver's cache."""
+    q = _Query(0, 0)
+    raw = _ioctl(h, IOCTL_STORAGE_QUERY_PROPERTY, ctypes.byref(q), ctypes.sizeof(q))
+    if not raw or len(raw) < 32:
+        return None
+    vendor_off, product_off = int.from_bytes(raw[12:16], "little"), int.from_bytes(raw[16:20], "little")
+    bus = int.from_bytes(raw[28:32], "little")
+
+    def text(off: int) -> str:
+        if not off or off >= len(raw):
+            return ""
+        return raw[off:].split(b"\0", 1)[0].decode("ascii", "replace").strip()
+
+    return BUS_TYPES.get(bus, f"bus{bus}"), " ".join(t for t in (text(vendor_off), text(product_off)) if t) or "Disk"
+
+
+def _size(h) -> int:
+    raw = _ioctl(h, IOCTL_DISK_GET_DRIVE_GEOMETRY_EX, outsize=256)   # fails when no card is inserted
+    return int.from_bytes(raw[24:32], "little") if raw and len(raw) >= 32 else 0
+
+
+def _volumes_by_disk() -> dict[int, list[Volume]]:
+    found: dict[int, list[Volume]] = {}
+    mask = _k32.GetLogicalDrives()
+    for i, letter in enumerate(string.ascii_uppercase):
+        if not mask & (1 << i) or _k32.GetDriveTypeW(f"{letter}:\\") not in (DRIVE_REMOVABLE, DRIVE_FIXED):
+            continue
+        h = _open(f"\\\\.\\{letter}:")
+        if h is None:
+            continue
+        try:
+            raw = _ioctl(h, IOCTL_STORAGE_GET_DEVICE_NUMBER, outsize=ctypes.sizeof(_DevNumber))
+        finally:
+            _k32.CloseHandle(h)
+        if raw and len(raw) >= 8:
+            num = int.from_bytes(raw[4:8], "little")
+            found.setdefault(num, []).append(Volume(f"{letter}:\\", "", ""))
+    return found
+
+
+def _fill_volume_info(v: Volume) -> None:
+    name, fs = ctypes.create_unicode_buffer(64), ctypes.create_unicode_buffer(32)
+    serial, maxlen, flags = wintypes.DWORD(), wintypes.DWORD(), wintypes.DWORD()
+    if _k32.GetVolumeInformationW(v.mount, name, 64, ctypes.byref(serial), ctypes.byref(maxlen),
+                                  ctypes.byref(flags), fs, 32):
+        v.filesystem, v.label = fs.value, name.value
+
+
+MEDIA_TIMEOUT_S = 1.5
+# Slot queries still running from an earlier listing (an empty card-reader
+# slot can block ~13 s on its first media query). Never start a second one.
+_pending: dict[int, concurrent.futures.Future] = {}
+_pool = concurrent.futures.ThreadPoolExecutor(max_workers=8, thread_name_prefix="sd-media")
+
+
+def _media_size(n: int) -> int:
+    h = _open(f"\\\\.\\PhysicalDrive{n}")
+    if h is None:
+        return 0
+    try:
+        return _size(h)
+    finally:
+        _k32.CloseHandle(h)
+
+
+def list_disks(buses: set[str]) -> list[Disk]:
+    """Disks on the given buses (e.g. {"USB", "SD", "MMC"}), with size and volumes.
+
+    Media queries run in parallel with a short timeout: a slot that does not
+    answer in time is reported as "no card" instead of freezing the caller.
+    """
+    candidates: list[tuple[int, tuple[str, str]]] = []
+    for n in range(MAX_DRIVES):
+        h = _open(f"\\\\.\\PhysicalDrive{n}")
+        if h is None:
+            continue
+        try:
+            desc = _descriptor(h)
+        finally:
+            _k32.CloseHandle(h)
+        if desc is not None and desc[0] in buses:   # internal disks: only the cached descriptor is read
+            candidates.append((n, desc))
+    for n, _ in candidates:
+        if n not in _pending or _pending[n].done():
+            _pending[n] = _pool.submit(_media_size, n)
+    concurrent.futures.wait([_pending[n] for n, _ in candidates], timeout=MEDIA_TIMEOUT_S)
+    volumes: dict[int, list[Volume]] | None = None
+    disks = []
+    for n, (bus, name) in candidates:
+        fut = _pending[n]
+        size = fut.result() if fut.done() and fut.exception() is None else 0
+        if size and volumes is None:
+            volumes = _volumes_by_disk()
+        vols = (volumes or {}).get(n, []) if size else []
+        for v in vols:
+            _fill_volume_info(v)
+        disks.append(Disk(str(n), name, size, bus, vols, has_media=size > 0))
+    return disks

kota_tech/sd/win_format.py

@@ -0,0 +1,192 @@
+"""Elevated Windows SD-card formatter (runs as: python -m kota_tech.sd.win_format ...).
+
+Replaces Clear-Disk / New-Partition / Format-Volume: every Storage cmdlet
+goes through the storage provider, which stalls ~13 s on an empty card
+reader slot, several times per format. This helper touches only the chosen
+disk through its own driver:
+
+  1. guard: bus is USB/SD/MMC, size is exactly the one the technician
+     confirmed, and the disk does not hold the Windows drive;
+  2. lock + dismount the card's volumes;
+  3. raw writes: zero old MBR/GPT, FAT32 structures (kota_tech.sd.fat32),
+     then the new MBR last;
+  4. unlock, let Windows re-read the disk, wait for the FAT32 'KOTA' volume;
+  5. read-only `chkdsk` of the new volume.
+
+The result (with per-step timings) goes to a JSON file for the non-elevated
+tool, which then writes ENV.TXT through the normal file API.
+"""
+
+from __future__ import annotations
+
+import argparse
+import ctypes
+import json
+import os
+import random
+import subprocess
+import sys
+import time
+from ctypes import wintypes
+
+from . import fat32, win_disks
+
+GENERIC_RW, SHARE_RW, OPEN_EXISTING = 0xC0000000, 0x3, 3
+FSCTL_LOCK_VOLUME, FSCTL_UNLOCK_VOLUME, FSCTL_DISMOUNT_VOLUME = 0x00090018, 0x0009001C, 0x00090020
+IOCTL_DISK_UPDATE_PROPERTIES = 0x00070140
+CARD_BUSES = {"USB", "SD", "MMC"}
+CHUNK = 1024 * 1024
+
+k32 = win_disks._k32
+k32.WriteFile.argtypes = [wintypes.HANDLE, wintypes.LPCVOID, wintypes.DWORD,
+                          ctypes.POINTER(wintypes.DWORD), wintypes.LPVOID]
+k32.SetFilePointerEx.argtypes = [wintypes.HANDLE, ctypes.c_longlong, ctypes.POINTER(ctypes.c_longlong), wintypes.DWORD]
+k32.VirtualAlloc.restype = wintypes.LPVOID
+k32.VirtualAlloc.argtypes = [wintypes.LPVOID, ctypes.c_size_t, wintypes.DWORD, wintypes.DWORD]
+
+
+class FormatError(RuntimeError):
+    pass
+
+
+def _open_rw(path: str):
+    h = k32.CreateFileW(path, GENERIC_RW, SHARE_RW, None, OPEN_EXISTING, 0, None)
+    if h in (None, win_disks._INVALID):
+        raise FormatError(f"cannot open {path} (error {ctypes.get_last_error()})")
+    return h
+
+
+def _ioctl(h, code: int) -> bool:
+    got = wintypes.DWORD()
+    return bool(k32.DeviceIoControl(h, code, None, 0, None, 0, ctypes.byref(got), None))
+
+
+class RawDisk:
+    """Sector-aligned writes through a page-aligned buffer (device alignment rules)."""
+
+    def __init__(self, number: int, bps: int):
+        self.h = _open_rw(rf"\\.\PhysicalDrive{number}")
+        self.bps = bps
+        self.buf = k32.VirtualAlloc(None, CHUNK, 0x3000, 0x04)      # MEM_COMMIT|RESERVE, RW
+
+    def write(self, offset: int, data: bytes) -> None:
+        if offset % self.bps or len(data) % self.bps:
+            raise FormatError("unaligned write")
+        pos = 0
+        while pos < len(data):
+            n = min(CHUNK, len(data) - pos)
+            ctypes.memmove(self.buf, data[pos:pos + n], n)
+            self._raw(offset + pos, n)
+            pos += n
+
+    def zero(self, offset: int, length: int) -> None:
+        ctypes.memset(self.buf, 0, CHUNK)
+        pos = 0
+        while pos < length:
+            n = min(CHUNK, length - pos)
+            self._raw(offset + pos, n)
+            pos += n
+
+    def _raw(self, offset: int, n: int) -> None:
+        if not k32.SetFilePointerEx(self.h, offset, None, 0):
+            raise FormatError(f"seek failed (error {ctypes.get_last_error()})")
+        done = wintypes.DWORD()
+        if not k32.WriteFile(self.h, self.buf, n, ctypes.byref(done), None) or done.value != n:
+            raise FormatError(f"write at {offset} failed (error {ctypes.get_last_error()}) - write-protected card?")
+
+    def close(self) -> None:
+        k32.FlushFileBuffers(self.h)
+        _ioctl(self.h, IOCTL_DISK_UPDATE_PROPERTIES)                 # re-read the new partition table
+        k32.CloseHandle(self.h)
+
+
+def format_card(number: int, expected_size: int, label: str, timings: dict) -> str:
+    t0 = time.perf_counter()
+    disk = next((d for d in win_disks.list_disks(CARD_BUSES) if d.id == str(number)), None)
+    if disk is None:
+        raise FormatError("Refusing: the disk is not a USB/SD/MMC card reader.")
+    if disk.size != expected_size:
+        raise FormatError("Refusing: the disk changed since it was selected (card swapped?).")
+    system = os.environ.get("SystemDrive", "C:").upper().rstrip("\\") + "\\"
+    if any(v.mount.upper() == system for v in disk.volumes):
+        raise FormatError("Refusing: this disk holds the Windows drive.")
+    timings["guard"] = time.perf_counter() - t0
+
+    t = time.perf_counter()
+    locked = []
+    for v in disk.volumes:
+        h = _open_rw(rf"\\.\{v.mount[0]}:")
+        for _ in range(20):
+            if _ioctl(h, FSCTL_LOCK_VOLUME):
+                break
+            time.sleep(0.25)
+        else:
+            k32.CloseHandle(h)
+            raise FormatError(f"{v.mount} is in use by another program - close it and try again.")
+        _ioctl(h, FSCTL_DISMOUNT_VOLUME)
+        locked.append(h)
+    timings["lock_volumes"] = time.perf_counter() - t
+
+    t = time.perf_counter()
+    lay = fat32.plan(disk.size)
+    zeros, writes = fat32.build(lay, label, random.getrandbits(32), random.getrandbits(32), disk.size)
+    raw = RawDisk(number, lay.bytes_per_sector)
+    try:
+        for off, n in zeros:
+            raw.zero(off, n)
+        for off, data in writes:                       # MBR is last: the partition appears complete
+            raw.write(off, data)
+    finally:
+        for h in locked:
+            _ioctl(h, FSCTL_UNLOCK_VOLUME)
+            k32.CloseHandle(h)
+        raw.close()
+    timings["write"] = time.perf_counter() - t
+
+    t = time.perf_counter()
+    drive = ""
+    for _ in range(80):                                # Windows mounts the new volume by itself
+        d = next((x for x in win_disks.list_disks(CARD_BUSES) if x.id == str(number)), None)
+        vol = next((v for v in (d.volumes if d else []) if v.filesystem.upper() == "FAT32"), None)
+        if vol and vol.label.upper() == label.upper():
+            drive = vol.mount
+            break
+        time.sleep(0.25)
+    timings["mount"] = time.perf_counter() - t
+    if not drive:
+        raise FormatError("Formatted, but Windows did not mount the card - remove and re-insert it.")
+
+    t = time.perf_counter()
+    chk = subprocess.run(["chkdsk", drive.rstrip("\\")], capture_output=True, text=True, timeout=120,
+                         creationflags=subprocess.CREATE_NO_WINDOW)
+    timings["chkdsk"] = time.perf_counter() - t
+    if chk.returncode != 0:
+        tail = " ".join(chk.stdout.split()[-30:])
+        raise FormatError(f"chkdsk reported problems on the new file system: {tail}")
+    return drive
+
+
+def main(argv: list[str] | None = None) -> int:
+    ap = argparse.ArgumentParser()
+    ap.add_argument("--disk", type=int, required=True)
+    ap.add_argument("--size", type=int, required=True)
+    ap.add_argument("--label", default="KOTA")
+    ap.add_argument("--result", required=True)
+    a = ap.parse_args(argv)
+    timings: dict[str, float] = {}
+    result = {"ok": False, "message": "", "drive": "", "timings": timings}
+    try:
+        result["drive"] = format_card(a.disk, a.size, a.label, timings)
+        result["ok"] = True
+        result["message"] = "Formatted FAT32 (MBR), checked with chkdsk."
+    except FormatError as exc:
+        result["message"] = str(exc)
+    except Exception as exc:                            # report everything to the tool
+        result["message"] = f"Unexpected error: {exc!r}"
+    with open(a.result, "w", encoding="utf-8") as fh:
+        json.dump(result, fh)
+    return 0 if result["ok"] else 1
+
+
+if __name__ == "__main__":
+    sys.exit(main())

kota_tech/service/report.py

@@ -0,0 +1,155 @@
+"""Hand-off of a diagnosis to the KOTA service system (Google Apps Script).
+
+The tool opens the box's service page in the technician's browser:
+    <base><MAC>#kota-report=<base64url(JSON)>
+The service page (v1.1.0+) reads the fragment and pre-fills status and note;
+the technician checks it, adds the location and saves - so the report is
+authored by their own Google login and the tool holds no credentials.
+The fragment is never sent to any server (redirect host or Apps Script).
+"""
+
+from __future__ import annotations
+
+import base64
+import json
+import re
+
+from .. import __version__
+from ..diag.engine import Report, Severity
+
+DEFAULT_BASE = "https://service.kota-app.com/"
+NOTE_LIMIT = 4800        # the service form and Code.gs accept 5000; leave room for the technician
+
+# Status names exactly as in the service system (Code.gs STATUSES).
+OK = "Działa poprawnie"
+CHECK = "Do sprawdzenia"
+IN_SERVICE = "W trakcie serwisu"
+HARDWARE = "Błąd hardware"
+SOFTWARE = "Błąd software"
+POWER = "Problem z zasilaniem"
+CONNECTIVITY = "Problem z łącznością"
+
+# Root-finding rule id prefix -> service status (first match wins).
+_STATUS_BY_RULE = [
+    ("reboot.brownout", POWER), ("reboot.power", POWER), ("tech.power.", POWER),
+    ("sys.crash", SOFTWARE), ("reboot.watchdog", SOFTWARE), ("sys.out_of_resources", SOFTWARE),
+    ("influx.bad_request", SOFTWARE), ("ota.selfcheck_failed", SOFTWARE), ("tech.quick.hung", SOFTWARE),
+    ("rtc.init_failed", HARDWARE), ("rtc.lost_after_sync", HARDWARE), ("i2c.", HARDWARE), ("sensor.", HARDWARE),
+    ("sd.", HARDWARE), ("sen66.", HARDWARE), ("bme688.", HARDWARE), ("as7341.", HARDWARE),
+    ("mic.read_fail", HARDWARE), ("mic.silent", HARDWARE), ("tech.rtc_i2c.", HARDWARE), ("tech.sensors.", HARDWARE),
+    ("tech.mic.mic_faulty", HARDWARE), ("tech.mic.mic_switch_faulty", HARDWARE), ("tech.white.sd_", HARDWARE),
+    ("matter.", CONNECTIVITY), ("net.", CONNECTIVITY), ("wifi.", CONNECTIVITY), ("influx.", CONNECTIVITY),
+    ("ota.", CONNECTIVITY), ("tech.network.", CONNECTIVITY),
+    # firmware 1.0.16+ (KOTA: lines, status, error IDs)
+    ("reboot.crash", SOFTWARE), ("reboot.status_oom_watchdog", SOFTWARE), ("status.oom", SOFTWARE),
+    ("kota.low_heap", SOFTWARE),
+    ("kota.i2c_stuck", HARDWARE), ("kota.sensor_missing", HARDWARE), ("kota.rtc_", HARDWARE),
+    ("kota.sd_", HARDWARE), ("status.error", HARDWARE), ("status.rtc", HARDWARE), ("status.sd", HARDWARE),
+    ("kota.wifi_down", CONNECTIVITY), ("kota.weak_wifi", CONNECTIVITY), ("kota.no_upload", CONNECTIVITY),
+    ("kota.ota_unregistered", CONNECTIVITY), ("kota.buffer_backlog", CONNECTIVITY), ("status.conn", CONNECTIVITY),
+    ("kota.time_invalid", CHECK),
+    *((f"eid.{m}", HARDWARE) for m in ("SD", "ENV", "RTC", "BME", "SEN", "AS", "MIC", "FLK", "SPI")),
+    *((f"eid.{m}", CONNECTIVITY) for m in ("INF", "WIFI", "OTA", "PROV")),
+    ("eid.", SOFTWARE),
+    ("rtc.clock_not_running", CHECK), ("reboot.", CHECK),
+]
+_MAC = re.compile(r"^[0-9A-F]{12}$")
+
+
+def normalize_mac(mac: str) -> str:
+    return re.sub(r"[^0-9A-Fa-f]", "", mac or "").upper()
+
+
+def service_status(report: Report) -> str:
+    """Suggested status; the technician can change it in the form."""
+    problems = [rc for rc in report.roots if rc.severity >= Severity.WARNING]
+    if not problems:
+        return OK if any(m == "data_uploaded" and t is not None for m, _, t in report.milestones) else CHECK
+    rid = problems[0].finding.rule_id
+    for prefix, status in _STATUS_BY_RULE:
+        if rid.startswith(prefix):
+            return status
+    return CHECK
+
+
+BOX_MARK = {"ok": "✔", "warn": "!", "bad": "✖", "info": "i"}   # same marks as the Diagnosis panel
+SD_WIFI = {True: "reads Wi-Fi settings from the SD card",
+           False: "does not read Wi-Fi settings from the SD card",
+           None: "Wi-Fi-from-SD support unknown"}
+
+
+def service_note(report: Report, limit: int = NOTE_LIMIT) -> str:
+    """The Diagnosis panel as text: verdict, LED, firmware, box self-report,
+    start-up progress with times, findings with details and when they were seen.
+
+    Falls back to shorter finding details when the full text does not fit the
+    service form (consequences' explanations first, then all), then truncates.
+    """
+    for detail in ("all", "roots", "none"):
+        text = _note(report, detail)
+        if len(text) <= limit:
+            return text
+    return text[:limit - 20].rstrip() + "\n...(shortened)"
+
+
+def _note(report: Report, detail: str) -> str:
+    fw = report.firmware
+    source = " (reported by the box)" if report.led_exact else ""
+    lines = [f"[KOTA Technician Tool {__version__}] {report.verdict}", "",
+             f"Status LED should be: {report.led_text()}{source}"]
+    if report.led_reason:
+        lines.append(f"  from: {report.led_reason}")
+    lines += ["", f"Firmware: {fw.describe()}", f"  {SD_WIFI[fw.supports_sd_wifi]}"]
+    if report.box:
+        lines += ["", "Box self-report (KOTA lines):"]
+        lines += [f"  {BOX_MARK.get(st, '-')} {topic}: {text}" for topic, text, st in report.box]
+    lines += ["", "Start-up progress (current boot):"]
+    lines += [f"  ✔ {label} ({t / 1000:.1f} s)" if t is not None else f"  ○ {label}"
+              for _, label, t in report.milestones]
+    lines += ["", "Findings - root causes first:" if report.roots else "Findings: no problems detected in the log"]
+    for rc in report.roots:
+        lines += _finding(rc.finding, "", detail in ("all", "roots"))
+        for c in rc.consequences:
+            lines += _finding(c, "    ↳ ", detail == "all")
+    for title, items in (("Seen in earlier boots only", report.earlier),
+                         ("Resolved during this session", report.resolved)):
+        if items:
+            lines += ["", f"{title} ({len(items)}):"]
+            lines += [f"  - [{f.severity.label}] {f.title} - {f.seen_text()}" for f in items]
+    if report.technician:
+        lines += ["", "Technician checks:"]
+        lines += [f"  * {t}" for t in report.technician[-12:]]
+    return "\n".join(lines)
+
+
+def _finding(f, prefix: str, detailed: bool) -> list[str]:
+    ind = " " * len(prefix) + "  "
+    out = [f"{prefix}[{f.severity.label}] {f.title}"]
+    if detailed:
+        out.append(f"{ind}What it means: {f.meaning}")
+        if f.actions:
+            out.append(f"{ind}What to do:")
+            out += [f"{ind}  {i}. {a}" for i, a in enumerate(f.actions, 1)]
+        out += [f"{ind}Error {eid}" + (f": {a}" if a else "") for eid, a in f.error_ids.items()]
+    out.append(f"{ind}{f.seen_text()}")
+    if f.evidence:
+        out.append(f"{ind}Log: {f.evidence[-1]}")
+    return out
+
+
+def report_url(mac: str, report: Report, base: str = DEFAULT_BASE) -> str:
+    mac = normalize_mac(mac)
+    if not _MAC.match(mac):
+        raise ValueError(f"not a box MAC address: {mac!r}")
+    payload = {"v": 1, "mac": mac, "status": service_status(report), "note": service_note(report),
+               "tool": f"v{__version__}"}
+    raw = json.dumps(payload, ensure_ascii=False, separators=(",", ":")).encode("utf-8")
+    frag = base64.urlsafe_b64encode(raw).decode("ascii").rstrip("=")
+    base = base if base.endswith("/") else base + "/"
+    return f"{base}{mac}#kota-report={frag}"
+
+
+def decode_fragment(url: str) -> dict:
+    """Inverse of report_url (used by tests and for troubleshooting)."""
+    frag = url.split("#kota-report=", 1)[1]
+    return json.loads(base64.urlsafe_b64decode(frag + "=" * (-len(frag) % 4)).decode("utf-8"))

kota_tech/ui/cheatsheet.py

@@ -1,52 +1,55 @@
 """Quick-start cheat sheet shown on launch.
 
-Targets the DEPLOYED firmware: new_system.bin, app "kota-sensorboard"
-1.0, built Jun 29 2026 11:03:32, ELF SHA256 45fa9d5b9... (verified on a
-live board). That build has no Wi-Fi setup portal / SSID-on-SD support;
-those exist only in the newer, unbuilt source. The status LED is always
-SOLID; the separate small LED toggles every second while alive.
+LED table for firmware 1.0.16+ (firmware-diagnostics-what-changed.md,
+status.cpp Status::pattern_for): colour AND pattern name the fault. Older
+boxes (v1.0, built Jun 29 2026) show the same colours, always solid.
 """
 
-# (swatch colour, LED name, meaning, first action)
+# (swatch colour, LED name, pattern -> meaning, first action)
 LED_TABLE = [
-    ("#2e9e44", "Green", "Everything OK.", "Nothing to do."),
-    ("#8e44ad", "Purple",
-     "No Internet / InfluxDB or OTA server unreachable.",
-     "Check the box is commissioned in the Matter app (sticker QR code) and the "
-     "site Wi-Fi has Internet. Board reboots itself after ~2.5 min of purple."),
-    ("#d64541", "Red",
-     "Sensor or hardware fault (BME688, SEN66, AS7341, microphone, flicker) "
-     "or failed self-check after update.",
-     "Connect serial - the log names the failing sensor. Check sensor cables."),
-    ("#2f6fd6", "Blue",
-     "Clock (RTC DS1307) failed to start. The RTC is the first I2C device, "
-     "so a broken I2C cable also shows blue.",
-     "Check the I2C harness first, then the RTC module / coin cell."),
-    ("#e6c229", "Yellow", "Firmware update downloading.", "Do not switch off. Wait."),
-    ("#f08c1a", "Orange", "Self-check after an update (~2.5 min).",
-     "Wait; should turn green (or red on failure)."),
+    ("#2e9e44", "Green", "solid: everything OK.", "Nothing to do."),
+    ("#1fc8d8", "Cyan",
+     "breathing: not paired in Matter yet<br>fast blink: a phone is connected for pairing.",
+     "Pair the box in the Matter app (QR sticker or the QR code in the tool)."),
     ("#f4f4f4", "White",
-     "SD card missing/unreadable or ENV.TXT incomplete - or a factory reset is "
-     "in progress (Matter button held 5 s).",
-     "If nobody pressed the Matter button: the SD card is inside the case - "
-     "unscrew, re-seat or re-provision it."),
+     "fast blink: SD card or ENV.TXT error<br>solid: factory reset (Matter button held 5 s)<br>"
+     "breathing: Wi-Fi setup portal.",
+     "SD card is inside the case: re-seat or re-provision it. Setup portal: short-press the button to leave."),
+    ("#d64541", "Red",
+     "1-6 pulses: 1 BME688, 2 SEN66, 3 AS7341, 4 microphone, 5 flicker, 6 self-check failed<br>"
+     "solid: other internal error / out of memory.",
+     "Count the pulses, then check that sensor's cable. The box restarts itself after 150 s."),
+    ("#2f6fd6", "Blue",
+     "1 pulse: clock (RTC) not responding<br>2 pulses: I2C bus stuck (shorted / broken sensor cable).",
+     "Check the I2C cable between the boards first, then the RTC module."),
+    ("#8e44ad", "Purple",
+     "solid: no network<br>blinking: server rejected the box (wrong ENV.TXT credentials).",
+     "Solid: check Wi-Fi / Internet. Blinking: re-provision the SD card with the current ENV.TXT."),
+    ("#e6c229", "Yellow", "blinking, faster over time: downloading an update.", "Do not switch off. Wait."),
+    ("#f08c1a", "Orange", "solid: self-check after an update (~2.5 min).",
+     "Wait; should turn green (or red on failure)."),
     ("#444444", "Off", "Firmware did not start (or crashed very early).",
      "Check power switch & USB cable. If the small LED is also dark: re-flash."),
 ]
 
 HINTS = [
-    "<b>Colour keeps changing / LED goes dark every few seconds</b> = reboot loop. "
-    "Connect serial and press <i>Reset &amp; capture</i>: the last lines before the "
-    "reboot name the cause.",
-    "<b>Small LED next to the RGB LED</b> blinks once per second while the "
-    "firmware runs. Not blinking = firmware hung or not running.",
-    "<b>Outside the case</b>: power switch and the Matter button. Holding the "
+    "<b>Before a self-restart</b> the LED flashes the error colour 3 times; <b>after the restart</b> it "
+    "shows the previous error for 3 s. So a reboot loop shows its cause. Connect serial and press "
+    "<i>Reset &amp; capture</i>: the tool reads the restart reason from the box.",
+    "<b>Small LED next to the RGB LED</b> (heartbeat): blinks once per second while online, "
+    "double-blinks while offline. Dark or steady = firmware hung or not running.",
+    "<b>Serial monitor</b>: lines starting with <b>KOTA:</b> are the box's own diagnosis (boot, I2C, SD, "
+    "clock, Matter, microphone, status, LED, and a health line every 60 s). The Diagnosis panel reads them "
+    "directly; filter the view with <i>KOTA diagnostics + errors</i>. Error lines carry a code like "
+    "<b>[E-SD-03]</b> - the tool shows the recommended action for it.",
+    "<b>Outside the case</b> (back): power switch, the <b>microphone switch</b> just above it "
+    "(off = no noise measurements), and the Matter button. Holding the "
     "Matter button <b>5 s</b> factory-resets the box (it forgets its Matter "
     "network and must be commissioned again with the sticker QR code).",
     "<b>Inside the case</b> (unscrew): RESET and BOOT buttons and the SD card. "
     "Normally not needed - the tool resets the board over USB.",
-    "<b>Gathering messages for the first ~2 minutes</b> are normal "
-    "(the air-quality sensor warms up for 120 s).",
+    "<b>Flashing</b> uses only the firmware files in the tool's <b>firmware</b> folder; choose the build "
+    "by its compile date.",
 ]
 
 STEPS = [
@@ -55,7 +58,8 @@ STEPS = [
     "Open the <b>Serial monitor</b> tab, choose the sensorbox port, press "
     "<b>Connect</b>.",
     "Press <b>Reset &amp; capture</b> to record a full boot log from the first line.",
-    "Note the RGB LED colour and compare with the table below.",
+    "Read the <b>Diagnosis</b> panel on the right, then open <b>Guided troubleshooting</b> "
+    "and start <b>Quick check</b>: the tool asks what you see and checks the log live.",
 ]
 
 
@@ -71,10 +75,10 @@ def cheatsheet_html() -> str:
     return f"""
     <h2>Sensorbox quick start</h2>
     <ol>{steps}</ol>
-    <h3>RGB status LED (always solid colour)</h3>
+    <h3>RGB status LED - colour and pattern</h3>
     <table border='1' cellspacing='0' cellpadding='0' width='100%'>
       <tr><th align='left' style='padding:6px'>LED</th>
-          <th align='left' style='padding:6px'>Most likely meaning</th>
+          <th align='left' style='padding:6px'>Pattern: meaning</th>
           <th align='left' style='padding:6px'>First action</th></tr>
       {rows}
     </table>

kota_tech/ui/diag_panel.py

@@ -1,8 +1,9 @@
 """Diagnostics side panel: renders a diag.engine.Report.
 
-Layout: verdict banner, expected LED, firmware, start-up milestones, a
-findings tree (root causes; their consequences as children; titles only)
-and a wrapped detail pane for the selected finding.
+Layout: verdict banner, expected LED (colour + pattern + meaning when the
+box reports it), firmware, the box's own self-report (KOTA lines), start-up
+milestones, a findings tree (root causes; their consequences as children;
+titles only) and a wrapped detail pane for the selected finding.
 """
 
 from __future__ import annotations
@@ -15,6 +16,7 @@ from PySide6.QtWidgets import (
     QLabel,
     QListWidget,
     QListWidgetItem,
+    QPushButton,
     QSizePolicy,
     QSplitter,
     QTextBrowser,
@@ -40,6 +42,7 @@ BANNER = {
     None: ("#d8f0dd", "#1b5e2a"),
 }
 _KEY = Qt.ItemDataRole.UserRole
+BOX_STATE = {"ok": ("#1b7a33", "✔"), "warn": ("#c77c02", "!"), "bad": ("#b03a2e", "✖"), "info": ("#2e6da4", "i")}
 
 
 def _heading(text: str) -> QLabel:
@@ -76,6 +79,11 @@ class DiagnosticsPanel(QWidget):
         self.firmware = QLabel(wordWrap=True)
         self.firmware.setTextInteractionFlags(Qt.TextInteractionFlag.TextSelectableByMouse)
 
+        self.box_title = _heading("Box self-report (KOTA lines)")
+        self.box = QLabel(wordWrap=True)
+        self.box.setTextFormat(Qt.TextFormat.RichText)
+        self.box.setTextInteractionFlags(Qt.TextInteractionFlag.TextSelectableByMouse)
+
         self.milestones = QListWidget()
         self.milestones.setFrameShape(QFrame.Shape.NoFrame)
         self.milestones.setSelectionMode(QListWidget.SelectionMode.NoSelection)
@@ -99,6 +107,11 @@ class DiagnosticsPanel(QWidget):
         lay.addLayout(led_row)
         lay.addWidget(_heading("Firmware"))
         lay.addWidget(self.firmware)
+        self.qr_btn = QPushButton("Matter pairing QR code...")
+        self.qr_btn.setToolTip("Show the box's Matter QR code on screen to scan with the phone")
+        lay.addWidget(self.qr_btn, 0, Qt.AlignmentFlag.AlignLeft)
+        lay.addWidget(self.box_title)
+        lay.addWidget(self.box)
         lay.addWidget(_heading("Start-up progress (current boot)"))
         lay.addWidget(self.milestones)
         lay.addWidget(_heading("Findings - root causes first; click one for details"))
@@ -124,8 +137,11 @@ class DiagnosticsPanel(QWidget):
         self.led_swatch.setStyleSheet(
             f"QLabel {{ background:{colour}; border:1px solid #777; border-radius:11px; }}")
         ask = "" if r.led == "UNKNOWN" else " - <i>check it matches the box</i>"
+        pattern = f", {_esc(r.led_pattern)}" if r.led_pattern else ""
+        meaning = f" = {_esc(r.led_meaning)}" if r.led_meaning else ""
+        source = " <small style='color:#1b7a33'>(reported by the box)</small>" if r.led_exact else ""
         reason = f"<br><small style='color:#666'>from: {_esc(r.led_reason)}</small>" if r.led_reason else ""
-        self.led_text.setText(f"<b>{name}</b>{ask}{reason}")
+        self.led_text.setText(f"<b>{name}{pattern}</b>{meaning}{source}{ask}{reason}")
 
         fw = r.firmware
         sd = {True: "reads Wi-Fi settings from the SD card",
@@ -133,6 +149,13 @@ class DiagnosticsPanel(QWidget):
               None: "Wi-Fi-from-SD support unknown"}
         self.firmware.setText(f"{_esc(fw.describe())}<br><small>{sd[fw.supports_sd_wifi]}</small>")
 
+        self.box_title.setVisible(bool(r.box))
+        self.box.setVisible(bool(r.box))
+        self.box.setText("<table cellspacing='0' cellpadding='1'>" + "".join(
+            f"<tr><td style='color:{BOX_STATE[st][0]}'><b>{BOX_STATE[st][1]}</b>&nbsp;</td>"
+            f"<td><b>{_esc(topic)}</b>&nbsp;</td><td>{_esc(text)}</td></tr>"
+            for topic, text, st in r.box) + "</table>")
+
         self.milestones.clear()
         for _, label, t in r.milestones:
             done = t is not None
@@ -214,16 +237,15 @@ class DiagnosticsPanel(QWidget):
 def _detail_html(f: Finding) -> str:
     colour = SEV_COLOR.get(f.severity, "#333")
     actions = "".join(f"<li>{_esc(a)}</li>" for a in f.actions)
-    seen = f"Seen {f.count}x"
-    if f.first_uptime_ms is not None:
-        seen += f", first at {f.first_uptime_ms / 1000:.1f} s after start"
-    if f.resolved and f.resolved_by:
-        seen += f" - resolved ({_esc(f.resolved_by)})"
+    seen = _esc(f.seen_text())
     evidence = "<br>".join(_esc(e) for e in f.evidence)
+    codes = "".join(f"<li><b>{_esc(eid)}</b>" + (f" - {_esc(a)}" if a else "") + "</li>"
+                    for eid, a in f.error_ids.items())
     return (
         f"<h3 style='color:{colour}; margin:0'>{_esc(f.title)}</h3>"
         f"<p><b>What it means:</b> {_esc(f.meaning)}</p>"
         + (f"<p><b>What to do:</b></p><ol>{actions}</ol>" if actions else "")
+        + (f"<p><b>Firmware error codes</b> (error_ids.csv):</p><ul>{codes}</ul>" if codes else "")
         + f"<p style='color:#666'>{seen}</p>"
         + (f"<p style='color:#555; font-family:Consolas,Menlo,monospace; font-size:9pt'>{evidence}</p>"
            if evidence else "")

kota_tech/ui/flash_tab.py

@@ -0,0 +1,364 @@
+"""Flash firmware tab: only the .bin files in the tool's firmware/ folder,
+chosen by their compile date; App-only by default."""
+
+from __future__ import annotations
+
+import datetime as dt
+import tempfile
+from pathlib import Path
+
+from PySide6.QtCore import QObject, Qt, QTimer, QUrl, Signal
+from PySide6.QtGui import QDesktopServices
+from PySide6.QtWidgets import (
+    QButtonGroup,
+    QCheckBox,
+    QComboBox,
+    QGroupBox,
+    QHBoxLayout,
+    QLabel,
+    QMessageBox,
+    QPlainTextEdit,
+    QProgressBar,
+    QPushButton,
+    QRadioButton,
+    QVBoxLayout,
+    QWidget,
+)
+
+from ..core.session import SESSIONS_DIR
+from ..diag.firmware import local_build, register_local_build, same_build
+from ..flash.image import FIRMWARE_DIR, FirmwareImage, folder_images
+from ..flash.plan import Mode, build_plan
+from ..flash.runner import FlashRunner, Result
+from ..serialio.ports import PortInfo, list_serial_ports
+
+BACKUP_DIR = SESSIONS_DIR.parent / "backups"
+VERIFY_TIMEOUT_MS = 45_000
+
+HELP = (
+    "<b>If flashing cannot connect:</b> use a data-capable USB cable directly on the laptop, close "
+    "other programs using the port, then retry. Last resort (case must be opened): hold <b>BOOT</b>, "
+    "press and release <b>RESET</b>, release <b>BOOT</b>, and press Start again."
+)
+
+
+class _Bridge(QObject):
+    step = Signal(int, str)
+    progress = Signal(int)
+    output = Signal(str)
+    done = Signal(object)
+
+
+class FlashTab(QWidget):
+    def __init__(self, serial_tab, parent: QWidget | None = None):
+        super().__init__(parent)
+        self.serial_tab = serial_tab
+        self._images: list[FirmwareImage] = []
+        self._ports: list[PortInfo] = []   # before any signal can call _update()
+        self._runner: FlashRunner | None = None
+        self._port: PortInfo | None = None
+        self._image: FirmwareImage | None = None
+
+        # 1. box
+        box = QGroupBox("1. Sensorbox")
+        self.port_combo = QComboBox(minimumWidth=360)
+        refresh = QPushButton("Refresh")
+        refresh.clicked.connect(self.refresh_ports)
+        self.box_fw = QLabel(wordWrap=True)
+        bl = QVBoxLayout(box)
+        row = QHBoxLayout()
+        row.addWidget(self.port_combo)
+        row.addWidget(refresh)
+        row.addStretch(1)
+        bl.addLayout(row)
+        bl.addWidget(self.box_fw)
+
+        # 2. firmware - only files in the tool's firmware/ folder
+        fwbox = QGroupBox("2. Firmware (by compile date)")
+        self.image_combo = QComboBox(minimumWidth=360)
+        self.image_combo.setToolTip(f"Firmware files in {FIRMWARE_DIR}")
+        self.reload_btn = QPushButton("Refresh list")
+        self.reload_btn.setToolTip("Read the firmware folder again (after the firmware team added a file)")
+        self.reload_btn.clicked.connect(lambda: self._load_images(self._selected_sha()))
+        self.folder_btn = QPushButton("Open firmware folder")
+        self.folder_btn.clicked.connect(
+            lambda: QDesktopServices.openUrl(QUrl.fromLocalFile(str(FIRMWARE_DIR))))
+        self.image_info = QLabel(wordWrap=True)
+        self.image_info.setTextInteractionFlags(Qt.TextInteractionFlag.TextSelectableByMouse)
+        fl = QVBoxLayout(fwbox)
+        fl.addWidget(self.image_combo)
+        brow = QHBoxLayout()
+        brow.addWidget(self.reload_btn)
+        brow.addWidget(self.folder_btn)
+        brow.addStretch(1)
+        fl.addLayout(brow)
+        fl.addWidget(self.image_info)
+        self._problems: list[str] = []
+
+        # 3. mode
+        modebox = QGroupBox("3. What to write")
+        self.rb_app = QRadioButton("App only  (recommended for repairs)")
+        self.rb_full = QRadioButton("Full image  (new or completely wiped boards)")
+        self.mode_group = QButtonGroup(self)
+        self.mode_group.addButton(self.rb_app)
+        self.mode_group.addButton(self.rb_full)
+        self.rb_app.setChecked(True)
+        app_note = QLabel("Replaces the firmware only. Keeps the Matter pairing, the OTA registration and the "
+                          "settings stored on the box.", wordWrap=True)
+        full_note = QLabel("Writes everything like the factory. <b>Erases the Matter pairing and the OTA "
+                           "registration</b> - the box must be paired again afterwards.", wordWrap=True)
+        for n in (app_note, full_note):
+            n.setContentsMargins(24, 0, 0, 6)
+            n.setStyleSheet("color:#555")
+        self.confirm_full = QCheckBox("I understand the pairing and OTA registration will be erased")
+        self.backup = QCheckBox("Back up the box's complete flash first (8 MB, about 3 minutes)")
+        ml = QVBoxLayout(modebox)
+        for w in (self.rb_app, app_note, self.rb_full, full_note, self.confirm_full, self.backup):
+            ml.addWidget(w)
+
+        # 4. run
+        runbox = QGroupBox("4. Flash")
+        self.plan_label = QLabel(wordWrap=True)
+        self.start_btn = QPushButton("Start flashing")
+        self.start_btn.setMinimumHeight(36)
+        self.start_btn.clicked.connect(self._start)
+        self.step_label = QLabel()
+        self.bar = QProgressBar()
+        self.result = QLabel(wordWrap=True)
+        self.result.setMargin(8)
+        self.result.setTextFormat(Qt.TextFormat.RichText)
+        self.details_btn = QPushButton("Show esptool output")
+        self.details_btn.setCheckable(True)
+        self.output = QPlainTextEdit(readOnly=True)
+        self.output.setVisible(False)
+        self.details_btn.toggled.connect(self.output.setVisible)
+        rl = QVBoxLayout(runbox)
+        for w in (self.plan_label, self.start_btn, self.step_label, self.bar, self.result, self.details_btn, self.output):
+            rl.addWidget(w)
+        help_lbl = QLabel(HELP, wordWrap=True)
+        help_lbl.setStyleSheet("color:#555")
+        rl.addWidget(help_lbl)
+        rl.addStretch(1)   # keep the run column packed at the top
+
+        left = QVBoxLayout()
+        for w in (box, fwbox, modebox):
+            left.addWidget(w)
+        left.addStretch(1)
+        lay = QHBoxLayout(self)
+        lay.addLayout(left, 1)
+        lay.addWidget(runbox, 1)
+
+        self._bridge = _Bridge()
+        self._bridge.step.connect(self._on_step)
+        self._bridge.progress.connect(self.bar.setValue)
+        self._bridge.output.connect(self.output.appendPlainText)
+        self._bridge.done.connect(self._on_done)
+        self._verify_timer = QTimer(self, interval=500)
+        self._verify_timer.timeout.connect(self._check_verify)
+
+        for sig in (self.rb_app.toggled, self.confirm_full.toggled, self.backup.toggled):
+            sig.connect(self._update)
+        self.rb_full.toggled.connect(lambda on: self.backup.setChecked(on))  # backup default on for Full
+        self.image_combo.currentIndexChanged.connect(self._update)
+        self.port_combo.currentIndexChanged.connect(self._update)
+
+        self._load_images()
+        self.refresh_ports()
+        self._show_result("", None)
+
+    # ------------------------------------------------------------ setup
+    def _load_images(self, select_sha: str | None = None) -> None:
+        self._images, self._problems = folder_images()
+        for img in self._images:     # lets the Serial monitor show a box build's compile date
+            register_local_build(img.app.elf_sha, img.app.version, img.app.built, img.name)
+        self.image_combo.blockSignals(True)
+        self.image_combo.clear()
+        for img in self._images:
+            self.image_combo.addItem(img.label())
+        if not self._images:
+            self.image_combo.addItem("No firmware file in the firmware folder")
+        idx = next((i for i, im in enumerate(self._images) if im.sha256 == select_sha), 0)
+        self.image_combo.setCurrentIndex(idx)             # default: newest compile date
+        self.image_combo.blockSignals(False)
+        self._update()
+
+    def _selected_sha(self) -> str | None:
+        img = self._selected_image()
+        return img.sha256 if img else None
+
+    def refresh_ports(self) -> None:
+        current = self.port_combo.currentData()
+        self._ports = list_serial_ports()
+        self.port_combo.clear()
+        for p in self._ports:
+            self.port_combo.addItem(p.label, p.device)
+        if not self._ports:
+            self.port_combo.addItem("No sensorbox found - check USB cable and power switch", None)
+        self.port_combo.setCurrentIndex(max(self.port_combo.findData(current), 0))
+        self._update()
+
+    def showEvent(self, event):  # noqa: N802 - refresh when the tab is opened
+        self.refresh_ports()
+        super().showEvent(event)
+
+    # ------------------------------------------------------------ state
+    def _selected_image(self) -> FirmwareImage | None:
+        i = self.image_combo.currentIndex()
+        return self._images[i] if 0 <= i < len(self._images) else None
+
+    def _selected_port(self) -> PortInfo | None:
+        dev = self.port_combo.currentData()
+        return next((p for p in self._ports if p.device == dev), None)
+
+    def _update(self) -> None:
+        img = self._selected_image()
+        info = ""
+        if img:
+            a = img.app
+            kind = "complete image (bootloader + layout + app)" if img.kind == "merged" else "app only"
+            info = (f"<b>Compiled {a.built}</b> &middot; {a.project} v{a.version}, ESP-IDF {a.idf}, {kind}<br>"
+                    f"<small>file firmware/{img.name} &middot; build {a.elf_sha[:8]} &middot; "
+                    f"SHA-256 {img.sha256[:16]}... &middot; checksum OK</small>")
+        else:
+            info = (f"Put the firmware .bin file from the firmware team into<br><code>{FIRMWARE_DIR}</code><br>"
+                    "and press <b>Refresh list</b>. Only files in this folder can be flashed.")
+        if self._problems:
+            info += ("<br><span style='color:#b03a2e'><b>Not offered:</b> "
+                     + "; ".join(self._problems) + "</span>")
+        self.image_info.setText(info)
+        # An app-only file has no bootloader/layout: Full mode is impossible.
+        full_ok = bool(img and img.kind == "merged")
+        self.rb_full.setEnabled(full_ok and self._runner is None)
+        if not full_ok and self.rb_full.isChecked():
+            self.rb_app.setChecked(True)
+        self.box_fw.setText(self._box_text(img))
+
+        self.confirm_full.setVisible(self.rb_full.isChecked())
+        ok = bool(img and self._selected_port() and self._runner is None
+                  and (self.rb_app.isChecked() or self.confirm_full.isChecked()))
+        self.start_btn.setEnabled(ok)
+        if img and self._selected_port():
+            mode = Mode.APP_ONLY if self.rb_app.isChecked() else Mode.FULL
+            steps = ["Back up the complete flash (~3 min)"] if self.backup.isChecked() else []
+            if mode == Mode.APP_ONLY:
+                steps += ["Check the box has the same partition layout", "Write the firmware app (~20 s)"]
+            else:
+                steps += ["Write the complete image (~25 s)"]
+            steps += ["Restart the box and verify the new firmware boots"]
+            self.plan_label.setText("<b>Plan:</b><ol>" + "".join(f"<li>{s}</li>" for s in steps) + "</ol>")
+        else:
+            self.plan_label.setText("Select a sensorbox and a firmware image.")
+
+    def _box_text(self, img: FirmwareImage | None) -> str:
+        fw = self.serial_tab.engine.firmware
+        if not fw.elf_sha:
+            return "Firmware on the box: unknown - connect in the Serial monitor and press Reset & capture to see it."
+        msg = f"Box currently runs: {fw.describe()}"
+        if not img:
+            return msg
+        if same_build(fw.elf_sha, img.app.elf_sha):
+            return msg + "<br><i>It already has this firmware. Re-flash only if you suspect the firmware is damaged.</i>"
+        local = local_build(fw.elf_sha)
+        box_built, img_built = _parse_built(fw.built or (local[1] if local else None)), img.app.built_at
+        if box_built and img_built and img_built > box_built:
+            return msg + f"<br><b style='color:#2e6da4'>The selected firmware is newer (built {img.app.built}).</b>"
+        if box_built and img_built and img_built < box_built:
+            return msg + ("<br><b style='color:#c77c02'>The selected firmware is OLDER than the box's (the box was "
+                          "probably updated over OTA). The box updates itself again once online.</b>")
+        return msg + "<br><b style='color:#c77c02'>The box runs a different build.</b>"
+
+    # ------------------------------------------------------------ flash
+    def _start(self) -> None:
+        img, port = self._selected_image(), self._selected_port()
+        if not img or not port:
+            return
+        mode = Mode.APP_ONLY if self.rb_app.isChecked() else Mode.FULL
+        what = ("the firmware app (pairing and settings are kept)" if mode == Mode.APP_ONLY
+                else "the COMPLETE image (pairing and OTA registration are erased)")
+        if QMessageBox.question(self, "Flash firmware",
+                                f"Write {what}\n\nFirmware: v{img.app.version}, compiled {img.app.built}\n"
+                                f"File: firmware/{img.name}\nBox: {port.label}\n\n"
+                                "Keep the box powered and the USB cable connected until it finishes.",
+                                QMessageBox.StandardButton.Ok | QMessageBox.StandardButton.Cancel
+                                ) != QMessageBox.StandardButton.Ok:
+            return
+        backup_to = None
+        if self.backup.isChecked():
+            BACKUP_DIR.mkdir(parents=True, exist_ok=True)
+            stamp = dt.datetime.now().strftime("%Y%m%d_%H%M%S")
+            backup_to = BACKUP_DIR / f"{(port.mac or port.device).replace(':', '')}_{stamp}.bin"
+        plan = build_plan(img, mode, port.device, Path(tempfile.mkdtemp(prefix="kota_flash_")), backup_to)
+
+        self._port, self._image = port, img
+        self.serial_tab.release_port()          # esptool needs the port exclusively
+        self.output.clear()
+        self.output.appendPlainText("\n".join(plan.summary()))
+        self._show_result("", None)
+        self._runner = FlashRunner(plan, self._bridge.step.emit, self._bridge.progress.emit,
+                                   self._bridge.output.emit, self._bridge.done.emit)
+        self._set_busy(True)
+        self._runner.start()
+
+    def _set_busy(self, busy: bool) -> None:
+        for w in (self.port_combo, self.image_combo, self.rb_app, self.backup, self.confirm_full,
+                  self.reload_btn):
+            w.setEnabled(not busy)
+        self._update()
+
+    def _on_step(self, i: int, title: str) -> None:
+        n = len(self._runner.plan.steps) if self._runner else 0
+        self.step_label.setText(f"Step {i + 1} of {n + 1}: {title}")
+
+    def _on_done(self, res: Result) -> None:
+        self._runner = None
+        if not res.ok:
+            self._set_busy(False)
+            self.step_label.setText("Stopped.")
+            hint = f"<p>{res.hint}</p>" if res.hint else ""
+            self._show_result(f"<b>Flashing failed.</b> {res.message}{hint}", "error")
+            self.details_btn.setChecked(True)
+            return
+        self.step_label.setText("Final step: restarting the box and checking which firmware it boots...")
+        self.bar.setValue(0)
+        self._show_result("Firmware written. Waiting for the box to start...", "info")
+        self.serial_tab.connect_port(self._port, capture=True)
+        self._verify_ms = 0
+        self._verify_timer.start()
+
+    def _check_verify(self) -> None:
+        self._verify_ms += self._verify_timer.interval()
+        self.bar.setValue(min(100, int(100 * self._verify_ms / VERIFY_TIMEOUT_MS)))
+        fw = self.serial_tab.engine.firmware
+        want = self._image.app.elf_sha[:8]
+        done = same_build(fw.elf_sha, self._image.app.elf_sha)
+        if done or self._verify_ms >= VERIFY_TIMEOUT_MS:
+            self._verify_timer.stop()
+            self._set_busy(False)
+            self.bar.setValue(100)
+            if done:
+                self.step_label.setText("Done.")
+                self._show_result(f"<b>Success.</b> The box boots the new firmware (build {want}). "
+                                  "Check the Diagnosis panel in the Serial monitor.", "ok")
+            else:
+                seen = fw.elf_sha[:8] if fw.elf_sha else "no boot seen"
+                self._show_result(f"<b>Written, but not verified.</b> Expected build {want}, saw: {seen}. "
+                                  "Open the Serial monitor and press Reset & capture.", "warning")
+
+    def _show_result(self, html: str, kind: str | None) -> None:
+        colours = {"ok": ("#2e9e44", "#e3f4e7"), "info": ("#2e6da4", "#e3edf7"),
+                   "warning": ("#c77c02", "#fdf0d6"), "error": ("#d9534f", "#f9e0df")}
+        self.result.setVisible(bool(html))
+        if html:
+            border, bg = colours[kind or "info"]
+            self.result.setStyleSheet(f"QLabel {{ border:2px solid {border}; background:{bg}; border-radius:6px; }}")
+            self.result.setText(html)
+
+
+def _parse_built(s: str | None) -> dt.datetime | None:
+    """'Jun 29 2026 11:03:32' (app_init "Compile time") -> datetime."""
+    if not s:
+        return None
+    try:
+        return dt.datetime.strptime(" ".join(s.split()), "%b %d %Y %H:%M:%S")
+    except ValueError:
+        return None

kota_tech/ui/guide_panel.py

@@ -0,0 +1,225 @@
+"""Guided troubleshooting panel: renders a diag.guides.GuideRunner."""
+
+from __future__ import annotations
+
+from PySide6.QtCore import QSize, Qt
+from PySide6.QtGui import QBrush, QColor, QIcon, QLinearGradient, QPainter, QPixmap
+from PySide6.QtWidgets import (
+    QFrame,
+    QHBoxLayout,
+    QLabel,
+    QListWidget,
+    QListWidgetItem,
+    QProgressBar,
+    QPushButton,
+    QVBoxLayout,
+    QWidget,
+)
+
+from ..diag.engine import LED, DiagnosticsEngine
+from ..diag.guides import GuideRunner, recommended
+from ..matter.payload import SetupPayload
+from .matter_qr import MatterQrWidget
+
+END_STYLE = {  # end severity -> (border, background)
+    "ok": ("#2e9e44", "#e3f4e7"),
+    "info": ("#2e6da4", "#e3edf7"),
+    "warning": ("#c77c02", "#fdf0d6"),
+    "error": ("#d9534f", "#f9e0df"),
+    "critical": ("#b03a2e", "#f6d5d1"),
+}
+
+
+def _swatch(key: str, size: int = 22) -> QIcon:
+    """Round LED-colour icon; CYCLING is drawn as a blue-dark-red gradient."""
+    pm = QPixmap(size, size)
+    pm.fill(QColor(0, 0, 0, 0))
+    p = QPainter(pm)
+    p.setRenderHint(QPainter.RenderHint.Antialiasing)
+    if key == "CYCLING":
+        g = QLinearGradient(0, 0, size, 0)
+        for stop, c in ((0.0, "#2f6fd6"), (0.5, "#444444"), (1.0, "#d64541")):
+            g.setColorAt(stop, QColor(c))
+        p.setBrush(QBrush(g))
+    else:
+        p.setBrush(QColor(LED.get(key, ("", "#888888"))[1]))
+    p.setPen(QColor("#777777"))
+    p.drawEllipse(1, 1, size - 2, size - 2)
+    p.end()
+    return QIcon(pm)
+
+
+def _esc(s: str) -> str:
+    return s.replace("&", "&amp;").replace("<", "&lt;").replace(">", "&gt;")
+
+
+class GuidePanel(QWidget):
+    def __init__(self, runner: GuideRunner, engine: DiagnosticsEngine, parent: QWidget | None = None,
+                 matter_payload=None):
+        super().__init__(parent)
+        self.runner, self.engine = runner, engine
+        self._matter_payload = matter_payload or SetupPayload   # callable -> SetupPayload
+        self._shown_key: tuple | None = None
+
+        # --- picker (no guide running)
+        self.picker = QWidget()
+        pl = QVBoxLayout(self.picker)
+        pl.setContentsMargins(0, 0, 0, 0)
+        pl.addWidget(QLabel("<b>Recommended checks for this box</b> (based on the log):"))
+        self.guide_list = QListWidget()
+        self.guide_list.itemDoubleClicked.connect(lambda it: self._start(it.data(Qt.ItemDataRole.UserRole)))
+        pl.addWidget(self.guide_list, 1)
+        self.start_btn = QPushButton("Start selected check")
+        self.start_btn.clicked.connect(self._start_selected)
+        pl.addWidget(self.start_btn)
+
+        # --- running guide
+        self.card = QFrame()
+        self.card.setFrameShape(QFrame.Shape.StyledPanel)
+        cl = QVBoxLayout(self.card)
+        self.guide_title = QLabel()
+        self.guide_title.setStyleSheet("color:#666")
+        self.step_text = QLabel(wordWrap=True)
+        f = self.step_text.font()
+        f.setPointSize(f.pointSize() + 2)
+        self.step_text.setFont(f)
+        self.step_text.setTextFormat(Qt.TextFormat.RichText)
+        self.options = QVBoxLayout()
+        self.wait_bar = QProgressBar()
+        self.wait_bar.setTextVisible(False)
+        self.wait_label = QLabel()
+        self.note = QLabel(wordWrap=True)
+        self.note.setStyleSheet("color:#b03a2e")
+        self.continue_btn = QPushButton("Continue")
+        self.continue_btn.clicked.connect(self._proceed)
+        self.skip_btn = QPushButton("Skip waiting / it did not work")
+        self.skip_btn.clicked.connect(self._proceed)
+        self.end_box = QLabel(wordWrap=True)
+        self.end_box.setTextFormat(Qt.TextFormat.RichText)
+        self.end_box.setMargin(10)
+        self.qr = MatterQrWidget(SetupPayload(), 220)
+        for w in (self.guide_title, self.step_text, self.qr):
+            cl.addWidget(w)
+        cl.addLayout(self.options)
+        for w in (self.wait_label, self.wait_bar, self.note, self.continue_btn, self.skip_btn, self.end_box):
+            cl.addWidget(w)
+        cl.addStretch(1)
+        nav = QHBoxLayout()
+        self.back_btn = QPushButton("← Back")
+        self.back_btn.clicked.connect(self._back)
+        self.done_btn = QPushButton("Back to checks list")
+        self.done_btn.clicked.connect(self._cancel)
+        nav.addWidget(self.back_btn)
+        nav.addStretch(1)
+        nav.addWidget(self.done_btn)
+        cl.addLayout(nav)
+
+        lay = QVBoxLayout(self)
+        lay.setContentsMargins(4, 0, 0, 0)
+        lay.addWidget(self.picker, 1)
+        lay.addWidget(self.card, 1)
+        self.refresh()
+
+    # ------------------------------------------------------------ actions
+    def _start_selected(self) -> None:
+        it = self.guide_list.currentItem() or self.guide_list.item(0)
+        if it:
+            self._start(it.data(Qt.ItemDataRole.UserRole))
+
+    def _start(self, guide_id: str) -> None:
+        self.runner.start(guide_id)
+        self.refresh()
+
+    def _answer(self, key: str) -> None:
+        self.runner.answer(key)
+        self.refresh()
+
+    def _proceed(self) -> None:
+        self.runner.proceed()
+        self.refresh()
+
+    def _back(self) -> None:
+        self.runner.back()
+        self.refresh()
+
+    def _cancel(self) -> None:
+        self.runner.cancel()
+        self.refresh()
+
+    # ------------------------------------------------------------- render
+    def refresh(self) -> None:
+        """Called after every interaction and periodically (timeouts, countdown)."""
+        self.runner.tick()
+        v = self.runner.view()
+        running = v.guide is not None
+        self.picker.setVisible(not running)
+        self.card.setVisible(running)
+        if not running:
+            self._fill_picker()
+            self._shown_key = None
+            return
+        key = (v.guide.id, v.step.id if v.step else None, v.end.id if v.end else None)
+        if key != self._shown_key:
+            self._shown_key = key
+            self._render_step(v)
+        if v.waiting:
+            total = v.step.timeout_s
+            self.wait_bar.setMaximum(int(total))
+            self.wait_bar.setValue(int(total - v.remaining_s))
+            m, s = divmod(int(v.remaining_s), 60)
+            self.wait_label.setText(f"Watching the live log... {m}:{s:02d} left")
+        self.note.setText(v.note)
+        self.note.setVisible(bool(v.note))
+        self.back_btn.setEnabled(v.can_back)
+
+    def _fill_picker(self) -> None:
+        wanted = [(g.id, g.title, g.summary) for g in recommended(self.runner.guides, self.engine)]
+        current = [(self.guide_list.item(i).data(Qt.ItemDataRole.UserRole)) for i in range(self.guide_list.count())]
+        if [w[0] for w in wanted] == current:
+            return
+        self.guide_list.clear()
+        for gid, title, summary in wanted:
+            it = QListWidgetItem(f"{title}\n    {summary}")
+            it.setData(Qt.ItemDataRole.UserRole, gid)
+            self.guide_list.addItem(it)
+        self.guide_list.setCurrentRow(0)
+
+    def _render_step(self, v) -> None:
+        self.guide_title.setText(v.guide.title)
+        while self.options.count():
+            w = self.options.takeAt(0).widget()
+            if w:
+                # Detach now; deleteLater alone leaves it visible until the
+                # event loop processes the deferred delete.
+                w.hide()
+                w.setParent(None)
+                w.deleteLater()
+        is_end = v.end is not None
+        self.step_text.setVisible(not is_end)
+        self.step_text.setText(_esc(v.text))
+        show_qr = bool(v.step and v.step.show_qr)
+        if show_qr:
+            self.qr.set_payload(self._matter_payload())
+        self.qr.setVisible(show_qr)
+        for opt_key, label in v.options:
+            b = QPushButton(label)
+            b.setMinimumHeight(34)
+            if v.step and v.step.type == "led":
+                b.setIcon(_swatch(opt_key))
+                b.setIconSize(QSize(22, 22))
+                b.setStyleSheet("QPushButton { text-align:left; padding-left:10px; }")
+            b.clicked.connect(lambda _=False, k=opt_key: self._answer(k))
+            self.options.addWidget(b)
+        step_type = v.step.type if v.step else None
+        self.continue_btn.setVisible(step_type == "info")
+        self.skip_btn.setVisible(step_type == "wait")
+        self.wait_bar.setVisible(step_type == "wait")
+        self.wait_label.setVisible(step_type == "wait")
+        self.end_box.setVisible(is_end)
+        if is_end:
+            e = v.end
+            border, bg = END_STYLE.get(e.severity, END_STYLE["info"])
+            acts = "".join(f"<li>{_esc(a)}</li>" for a in e.actions)
+            self.end_box.setStyleSheet(f"QLabel {{ border:2px solid {border}; background:{bg}; border-radius:6px; }}")
+            self.end_box.setText(f"<h3 style='margin:0'>{_esc(e.title)}</h3><p>{_esc(e.text)}</p>"
+                                 + (f"<ol>{acts}</ol>" if acts else ""))

kota_tech/ui/main_window.py

@@ -2,15 +2,17 @@ from __future__ import annotations
 
 from pathlib import Path
 
-from PySide6.QtCore import QObject, Qt, QTimer, QUrl, Signal
+from PySide6.QtCore import QCoreApplication, QObject, QSettings, Qt, QTimer, QUrl, Signal
 from PySide6.QtGui import QColor, QDesktopServices, QFont, QGuiApplication, QTextCharFormat, QTextCursor
 from PySide6.QtWidgets import (
     QCheckBox,
     QComboBox,
     QFileDialog,
     QHBoxLayout,
+    QInputDialog,
     QLabel,
     QMainWindow,
+    QMessageBox,
     QPlainTextEdit,
     QPushButton,
     QSplitter,
@@ -22,16 +24,25 @@ from PySide6.QtWidgets import (
 
 from .. import __version__
 from ..core.logfile import read_log_file
-from ..core.logline import LineKind, LogLine
+from ..core.logline import LineKind, LogLine, host_event
 from ..core.session import SessionLog
 from ..diag.engine import DiagnosticsEngine
+from ..diag.guides import GuideRunner
 from ..serialio.manager import SerialManager, State
 from ..serialio.ports import PortInfo, list_serial_ports
+from ..matter.payload import SetupPayload, payload_from_log
+from ..service.report import DEFAULT_BASE, normalize_mac, report_url
 from .cheatsheet import cheatsheet_html
 from .diag_panel import DiagnosticsPanel
+from .flash_tab import FlashTab
+from .matter_qr import MatterQrDialog
+from .guide_panel import GuidePanel
+from .sd_tab import SdTab
 
 MAX_LINES = 20000
-LEVEL_FILTERS = {"All lines": None, "Warnings + errors": {"W", "E"}, "Errors only": {"E"}}
+# "KOTA" = the firmware's structured diagnostic lines (1.0.16+) plus errors.
+LEVEL_FILTERS = {"All lines": None, "KOTA diagnostics + errors": "KOTA",
+                 "Warnings + errors": {"W", "E"}, "Errors only": {"E"}}
 COLORS = {
     "E": "#ff6b6b",
     "W": "#f5c451",
@@ -40,6 +51,7 @@ COLORS = {
     LineKind.RESET: "#6fc3ff",
     LineKind.PANIC: "#ff4dd2",
     LineKind.HOST: "#7ee07e",
+    LineKind.KOTA: "#5fd7e8",
     LineKind.RAW: "#a8a8a8",
 }
 
@@ -63,6 +75,7 @@ class SerialTab(QWidget):
         self._counts = {"E": 0, "W": 0, "boots": 0}
         self._engine = DiagnosticsEngine()
         self._diag_dirty = True
+        self._runner = GuideRunner(self._engine, on_action=self._guide_action, on_log=self._guide_log)
 
         # --- controls
         self.port_combo = QComboBox(minimumWidth=320)
@@ -80,6 +93,14 @@ class SerialTab(QWidget):
         self.analyze_btn.setToolTip("Load a saved session log or serial capture and diagnose it")
         self.copy_btn = QPushButton("Copy report")
         self.copy_btn.setToolTip("Copy the diagnosis as text (e.g. to send to the firmware team)")
+        self.service_btn = QPushButton("Service report...")
+        self.service_btn.setToolTip("Open this box's page in the KOTA service system with the diagnosis "
+                                    "filled in; check it and press Save there")
+        self._settings = QSettings("KOTA", "TechnicianTool")
+        self.auto_service = QCheckBox("Open service report on disconnect")
+        self.auto_service.setChecked(self._settings.value("service/auto", False, type=bool))
+        self.auto_service.toggled.connect(lambda on: self._settings.setValue("service/auto", on))
+        self._active_port: PortInfo | None = None
 
         row1 = QHBoxLayout()
         for w in (QLabel("Port:"), self.port_combo, self.all_ports, self.refresh_btn,
@@ -88,7 +109,7 @@ class SerialTab(QWidget):
         row1.addStretch(1)
         row2 = QHBoxLayout()
         for w in (QLabel("Show:"), self.filter_combo, self.clear_btn, self.save_btn, self.folder_btn,
-                  self.analyze_btn, self.copy_btn):
+                  self.analyze_btn, self.copy_btn, self.service_btn, self.auto_service):
             row2.addWidget(w)
         row2.addStretch(1)
 
@@ -102,9 +123,13 @@ class SerialTab(QWidget):
         self.view.setStyleSheet("QPlainTextEdit { background:#1e1e1e; color:#d4d4d4; }")
 
         self.diag = DiagnosticsPanel()
+        self.guide = GuidePanel(self._runner, self._engine, matter_payload=self.matter_payload)
+        self.side_tabs = QTabWidget()
+        self.side_tabs.addTab(self.diag, "Diagnosis")
+        self.side_tabs.addTab(self.guide, "Guided troubleshooting")
         split = QSplitter(Qt.Orientation.Horizontal)
         split.addWidget(self.view)
-        split.addWidget(self.diag)
+        split.addWidget(self.side_tabs)
         split.setStretchFactor(0, 3)
         split.setStretchFactor(1, 2)
         split.setSizes([700, 480])
@@ -126,6 +151,8 @@ class SerialTab(QWidget):
         self.folder_btn.clicked.connect(self._open_folder)
         self.analyze_btn.clicked.connect(self._analyze_file)
         self.copy_btn.clicked.connect(self._copy_report)
+        self.service_btn.clicked.connect(lambda: self._open_service_report(auto=False))
+        self.diag.qr_btn.clicked.connect(lambda: MatterQrDialog(self.matter_payload(), self).exec())
 
         # Report refresh is throttled; lines can arrive at >100/s.
         self._diag_timer = QTimer(self, interval=400)
@@ -173,16 +200,75 @@ class SerialTab(QWidget):
         port = self._selected_port()
         if port is None:
             return
+        self._connect(port)
+
+    def _connect(self, port: PortInfo) -> None:
         self._counts = {"E": 0, "W": 0, "boots": 0}
         self._engine.reset()
+        self._runner.cancel()
         self._diag_dirty = True
         self._session.start(port.mac or port.device)
+        self._active_port = port
         self._manager.connect(port)
 
+    def matter_payload(self) -> SetupPayload:
+        """Pairing payload reported by this box (KOTA: matter), from its log, or the defaults."""
+        return payload_from_log([self._engine.matter_advert] if self._engine.matter_advert else [],
+                                self._engine.matter_qr, self._engine.matter_manual)
+
+    # ---- service system -------------------------------------------------
+    def _service_base(self) -> str:
+        return str(self._settings.value("service/base", DEFAULT_BASE))
+
+    def _open_service_report(self, auto: bool) -> None:
+        mac = normalize_mac(self._engine.mac or (self._active_port.mac if self._active_port else "") or "")
+        if len(mac) != 12:
+            if not auto:
+                QMessageBox.information(self, "Service report", "The box's MAC address is not known yet. "
+                                        "Connect to the box and press Reset & capture first.")
+            return
+        url = report_url(mac, self._engine.report(), self._service_base())
+        QDesktopServices.openUrl(QUrl(url))
+        # Log that it happened, not the report itself (it is already in the session log).
+        self._guide_log(f"service report for {mac} opened in the browser - check it and press Save there")
+
+    # ---- hand-off with the flash tab ------------------------------------
+    @property
+    def engine(self) -> DiagnosticsEngine:
+        return self._engine
+
+    def release_port(self) -> None:
+        """Stop monitoring so esptool can open the port exclusively."""
+        if self._manager.is_running:
+            self._no_auto_service = True        # a flash hand-off is not the end of a session
+            self._manager.disconnect()          # joins the reader thread
+            QCoreApplication.processEvents()    # deliver its queued final lines/state now
+            self._no_auto_service = False
+
+    def connect_port(self, port: PortInfo, capture: bool = True) -> None:
+        """Monitor `port`; with capture, restart the box once connected to record its boot."""
+        self.release_port()
+        idx = self.port_combo.findData(port.device)
+        if idx < 0:
+            self.port_combo.addItem(port.label, port.device)
+            self._ports.append(port)
+            idx = self.port_combo.count() - 1
+        self.port_combo.setCurrentIndex(idx)
+        self._reset_on_connect = capture
+        self._connect(port)
+
     def _on_state(self, state: State, detail: str) -> None:
         running = state != State.DISCONNECTED
+        if not running and self._manager.is_running:
+            return  # stale event from a session that was already replaced
+        if state == State.CONNECTED and getattr(self, "_reset_on_connect", False):
+            self._reset_on_connect = False
+            QTimer.singleShot(300, self._manager.reset_board)
         if not running and self._session.path is not None:
             self._session.write_report(self._engine.report().to_text())
+            if (self.auto_service.isChecked() and self._engine.lines
+                    and not getattr(self, "_no_auto_service", False)):
+                self._open_service_report(auto=True)
             self._session.stop()
         self.connect_btn.setText("Disconnect" if running else "Connect")
         self.reset_btn.setEnabled(state == State.CONNECTED)
@@ -206,6 +292,7 @@ class SerialTab(QWidget):
     def _on_line(self, line: LogLine) -> None:
         self._session.write(line)
         self._engine.feed(line)
+        self._runner.feed(line)
         self._diag_dirty = True
         if line.kind == LineKind.BOOT:
             self._counts["boots"] += 1
@@ -213,19 +300,24 @@ class SerialTab(QWidget):
             self._counts[line.level] += 1
         self._update_status()
 
+        if self._visible(line):
+            self._append(line)
+
+    def _visible(self, line: LogLine) -> bool:
         allowed = LEVEL_FILTERS[self.filter_combo.currentText()]
-        if allowed is not None and line.kind != LineKind.HOST and not (
-            line.level in allowed or line.kind in (LineKind.PANIC, LineKind.BOOT, LineKind.RESET)
-        ):
-            return
-        self._append(line)
+        if allowed is None or line.kind in (LineKind.HOST, LineKind.PANIC, LineKind.BOOT, LineKind.RESET):
+            return True
+        if allowed == "KOTA":
+            return line.kind == LineKind.KOTA or line.level == "E"
+        return line.level in allowed
 
     def _append(self, line: LogLine) -> None:
         sb = self.view.verticalScrollBar()
         at_bottom = sb.value() >= sb.maximum() - 4
         fmt = QTextCharFormat()
-        fmt.setForeground(QColor(COLORS.get(line.level) or COLORS.get(line.kind, "#d4d4d4")))
-        if line.kind in (LineKind.PANIC, LineKind.BOOT, LineKind.HOST):
+        colour = COLORS.get(line.kind) if line.kind == LineKind.KOTA and line.level == "I" else None
+        fmt.setForeground(QColor(colour or COLORS.get(line.level) or COLORS.get(line.kind, "#d4d4d4")))
+        if line.kind in (LineKind.PANIC, LineKind.BOOT, LineKind.HOST) or line.record in ("boot", "status"):
             fmt.setFontWeight(QFont.Weight.Bold)
         cur = QTextCursor(self.view.document())
         cur.movePosition(QTextCursor.MoveOperation.End)
@@ -240,6 +332,21 @@ class SerialTab(QWidget):
         if self._diag_dirty:
             self._diag_dirty = False
             self.diag.show_report(self._engine.report())
+        self.guide.refresh()   # countdowns and timeouts need a steady tick
+
+    # ---- guided troubleshooting hooks ------------------------------------
+    def _guide_action(self, action: str) -> bool:
+        if action == "reset" and self._manager.state == State.CONNECTED:
+            self._manager.reset_board()
+            return True
+        return False
+
+    def _guide_log(self, text: str) -> None:
+        # Technician answers go into the session log and the log view.
+        line = host_event(text)
+        self._session.write(line)
+        self._append(line)
+        self._diag_dirty = True
 
     def _copy_report(self) -> None:
         QGuiApplication.clipboard().setText(self._engine.report().to_text())
@@ -252,6 +359,7 @@ class SerialTab(QWidget):
         lines = read_log_file(Path(path))
         self.view.clear()
         self._engine.reset()
+        self._runner.cancel()
         self._counts = {"E": 0, "W": 0, "boots": 0}
         for line in lines:
             self._engine.feed(line)
@@ -290,9 +398,26 @@ class MainWindow(QMainWindow):
         guide = QTextBrowser(openExternalLinks=True)
         guide.setHtml(cheatsheet_html())
         self.serial_tab = SerialTab()
+        self.flash_tab = FlashTab(self.serial_tab)
         tabs.addTab(guide, "Quick start")
         tabs.addTab(self.serial_tab, "Serial monitor")
+        tabs.addTab(self.flash_tab, "Flash firmware")
+        self.sd_tab = SdTab(self.serial_tab)
+        tabs.addTab(self.sd_tab, "SD card")
         self.setCentralWidget(tabs)
+        settings_menu = self.menuBar().addMenu("Settings")
+        settings_menu.addAction("Service system address...", self._edit_service_base)
+
+    def _edit_service_base(self) -> None:
+        st = self.serial_tab
+        text, ok = QInputDialog.getText(
+            self, "Service system address",
+            "Address of the KOTA service system (the box MAC is added at the end):",
+            text=st._service_base())
+        if ok and text.strip().startswith(("https://", "http://")):
+            st._settings.setValue("service/base", text.strip())
+        elif ok:
+            QMessageBox.warning(self, "Service system address", "The address must start with https://")
 
     def closeEvent(self, event):  # noqa: N802 (Qt naming)
         self.serial_tab.shutdown()

kota_tech/ui/matter_qr.py

@@ -0,0 +1,76 @@
+"""Matter pairing QR code on screen, so the technician can scan it from the laptop."""
+
+from __future__ import annotations
+
+import segno
+from PySide6.QtCore import Qt
+from PySide6.QtGui import QColor, QImage, QPainter, QPixmap
+from PySide6.QtWidgets import QDialog, QDialogButtonBox, QLabel, QVBoxLayout, QWidget
+
+from ..matter.payload import SetupPayload
+
+
+def qr_pixmap(text: str, size: int = 260) -> QPixmap:
+    """Black-on-white QR with the quiet zone phones need (4 modules)."""
+    qr = segno.make(text, error="m")
+    matrix = [list(row) for row in qr.matrix_iter(scale=1, border=4)]
+    n = len(matrix)
+    module = max(1, size // n)
+    img = QImage(n * module, n * module, QImage.Format.Format_RGB32)
+    img.fill(QColor("white"))
+    p = QPainter(img)
+    p.setPen(Qt.PenStyle.NoPen)
+    p.setBrush(QColor("black"))
+    for y, row in enumerate(matrix):
+        for x, dark in enumerate(row):
+            if dark:
+                p.drawRect(x * module, y * module, module, module)
+    p.end()
+    return QPixmap.fromImage(img)
+
+
+class MatterQrWidget(QWidget):
+    def __init__(self, payload: SetupPayload, size: int = 260, parent: QWidget | None = None):
+        super().__init__(parent)
+        self.image = QLabel()
+        self.image.setAlignment(Qt.AlignmentFlag.AlignCenter)
+        self.code = QLabel()
+        self.code.setAlignment(Qt.AlignmentFlag.AlignCenter)
+        self.code.setTextInteractionFlags(Qt.TextInteractionFlag.TextSelectableByMouse)
+        f = self.code.font()
+        f.setPointSize(f.pointSize() + 4)
+        f.setBold(True)
+        self.code.setFont(f)
+        self.note = QLabel(wordWrap=True)
+        self.note.setAlignment(Qt.AlignmentFlag.AlignCenter)
+        self.note.setStyleSheet("color:#555")
+        lay = QVBoxLayout(self)
+        lay.addWidget(self.image)
+        lay.addWidget(self.code)
+        lay.addWidget(self.note)
+        self._size = size
+        self.set_payload(payload)
+
+    def set_payload(self, payload: SetupPayload) -> None:
+        self.payload = payload
+        self.image.setPixmap(qr_pixmap(payload.qr_text(), self._size))
+        self.code.setText(f"Manual code: {payload.manual_code_pretty()}")
+        if payload.from_box:
+            src = "QR and manual code exactly as reported by the box (KOTA: matter line)"
+        else:
+            src = f"Discriminator {payload.discriminator} " + (
+                "(from this box's log)" if payload.from_log else
+                "(standard code of the v1.0 firmware - connect the box to confirm)")
+        self.note.setText(f"Scan with the Matter app (Apple Home, Google Home, ...), or type the manual code. "
+                          f"{src}. Same as the sticker on the box.")
+
+
+class MatterQrDialog(QDialog):
+    def __init__(self, payload: SetupPayload, parent: QWidget | None = None):
+        super().__init__(parent)
+        self.setWindowTitle("Matter pairing code")
+        lay = QVBoxLayout(self)
+        lay.addWidget(MatterQrWidget(payload, 320))
+        buttons = QDialogButtonBox(QDialogButtonBox.StandardButton.Close)
+        buttons.rejected.connect(self.reject)
+        lay.addWidget(buttons)

kota_tech/ui/sd_tab.py

@@ -0,0 +1,321 @@
+"""SD card tab: format a card for the sensorbox and write / check ENV.TXT."""
+
+from __future__ import annotations
+
+import threading
+from pathlib import Path
+
+from PySide6.QtCore import QObject, QSettings, Qt, Signal
+from PySide6.QtWidgets import (
+    QCheckBox,
+    QFileDialog,
+    QFormLayout,
+    QGroupBox,
+    QHBoxLayout,
+    QLabel,
+    QLineEdit,
+    QListWidget,
+    QListWidgetItem,
+    QMessageBox,
+    QPlainTextEdit,
+    QPushButton,
+    QVBoxLayout,
+    QWidget,
+)
+
+from ..sd.disks import Disk, list_cards
+from ..sd.envfile import EnvConfig, load_template
+from ..sd.provision import Outcome, check_card, format_and_write, write_env
+
+# The shared settings file the factory script uses, next to the tool folders.
+DEFAULT_TEMPLATE = Path(__file__).resolve().parents[4] / "002-SD_card_format" / "ENV.txt"
+
+
+class _Bridge(QObject):
+    done = Signal(object)
+    listed = Signal(object)
+
+
+def _secret_field() -> tuple[QLineEdit, QCheckBox]:
+    edit = QLineEdit()
+    edit.setEchoMode(QLineEdit.EchoMode.Password)
+    show = QCheckBox("show")
+    show.toggled.connect(lambda on: edit.setEchoMode(
+        QLineEdit.EchoMode.Normal if on else QLineEdit.EchoMode.Password))
+    return edit, show
+
+
+class SdTab(QWidget):
+    def __init__(self, serial_tab, parent: QWidget | None = None):
+        super().__init__(parent)
+        self.serial_tab = serial_tab
+        self._settings = QSettings("KOTA", "TechnicianTool")
+        self._cards: list[Disk] = []
+        self._busy = False
+        self._listing = False
+
+        # --- 1. settings
+        sbox = QGroupBox("1. Settings written to the card (ENV.TXT)")
+        self.template_label = QLabel(wordWrap=True)
+        load_btn = QPushButton("Load settings from ENV file...")
+        load_btn.clicked.connect(self._choose_template)
+        self.url = QLineEdit()
+        self.token, show_token = _secret_field()
+        form = QFormLayout()
+        form.addRow("INFLUX_URL", self.url)
+        trow = QHBoxLayout()
+        trow.addWidget(self.token, 1)
+        trow.addWidget(show_token)
+        form.addRow("INFLUX_TOKEN", trow)
+        self.wifi_box = QGroupBox("Local Wi-Fi instead of Matter (optional)")
+        self.wifi_box.setCheckable(True)
+        self.wifi_box.setChecked(False)
+        self.ssid = QLineEdit()
+        self.password, show_pw = _secret_field()
+        wform = QFormLayout(self.wifi_box)
+        wform.addRow("SSID", self.ssid)
+        prow = QHBoxLayout()
+        prow.addWidget(self.password, 1)
+        prow.addWidget(show_pw)
+        wform.addRow("PASSWORD", prow)
+        self.wifi_note = QLabel(wordWrap=True)
+        self.wifi_note.setStyleSheet("color:#555")
+        wform.addRow(self.wifi_note)
+        self.issues = QLabel(wordWrap=True)
+        sl = QVBoxLayout(sbox)
+        sl.addWidget(self.template_label)
+        sl.addWidget(load_btn, 0, Qt.AlignmentFlag.AlignLeft)
+        sl.addLayout(form)
+        sl.addWidget(self.wifi_box)
+        sl.addWidget(self.issues)
+
+        # --- 2. card
+        cbox = QGroupBox("2. SD card (inside the sensorbox case)")
+        self.card_list = QListWidget()
+        self.card_list.setMinimumHeight(80)
+        self.others = QLabel(wordWrap=True)
+        self.others.setStyleSheet("color:#666")
+        refresh = QPushButton("Refresh cards")
+        refresh.clicked.connect(self.refresh_cards)
+        cl = QVBoxLayout(cbox)
+        cl.addWidget(QLabel("Insert the card into the laptop's reader. Only removable cards are listed."))
+        cl.addWidget(self.card_list)
+        cl.addWidget(self.others)
+        cl.addWidget(refresh, 0, Qt.AlignmentFlag.AlignLeft)
+
+        # --- 3. actions
+        abox = QGroupBox("3. Action")
+        self.format_btn = QPushButton("Format card and write ENV.TXT")
+        self.format_btn.setMinimumHeight(34)
+        self.format_btn.setToolTip("Erases the card: FAT32 (MBR), label KOTA, then writes and verifies ENV.TXT")
+        self.write_btn = QPushButton("Write ENV.TXT only (keep card contents)")
+        self.write_btn.setToolTip("Keeps buffered measurements (BUFFER.TXT) on the card")
+        self.check_btn = QPushButton("Check card")
+        self.check_btn.setToolTip("Show what the box would read from this card")
+        self.format_btn.clicked.connect(self._format)
+        self.write_btn.clicked.connect(self._write_only)
+        self.check_btn.clicked.connect(self._check)
+        self.result = QLabel(wordWrap=True)
+        self.result.setTextFormat(Qt.TextFormat.RichText)
+        self.result.setMargin(8)
+        self.log = QPlainTextEdit(readOnly=True)
+        self.log.setMaximumBlockCount(500)
+        al = QVBoxLayout(abox)
+        for w in (self.format_btn, self.write_btn, self.check_btn, self.result, self.log):
+            al.addWidget(w)
+
+        left = QVBoxLayout()
+        left.addWidget(sbox)
+        left.addStretch(1)
+        right = QVBoxLayout()
+        right.addWidget(cbox)
+        right.addWidget(abox, 1)
+        lay = QHBoxLayout(self)
+        lay.addLayout(left, 1)
+        lay.addLayout(right, 1)
+
+        self._bridge = _Bridge()
+        self._bridge.done.connect(self._on_done)
+        self._bridge.listed.connect(self._on_listed)
+        for w in (self.url, self.token, self.ssid, self.password):
+            w.textChanged.connect(self._update)
+        self.wifi_box.toggled.connect(self._update)
+        self.card_list.currentRowChanged.connect(self._update)
+
+        path = Path(self._settings.value("sd/template", str(DEFAULT_TEMPLATE)))
+        self._load_template(path, quiet=True)
+        self._show_result("", "")
+        self._update()
+
+    # ---------------------------------------------------------- settings
+    def _choose_template(self) -> None:
+        path, _ = QFileDialog.getOpenFileName(self, "ENV file with the InfluxDB settings",
+                                              str(DEFAULT_TEMPLATE.parent), "Text (*.txt *.env);;All files (*)")
+        if path:
+            self._load_template(Path(path))
+
+    def _load_template(self, path: Path, quiet: bool = False) -> None:
+        try:
+            env = load_template(path)
+        except OSError as exc:
+            self.template_label.setText("No settings file loaded - load the ENV file the firmware team gave you.")
+            if not quiet:
+                QMessageBox.warning(self, "Cannot read file", str(exc))
+            return
+        self._settings.setValue("sd/template", str(path))
+        self.template_label.setText(f"Loaded from <code>{path}</code>")
+        self.url.setText(env.influx_url)
+        self.token.setText(env.influx_token)
+        # Wi-Fi is decided per box by the technician, never copied silently.
+        self._update()
+
+    def _env(self) -> EnvConfig:
+        wifi = self.wifi_box.isChecked()
+        return EnvConfig(self.url.text(), self.token.text(),
+                         self.ssid.text() if wifi else "", self.password.text() if wifi else "")
+
+    def _update(self) -> None:
+        env = self._env()
+        issues = env.problems()
+        colour = {"error": "#b03a2e", "warning": "#c77c02", "info": "#2e6da4"}
+        self.issues.setText("<br>".join(f"<span style='color:{colour[i.level]}'>{i.level.upper()}: {i.text}</span>"
+                                        for i in issues) or "<span style='color:#2e9e44'>Settings OK.</span>")
+        fw = self.serial_tab.engine.firmware
+        support = fw.supports_sd_wifi
+        self.wifi_note.setText(
+            "Only for boxes that should NOT use Matter. The box then joins this Wi-Fi directly. "
+            + {True: "The connected box's firmware supports this.",
+               False: "<b>The connected box runs the factory v1.0 firmware, which ignores these settings "
+                      "(it only uses Matter).</b> Newer firmware (after an OTA update) uses them.",
+               None: "Supported by newer firmware only; the factory v1.0 firmware ignores it."}[support])
+        errors = any(i.level == "error" for i in issues)
+        card = self._selected_card()
+        mounted = bool(card and card.volumes and card.volumes[0].mount)
+        self.format_btn.setEnabled(not self._busy and not errors and card is not None)
+        self.write_btn.setEnabled(not self._busy and not errors and mounted)
+        self.check_btn.setEnabled(not self._busy and mounted)
+
+    # -------------------------------------------------------------- cards
+    def showEvent(self, event):  # noqa: N802
+        self.refresh_cards()
+        super().showEvent(event)
+
+    def refresh_cards(self) -> None:
+        """List cards in the background: the UI never waits for a slow card reader."""
+        if self._busy or self._listing:
+            return
+        self._listing = True
+        self.others.setText("Looking for SD cards...")
+
+        def worker():
+            try:
+                result = list_cards()
+            except Exception as exc:        # show it, never leave the tab stuck
+                result = ([], [], str(exc))
+            self._bridge.listed.emit(result)
+
+        threading.Thread(target=worker, daemon=True, name="sd-list").start()
+
+    def _on_listed(self, result) -> None:
+        self._listing = False
+        self._cards, others = result[0], result[1]
+        if len(result) > 2:
+            self.others.setText(f"Could not list cards: {result[2]}")
+            self._update()
+            return
+        self.card_list.clear()
+        for d in self._cards:
+            self.card_list.addItem(QListWidgetItem(d.label))
+        if self._cards:
+            self.card_list.setCurrentRow(0)
+        empty = [d for d in others if not d.has_media]
+        big = [d for d in others if d.has_media]
+        notes = []
+        if empty:
+            notes.append("Card reader found but no card inserted: " + ", ".join(d.name for d in empty) + ".")
+        if big:
+            notes.append("Not offered (too large to be an SD card): " + ", ".join(d.label for d in big) + ".")
+        if not self._cards and not empty:
+            notes.append("No SD card or card reader found.")
+        self.others.setText(" ".join(notes))
+        self._update()
+
+    def _selected_card(self) -> Disk | None:
+        i = self.card_list.currentRow()
+        return self._cards[i] if 0 <= i < len(self._cards) else None
+
+    # ------------------------------------------------------------ actions
+    def _format(self) -> None:
+        card = self._selected_card()
+        if card is None:
+            return
+        box = QMessageBox(QMessageBox.Icon.Warning, "Format SD card",
+                          f"ALL DATA ON THIS CARD WILL BE ERASED:\n\n{card.label}\n\n"
+                          "Buffered measurements on the card are lost too. Continue?",
+                          QMessageBox.StandardButton.Cancel, self)
+        erase = box.addButton("Erase and format", QMessageBox.ButtonRole.DestructiveRole)
+        box.exec()
+        if box.clickedButton() is not erase:
+            return
+        env = self._env()
+        self._run(lambda: format_and_write(card, env), f"Formatting {card.name}...")
+
+    def _write_only(self) -> None:
+        card = self._selected_card()
+        if card and card.volumes:
+            env, mount = self._env(), card.volumes[0].mount
+            self._run(lambda: write_env(mount, env), f"Writing ENV.TXT to {mount}...")
+
+    def _check(self) -> None:
+        card = self._selected_card()
+        if not (card and card.volumes):
+            return
+        vol = card.volumes[0]
+        rep = check_card(vol.mount, vol.filesystem)
+        lines = [f"Card {vol.mount} ({vol.filesystem or '?'})"]
+        if rep.env:
+            lines += [f"  {k}={v}" for k, v in rep.env.masked().items()]
+            lines += [f"  {i.level.upper()}: {i.text}" for i in rep.env.issues]
+        lines += [f"  PROBLEM: {p}" for p in rep.problems]
+        if rep.buffered_lines is not None:
+            lines.append(f"  {rep.buffered_lines} measurement lines buffered on the card, waiting for upload.")
+        self.log.appendPlainText("\n".join(lines))
+        ok = not rep.problems and rep.env is not None and rep.env.ok
+        self._show_result("Card is OK for the sensorbox." if ok else "Card has problems - see below. "
+                          "Use 'Write ENV.TXT only' or 'Format card'.", "ok" if ok else "error")
+
+    def _run(self, job, what: str) -> None:
+        self._busy = True
+        self._update()
+        self._show_result(what, "info")
+
+        def worker():
+            try:
+                out = job()
+            except Exception as exc:   # report, never leave the tab busy
+                out = Outcome(False, f"Unexpected error: {exc}")
+            self._bridge.done.emit(out)
+
+        threading.Thread(target=worker, daemon=True).start()
+
+    def _on_done(self, out: Outcome) -> None:
+        self._busy = False
+        for line in out.log:
+            self.log.appendPlainText(line)
+        self.log.appendPlainText(out.message)
+        if out.ok:
+            self._show_result(f"<b>{out.message}</b><br>Insert the next card and press Refresh cards to "
+                              "provision another one.", "ok")
+        else:
+            self._show_result(f"<b>{out.message}</b>", "error")
+        self.refresh_cards()
+
+    def _show_result(self, html: str, kind: str) -> None:
+        colours = {"ok": ("#2e9e44", "#e3f4e7"), "info": ("#2e6da4", "#e3edf7"), "error": ("#d9534f", "#f9e0df")}
+        self.result.setVisible(bool(html))
+        if html:
+            border, bg = colours[kind]
+            self.result.setStyleSheet(f"QLabel {{ border:2px solid {border}; background:{bg}; border-radius:6px; }}")
+            self.result.setText(html)
+
+

pyproject.toml

@@ -1,15 +1,17 @@
 [project]
 name = "kota-technician-tool"
-version = "0.2.0"
+version = "0.8.0"
 description = "KOTA sensorbox technician diagnostic tool (demo)"
 requires-python = ">=3.11,<3.14"
 dependencies = [
     "pyserial>=3.5",
     "PySide6-Essentials>=6.7",
+    "esptool~=4.8",   # 4.x CLI (write_flash/read_flash); v5 renamed commands
+    "segno>=1.6",     # QR code for Matter pairing (pure Python)
 ]
 
 [dependency-groups]
-dev = ["pytest>=8"]
+dev = ["pytest>=8", "pyfatfs>=1.0", "setuptools<81"]   # pyfatfs (independent FAT32 check) needs pkg_resources
 
 [tool.uv]
 package = false

run_macos.command

@@ -2,8 +2,10 @@
 # Double-click in Finder, or run:  bash run_macos.command
 cd "$(dirname "$0")" || exit 1
 
+# If Finder refuses to open this file (Google Drive drops the executable bit), run it once as:
+#   bash run_macos.command     (or: chmod +x run_macos.command)
 # Keep the virtual environment out of the (Google Drive) tool folder.
-export UV_PROJECT_ENVIRONMENT="$HOME/Library/Caches/KotaTechnicianTool/venv-0.2"
+export UV_PROJECT_ENVIRONMENT="$HOME/Library/Caches/KotaTechnicianTool/venv-0.8"
 export PATH="$HOME/.local/bin:$PATH"
 
 if ! command -v uv >/dev/null 2>&1; then

run_windows.bat

@@ -3,7 +3,7 @@ setlocal
 cd /d "%~dp0"
 
 rem Keep the virtual environment out of the (Google Drive) tool folder.
-set "UV_PROJECT_ENVIRONMENT=%LOCALAPPDATA%\KotaTechnicianTool\venv-0.2"
+set "UV_PROJECT_ENVIRONMENT=%LOCALAPPDATA%\KotaTechnicianTool\venv-0.8"
 set "PATH=%USERPROFILE%\.local\bin;%PATH%"
 
 where uv >nul 2>nul

tests/fixtures/synthetic_fw1.0.16_healthy.txt

@@ -0,0 +1,22 @@
+ESP-ROM:esp32s3-20210327
+rst:0x15 (USB_UART_CHIP_RESET),boot:0x8 (SPI_FAST_FLASH_BOOT)
+I (1299) app_init: Project name:     kota-sensorboard
+I (1303) app_init: App version:      1.0.16
+I (1307) app_init: Compile time:     Sep 28 2026 15:07:57
+I (1317) app_init: ELF file SHA256:  4f10989e2...
+E (1402) ID: [E-MAIN-04] Device MAC address: A4:CB:8F:C9:46:F8
+I (1480) KOTA: led previous_boot status=CONNECTION_ERROR code=1
+I (1481) KOTA: led color=purple pattern=blink period=1000ms
+I (1790) KOTA: i2c SDA=1 SCL=1 0x39=AS7341 0x68=DS1307 0x6B=SEN66 0x76=BME688
+I (1795) KOTA: rtc running=1 time=2026-09-28T15:20:01
+I (1850) SD_CARD: SD card mounted successfully
+I (1990) KOTA: sd type=SDHC size=7.4GB fs=FAT32 free=7.3GB env_keys=INFLUX_URL,INFLUX_TOKEN buffer_lines=0
+I (2300) MAIN: ESP-Matter started successfully
+I (2310) KOTA: boot fw=1.0.16 build=4f10989e hw=2 mac=A4CB8FC946F8 reset=USB_UART_CHIP_RESET mode=matter commissioned=1 last_restart=none
+I (2315) KOTA: matter fabrics=1 window=closed qr=MT:Y.K9042C00KA0648G00 manual=34970112332
+I (2400) KOTA: mic enabled=1 (GPIO3=0, expected 0)
+I (4481) KOTA: led color=green pattern=solid
+I (5200) WIFI_SERVICE: Got IP address
+I (6100) SNTP: Time synchronized: Mon Sep 28 15:20:06 2026
+I (8100) KOTA: rtc verify running=1 delta=2s ok=1
+I (60010) KOTA: health up=60s status=OK wifi=connected rssi=-58 time_valid=1 sd=ok buffer=0 heap=143220 psram=7.6M last_upload=14s ota=registered

tests/test_engine.py

@@ -43,16 +43,20 @@ APP = ["I (1299) app_init: Project name:     kota-sensorboard",
 # ------------------------------------------------------------------ rules
 
 def test_rules_load_and_have_no_cycles():
-    rules = load_rules()
-    by_id = {r.id: r for r in rules}
-    for r in rules:
-        seen, todo = set(), list(r.explained_by)
+    from kota_tech.diag import kota
+    graph = {r.id: r.explained_by for r in load_rules()}
+    for st in ("ERROR", "OUT_OF_RESOURCES", "CONNECTION_ERROR", "RTC_ERROR", "SD_ERROR", "RESETING", "HTTP_SERVER"):
+        for code in range(7):
+            if sf := kota.status_finding(st, code):
+                graph[sf[0]] = sf[5]
+    for start, explained_by in graph.items():
+        seen, todo = set(), list(explained_by)
         while todo:
             rid = todo.pop()
-            assert rid != r.id, f"explained_by cycle through {r.id}"
+            assert rid != start, f"explained_by cycle through {start}"
             if rid not in seen:
                 seen.add(rid)
-                todo += by_id[rid].explained_by
+                todo += graph.get(rid, ())
 
 
 # --------------------------------------------------------- real captures
@@ -233,3 +237,23 @@ def test_session_log_format(tmp_path):
     for ln in lines:
         e.feed(ln)
     assert e.boot.tool_reset
+
+
+def test_live_brownout_loop_is_a_power_problem():
+    # Real capture (2026-09-28): "E BOD: Brownout detector was triggered" has no
+    # timestamp and the ROM reports RTC_SW_SYS_RST, not a brown-out reset.
+    r = replay("live_brownout_loop_A4CB8FC946F8_fw1.0.txt")
+    top = r.roots[0]
+    assert top.finding.rule_id == "reboot.brownout" and top.finding.count >= 5
+    assert "reboot.loop" in {c.rule_id for c in top.consequences}
+    assert r.verdict.startswith("Problem: Power supply")
+
+
+@pytest.mark.parametrize("line", [
+    "E (2893) wifi:sta is connecting, return error",
+    "E (2892) chip[DL]: esp_wifi_connect() failed: ESP_ERR_WIFI_CONN",
+    "E (5120) chip[DL]: Failed to get configured network when updating network status: Error ESP32:0x0500300F",
+])
+def test_harmless_wifi_start_errors_are_not_reported(line):
+    _, r = run(BOOT + APP + [line])
+    assert r.roots == [] and "Unrecognised" not in r.to_text()

tests/test_fat32.py

@@ -0,0 +1,103 @@
+"""FAT32/MBR layout: field-level checks against the FAT spec on an in-memory
+disk, plus an independent FAT implementation (pyfatfs) mounting the result."""
+
+import struct
+
+import pytest
+
+from kota_tech.sd import fat32
+
+MiB, GiB = 1024**2, 1024**3
+
+
+def make_disk(size: int, label="KOTA") -> tuple[bytearray, fat32.Fat32Layout]:
+    lay = fat32.plan(size)
+    disk = bytearray(b"\xAA" * size)                # old garbage everywhere
+    zeros, writes = fat32.build(lay, label, 0x12345678, 0xCAFEBABE, size)
+    for off, n in zeros:
+        disk[off:off + n] = bytes(n)
+    for off, data in writes:
+        disk[off:off + len(data)] = data
+    return disk, lay
+
+
+@pytest.fixture(scope="module")
+def small():
+    return make_disk(96 * MiB)
+
+
+def test_mbr_has_one_fat32_lba_partition(small):
+    disk, lay = small
+    assert disk[510:512] == b"\x55\xAA"
+    status, ptype, lba, count = struct.unpack_from("<B3xB3xII", disk, 0x1BE)
+    assert (status, ptype, lba) == (0, 0x0C, fat32.PART_START // 512)
+    assert count == lay.part_sectors
+    assert disk[0x1CE:0x1FE] == bytes(48)                    # other entries empty
+    assert struct.unpack_from("<I", disk, 0x1B8)[0] == 0xCAFEBABE
+
+
+def test_boot_sector_fields(small):
+    disk, lay = small
+    b = disk[fat32.PART_START:fat32.PART_START + 512]
+    bps, spc, rsvd, nfats, root_ent, tot16, media, fat16 = struct.unpack_from("<HBHBHHBH", b, 11)
+    assert (bps, spc, rsvd, nfats, root_ent, tot16, media, fat16) == (512, lay.sectors_per_cluster, 32, 2, 0, 0, 0xF8, 0)
+    hidden, tot32, fatsz, _, _, root_clus, fsinfo, bkboot = struct.unpack_from("<IIIHHIHH", b, 28)
+    assert hidden == fat32.PART_START // 512 and tot32 == lay.part_sectors and fatsz == lay.fat_sectors
+    assert (root_clus, fsinfo, bkboot) == (2, 1, 6)
+    assert b[66] == 0x29 and b[71:82] == b"KOTA       " and b[82:90] == b"FAT32   " and b[510:] == b"\x55\xAA"
+    assert disk[fat32.PART_START + 6 * 512:fat32.PART_START + 7 * 512] == b          # backup boot sector
+
+
+def test_fat_is_large_enough_and_clusters_valid(small):
+    _, lay = small
+    assert fat32.MIN_CLUSTERS <= lay.clusters
+    assert lay.fat_sectors * 512 // 4 >= lay.clusters + 2
+    assert lay.data_start + lay.clusters * lay.sectors_per_cluster <= lay.part_sectors
+
+
+def test_fsinfo_and_fat_entries(small):
+    disk, lay = small
+    info = disk[fat32.PART_START + 512:fat32.PART_START + 1024]
+    assert struct.unpack_from("<I", info, 0)[0] == 0x41615252
+    assert struct.unpack_from("<III", info, 484) == (0x61417272, lay.clusters - 1, 3)
+    assert struct.unpack_from("<I", info, 508)[0] == 0xAA550000
+    for fat in range(2):
+        off = fat32.PART_START + (32 + fat * lay.fat_sectors) * 512
+        assert struct.unpack_from("<III", disk, off) == (0x0FFFFFF8, 0x0FFFFFFF, 0x0FFFFFFF)
+        assert disk[off + 12:off + lay.fat_sectors * 512] == bytes(lay.fat_sectors * 512 - 12)
+
+
+def test_root_holds_only_the_label(small):
+    disk, lay = small
+    root = fat32.PART_START + lay.data_start * 512
+    assert disk[root:root + 11] == b"KOTA       " and disk[root + 11] == 0x08
+    assert disk[root + 32:root + lay.sectors_per_cluster * 512] == bytes(lay.sectors_per_cluster * 512 - 32)
+
+
+@pytest.mark.parametrize("size,spc", [(4 * GiB, 8), (15 * GiB, 16), (31_457_280_000, 32), (64 * GiB, 32)])
+def test_real_card_sizes(size, spc):
+    lay = fat32.plan(size)
+    assert lay.sectors_per_cluster == spc
+    assert lay.part_sectors * 512 <= min(size - fat32.PART_START, 32 * GiB)
+    assert fat32.MIN_CLUSTERS <= lay.clusters < fat32.MAX_CLUSTERS
+
+
+def test_too_small_card_refused():
+    with pytest.raises(ValueError):
+        fat32.plan(20 * MiB)
+
+
+def test_independent_fat_implementation_mounts_it(small, tmp_path):
+    pyfat = pytest.importorskip("pyfatfs.PyFat")
+    disk, lay = small
+    img = tmp_path / "part.img"
+    img.write_bytes(bytes(disk[fat32.PART_START:fat32.PART_START + lay.part_sectors * 512]))
+    fs = pyfat.PyFat()
+    fs.open(str(img))
+    assert fs.fat_type == pyfat.PyFat.FAT_TYPE_FAT32
+    assert fs.bpb_header["BPB_TotSec32"] == lay.part_sectors
+    fs.close()
+    from pyfatfs.PyFatFS import PyFatFS
+    with PyFatFS(str(img)) as ffs:                       # write + read back a file like ENV.TXT
+        ffs.writebytes("/ENV.TXT", b"INFLUX_URL=x\n")
+        assert ffs.readbytes("/ENV.TXT") == b"INFLUX_URL=x\n"

tests/test_flash.py

@@ -0,0 +1,247 @@
+"""Flashing: image validation on the real image in firmware/, the folder
+catalogue (compile-date order), plan building, and the runner against a fake
+esptool (no hardware)."""
+
+import hashlib
+import sys
+import threading
+from pathlib import Path
+
+import pytest
+
+from kota_tech.flash.image import ImageError, app_image_length, folder_images, inspect_image
+from kota_tech.flash.plan import Mode, build_plan, check_partition_table
+from kota_tech.flash.runner import FlashRunner
+
+FW_DIR = Path(__file__).resolve().parents[1] / "firmware"
+FW = sorted(FW_DIR.glob("*.bin"))[0]
+
+
+@pytest.fixture(scope="module")
+def image():
+    imgs, problems = folder_images()
+    assert imgs and problems == []
+    return imgs[0]
+
+
+# ------------------------------------------------------------------ image
+
+def test_folder_image_is_a_kota_build(image):
+    assert image.app.project == "kota-sensorboard"
+    assert image.kind == "merged"
+    assert image.app.built_at is not None                  # compile date is readable
+    assert image.flash_size == "8MB"
+    assert image.partition("ota_0").offset == 0x40000
+    assert image.partition("otadata").offset == 0x31000
+    assert image.partition("nvs").offset == 0x10000
+
+
+def test_label_starts_with_compile_date(image):
+    label = image.label()
+    assert label.startswith(f"Compiled {image.app.built_at:%Y-%m-%d %H:%M}")
+    assert image.app.version in label and image.name in label
+
+
+def test_app_bytes_are_a_complete_app_image(image):
+    app = image.app_bytes()
+    assert app[0] == 0xE9
+    assert len(app) == len(image.data) - 0x40000              # ends where the file ends
+    assert len(image.blank_otadata()) == 0x2000 and set(image.blank_otadata()) == {0xFF}
+
+
+@pytest.mark.parametrize("patch,msg", [
+    ((0, 0x00), "not an ESP32 firmware"),
+    ((12, 0x05), "not ESP32-S3"),
+])
+def test_wrong_images_are_rejected(tmp_path, patch, msg):
+    data = bytearray(FW.read_bytes())
+    data[patch[0]] = patch[1]
+    p = tmp_path / "x.bin"
+    p.write_bytes(data)
+    with pytest.raises(ImageError, match=msg):
+        inspect_image(p)
+
+
+def test_integrity_check_on_folder_image(image):
+    d = image.data
+    assert app_image_length(d, 0) > 0                          # bootloader
+    assert app_image_length(d, 0x40000) == len(d) - 0x40000    # app ends exactly at file end
+
+
+@pytest.mark.parametrize("damage,msg", [
+    (lambda b: b[:len(b) // 2], "truncated"),
+    (lambda b: b[:0x40000 + 5000] + bytes([b[0x40000 + 5000] ^ 1]) + b[0x40000 + 5001:], "corrupted"),
+])
+def test_corrupted_or_truncated_images_refused(tmp_path, damage, msg):
+    p = tmp_path / "broken.bin"
+    p.write_bytes(damage(FW.read_bytes()))
+    with pytest.raises(ImageError, match=msg):
+        inspect_image(p)
+
+
+# ------------------------------------------------------- firmware folder
+
+def _with_compile_date(data: bytes, date: str, time: str, off: int = 0x40000) -> bytes:
+    """Copy of a merged image whose app claims another compile date, with the
+    segment checksum and appended SHA-256 recomputed (a valid, different build)."""
+    d = bytearray(data)
+    desc = off + 0x20
+    old = bytes(d[desc + 80:desc + 112])
+    new = time.encode().ljust(16, b"\0") + date.encode().ljust(16, b"\0")
+    d[desc + 80:desc + 112] = new
+    end = off + app_image_length(data, off) - 32      # SHA-256 follows the checksum byte
+    xor = 0
+    for a, b in zip(old, new):
+        xor ^= a ^ b
+    d[end - 1] ^= xor
+    d[end:end + 32] = hashlib.sha256(bytes(d[off:end])).digest()
+    return bytes(d)
+
+
+def test_folder_lists_builds_newest_compile_date_first(tmp_path):
+    data = FW.read_bytes()
+    (tmp_path / "a_old.bin").write_bytes(_with_compile_date(data, "Jan  5 2026", "08:00:00"))
+    (tmp_path / "z_new.bin").write_bytes(_with_compile_date(data, "Dec 24 2026", "18:30:00"))
+    (tmp_path / "m_mid.bin").write_bytes(_with_compile_date(data, "Jun 15 2026", "12:00:00"))
+    imgs, problems = folder_images(tmp_path)
+    assert problems == []
+    assert [i.name for i in imgs] == ["z_new.bin", "m_mid.bin", "a_old.bin"]
+    assert imgs[0].label().startswith("Compiled 2026-12-24 18:30")
+    assert imgs[2].label().startswith("Compiled 2026-01-05 08:00")
+
+
+def test_folder_reports_bad_files_and_duplicates(tmp_path):
+    data = FW.read_bytes()
+    (tmp_path / "good.bin").write_bytes(data)
+    (tmp_path / "copy.bin").write_bytes(data)
+    (tmp_path / "notes.bin").write_bytes(b"hello firmware team")
+    (tmp_path / "readme.txt").write_text("ignored: not a .bin")
+    imgs, problems = folder_images(tmp_path)
+    assert len(imgs) == 1
+    assert any("notes.bin" in p and "not an ESP32 firmware" in p for p in problems)
+    assert any("same file as" in p for p in problems)
+    assert not any("readme" in p for p in problems)
+
+
+def test_app_only_file_uses_the_merged_layout(tmp_path, image):
+    (tmp_path / "merged.bin").write_bytes(image.data)
+    (tmp_path / "kota-sensorboard.bin").write_bytes(
+        _with_compile_date(image.data, "Dec  1 2026", "10:00:00")[0x40000:])
+    imgs, problems = folder_images(tmp_path)
+    assert problems == []
+    app = next(i for i in imgs if i.kind == "app")
+    assert imgs[0] is app                                      # newer compile date first
+    assert app.partition("ota_0").offset == 0x40000 and "app only" in app.label()
+    assert [s.kind for s in build_plan(app, Mode.APP_ONLY, "COM5", tmp_path / "w").steps] == ["read_pt", "write"]
+    with pytest.raises(ValueError, match="app only"):
+        build_plan(app, Mode.FULL, "COM5", tmp_path / "w")
+
+
+def test_app_only_file_without_merged_image_is_not_offered(tmp_path, image):
+    (tmp_path / "kota-sensorboard.bin").write_bytes(image.app_bytes())
+    imgs, problems = folder_images(tmp_path)
+    assert imgs == [] and "no complete (merged) image" in problems[0]
+
+
+def test_empty_or_missing_folder(tmp_path):
+    assert folder_images(tmp_path) == ([], [])
+    imgs, problems = folder_images(tmp_path / "nope")
+    assert imgs == [] and "not found" in problems[0]
+
+
+# ------------------------------------------------------------------- plan
+
+def test_app_only_plan_keeps_nvs(image, tmp_path):
+    plan = build_plan(image, Mode.APP_ONLY, "COM5", tmp_path)
+    kinds = [s.kind for s in plan.steps]
+    assert kinds == ["read_pt", "write"]
+    write = plan.steps[-1].args
+    offsets = [a for a in write if a.startswith("0x")]
+    assert offsets == ["0x31000", "0x40000"]          # otadata + ota_0 only
+    assert "0x10000" not in write and "0x0" not in write   # NVS / bootloader untouched
+    assert write[write.index("--after") + 1] == "hard_reset"
+    assert (tmp_path / "app_ota0.bin").read_bytes() == image.app_bytes()
+
+
+def test_full_plan_with_backup(image, tmp_path):
+    backup = tmp_path / "bk.bin"
+    plan = build_plan(image, Mode.FULL, "COM5", tmp_path, backup_to=backup)
+    assert [s.kind for s in plan.steps] == ["backup", "write"]
+    assert plan.steps[0].args[-3:] == ["0", "0x800000", str(backup)]
+    assert plan.steps[0].args[plan.steps[0].args.index("--after") + 1] == "no_reset"
+    assert plan.steps[1].args[-2:] == ["0x0", str(image.path)]
+    assert "Back up" in plan.summary()[0]
+
+
+def test_partition_table_check(image):
+    assert check_partition_table(image.partition_table, image) is None
+    assert "blank" in check_partition_table(b"\xff" * 0xC00, image)
+    other = bytearray(image.partition_table)
+    other[40] ^= 1
+    assert "different partition layout" in check_partition_table(bytes(other), image)
+
+
+# ----------------------------------------------------------------- runner
+
+FAKE = """
+import sys, pathlib
+args = sys.argv[1:]
+if "read_flash" in args:
+    out = pathlib.Path(args[-1])
+    src = pathlib.Path(r"{fw}").read_bytes()
+    off, size = int(args[-3], 0), int(args[-2], 0)
+    {pt_line}
+    print("Read ... (50 %)", end="\\r"); print("Read ... (100 %)")
+    sys.exit(0)
+if "write_flash" in args:
+    for p in (10, 60, 100):
+        print(f"Writing at 0x00040000... ({{p}} %)", end="\\r", flush=True)
+    print(); print("Hash of data verified.")
+    sys.exit({write_code})
+"""
+
+
+def _fake(tmp_path, write_code=0, pt="same", fail_text=""):
+    pt_line = {"same": "out.write_bytes(src[off:off+size])",
+               "blank": "out.write_bytes(b'\\xff' * size)"}[pt]
+    script = FAKE.format(fw=FW, pt_line=pt_line, write_code=write_code)
+    if fail_text:
+        script = script.replace('print("Hash of data verified.")', f'print("{fail_text}")')
+    f = tmp_path / "fake_esptool.py"
+    f.write_text(script)
+    return [sys.executable, str(f)]
+
+
+def _run(plan, cmd):
+    steps, progress, output, done = [], [], [], threading.Event()
+    result = {}
+    r = FlashRunner(plan, lambda i, t: steps.append(i), progress.append, output.append,
+                    lambda res: (result.setdefault("r", res), done.set()), esptool_cmd=cmd)
+    r.start()
+    assert done.wait(30)
+    return result["r"], steps, progress, output
+
+
+def test_runner_app_only_success(image, tmp_path):
+    plan = build_plan(image, Mode.APP_ONLY, "COM5", tmp_path)
+    res, steps, progress, output = _run(plan, _fake(tmp_path))
+    assert res.ok, res
+    assert steps == [0, 1]
+    assert 60 in progress and progress[-1] == 100
+    assert any("Hash of data verified" in o for o in output)
+
+
+def test_runner_refuses_app_only_on_blank_chip(image, tmp_path):
+    plan = build_plan(image, Mode.APP_ONLY, "COM5", tmp_path)
+    res, steps, *_ = _run(plan, _fake(tmp_path, pt="blank"))
+    assert not res.ok and "Full mode" in res.message
+    assert steps == [0]                       # never reached the write step
+
+
+def test_runner_reports_connect_failure_with_hint(image, tmp_path):
+    plan = build_plan(image, Mode.FULL, "COM5", tmp_path)
+    cmd = _fake(tmp_path, write_code=2,
+                fail_text="A fatal error occurred: Failed to connect to ESP32-S3: No serial data received.")
+    res, *_ = _run(plan, cmd)
+    assert not res.ok and res.failed_step == 0
+    assert "BOOT" in res.hint

tests/test_guides.py

@@ -0,0 +1,244 @@
+"""Guided troubleshooting: runner + engine with simulated technician
+answers, simulated board output and a fake clock."""
+
+from pathlib import Path
+
+import pytest
+
+from kota_tech.core.logfile import read_log_file
+from kota_tech.core.logline import parse_line
+from kota_tech.diag.engine import DiagnosticsEngine, Severity
+from kota_tech.diag.guides import LED_ANSWERS, GuideRunner, load_guides, recommended
+
+FIX = Path(__file__).parent / "fixtures"
+BOOT = ["ESP-ROM:esp32s3-20210327", "rst:0x1 (POWERON),boot:0x8 (SPI_FAST_FLASH_BOOT)",
+        "I (1299) app_init: Project name:     kota-sensorboard",
+        "I (1317) app_init: ELF file SHA256:  45fa9d5b9..."]
+
+
+class Clock:
+    def __init__(self):
+        self.t = 1000.0
+
+    def __call__(self):
+        return self.t
+
+
+@pytest.fixture
+def rig():
+    engine, clock, actions, log = DiagnosticsEngine(), Clock(), [], []
+    runner = GuideRunner(engine, on_action=lambda a: actions.append(a) or True,
+                         on_log=log.append, clock=clock)
+
+    def board(*lines):
+        for ln in lines:
+            parsed = parse_line(ln)
+            engine.feed(parsed)
+            runner.feed(parsed)
+
+    return engine, runner, clock, actions, board, log
+
+
+def _bench(engine):
+    for ln in read_log_file(FIX / "live_boot_A4CB8FC946F8_fw1.0.txt"):
+        engine.feed(ln)
+
+
+def test_all_guides_load_and_validate():
+    guides = load_guides()
+    assert "quick" in guides and len(guides) >= 8
+    led = guides["quick"].steps["led"]
+    assert set(led.route) == set(LED_ANSWERS)   # every colour has a route
+
+
+def test_recommendations_follow_findings(rig):
+    engine, *_ = rig
+    _bench(engine)
+    ids = [g.id for g in recommended(load_guides(), engine)]
+    assert ids[0] == "quick"
+    assert ids.index("network") < ids.index("clock")    # root order preserved
+    assert "mic" in ids
+
+
+def test_purple_uncommissioned_box_skips_to_pairing_and_follows_it_live(rig):
+    engine, runner, clock, _, board, log = rig
+    _bench(engine)                               # log: not commissioned, LED purple
+    runner.start("quick")
+    runner.answer("PURPLE")
+    # "Was it paired before?" is skipped: the log already shows it is not.
+    assert runner.step.id == "pair_intro"
+    runner.proceed()
+    assert runner.view().waiting and runner.step.id == "pair_start"
+    board("I (90000) MAIN: Commissioning session started")
+    assert runner.step.id == "pair_wifi"
+    board("I (95000) MAIN: Commissioning complete")
+    assert runner.step.id == "pair_time"
+    board("I (99000) SNTP: Time synchronized: Sat Sep 26 16:00:00 2026")
+    assert runner.step.id == "pair_upload"
+    board("I (120000) INFLUX: HTTP request performed, status code: 204")
+    assert runner.end.id == "online" and runner.end.severity == "ok"
+    assert any("Paired" in t or "paired" in t for t in engine.technician)
+    assert "matter.not_commissioned" not in {rc.finding.rule_id for rc in engine.report().roots}
+    assert any(l.startswith("technician:") for l in log)
+
+
+def test_pairing_timeout_asks_what_the_app_shows(rig):
+    engine, runner, clock, _, board, _ = rig
+    _bench(engine)
+    runner.start("network")
+    runner.proceed()                             # pair_intro -> pair_start
+    clock.t += 301
+    runner.tick()
+    assert runner.step.id == "not_found"
+    runner.answer("1")
+    assert runner.end.id == "ble_not_found"
+    f = engine.findings["tech.network.ble_not_found"]
+    assert f.severity == Severity.ERROR and f.active
+
+
+def test_led_mismatch_is_recorded(rig):
+    engine, runner, *_ = rig
+    _bench(engine)                               # log implies PURPLE
+    runner.start("quick")
+    runner.answer("GREEN")
+    f = engine.findings["tech.led_mismatch"]
+    assert "Green" in f.title and "Purple" in f.title
+    assert runner.step.id == "heartbeat"
+
+
+def test_led_match_records_nothing(rig):
+    engine, runner, *_ = rig
+    _bench(engine)
+    runner.start("quick")
+    runner.answer("PURPLE")
+    assert "tech.led_mismatch" not in engine.findings
+
+
+def test_blue_reseat_fixed_after_power_cycle(rig):
+    engine, runner, clock, _, board, _ = rig
+    board(*BOOT, "E (3511) MAIN: Failed to initialize RTC: ESP_ERR_TIMEOUT")
+    runner.start("quick")
+    runner.answer("BLUE")
+    runner.proceed()
+    runner.proceed()                             # -> verify (technician power-cycles)
+    assert runner.step.id == "verify"
+    board(*BOOT, "I (14800) temperature_sensor: Range [20°C ~ 100°C], error < 2°C")
+    assert runner.end.id == "i2c_fixed"
+
+
+def test_blue_still_failing_then_module(rig):
+    engine, runner, clock, _, board, _ = rig
+    board(*BOOT, "E (3511) MAIN: Failed to initialize RTC: ESP_ERR_TIMEOUT")
+    runner.start("rtc_i2c")
+    runner.proceed()
+    runner.proceed()
+    board(*BOOT, "E (3511) MAIN: Failed to initialize RTC: ESP_ERR_TIMEOUT")
+    assert runner.step.id == "damaged"
+    runner.answer("1")
+    assert runner.end.id == "rtc_module"
+
+
+def test_white_skips_portal_question_on_v1_firmware(rig):
+    engine, runner, clock, _, board, _ = rig
+    board(*BOOT)                                 # known v1.0: no setup portal
+    runner.start("white")
+    runner.answer("1")                           # nobody held the button
+    assert runner.step.id == "sd_reseat"
+
+
+def test_white_asks_portal_question_on_unknown_firmware(rig):
+    engine, runner, clock, _, board, _ = rig
+    board("ESP-ROM:esp32s3-20210327", "I (1317) app_init: ELF file SHA256:  0123456789...")
+    runner.start("white")
+    runner.answer("1")
+    assert runner.step.id == "portal"
+
+
+def test_red_routes_to_failing_sensor_and_names_it(rig):
+    engine, runner, clock, _, board, _ = rig
+    board(*BOOT, "E (14000) MAIN: Failed to initialize SEN66: ESP_ERR_TIMEOUT")
+    runner.start("sensors")
+    assert runner.step.id == "reseat"
+    assert "SEN66" in runner.view().text
+    runner.proceed()
+    board(*BOOT, "E (14000) MAIN: Failed to initialize SEN66: ESP_ERR_TIMEOUT")
+    assert runner.end.id == "sensor_replace"
+
+
+def test_reboot_loop_resets_board_then_routes_by_cause(rig):
+    engine, runner, clock, actions, board, _ = rig
+    runner.start("reboot_loop")
+    assert actions == ["reset"]
+    board(*BOOT, "E (1519) SD_CARD: Failed to initialize the card (ESP_ERR_TIMEOUT). x")
+    clock.t += 46
+    runner.tick()
+    assert runner.guide.id == "white"
+
+
+def test_reset_action_failure_is_shown(rig):
+    engine = DiagnosticsEngine()
+    runner = GuideRunner(engine, on_action=lambda a: False, clock=Clock())
+    runner.start("reboot_loop")
+    assert "connect" in runner.view().note.lower()
+
+
+def test_mic_switch_flip_verified_without_restart(rig):
+    engine, runner, clock, actions, board, _ = rig
+    _bench(engine)
+    runner.start("mic")
+    assert runner.step.id == "switch"
+    assert "above the power switch" in runner.view().text
+    runner.answer("0")                           # flipped the external switch
+    assert actions == []                         # the firmware re-reads it; no reset
+    board("I (95000) MICROPHONE: Read 300000 bytes in 4936 ms")
+    assert runner.end.id == "mic_on"
+
+
+def test_mic_switch_no_effect_in_both_positions(rig):
+    engine, runner, clock, actions, board, _ = rig
+    _bench(engine)
+    runner.start("mic")
+    runner.answer("0")
+    board("W (95000) MICROPHONE: Microphone is in shutdown state, skipping sample collection")
+    assert runner.step.id == "flip_back"
+    runner.answer("0")
+    board("W (105000) MICROPHONE: Microphone is in shutdown state, skipping sample collection")
+    assert runner.end.id == "mic_switch_faulty"
+
+
+def test_mic_clap_test_detects_dead_mic(rig):
+    engine, runner, clock, _, board, _ = rig
+    board(*BOOT, *["I (20036) MICROPHONE: Sum SQ: 0.000000, RMS pressure: 0.000000, "
+                   "Normalized: 0.000000, dB peak: -inf"] * 2)
+    runner.start("mic")
+    assert runner.step.id == "clap"
+    board("I (30036) MICROPHONE: Sum SQ: 0.000000, RMS pressure: 0.000000, Normalized: 0.000000, dB peak: -inf")
+    clock.t += 46
+    runner.tick()
+    assert runner.end.id == "mic_faulty"
+
+
+def test_mic_clap_test_passes_on_sound(rig):
+    engine, runner, clock, _, board, _ = rig
+    runner.start("mic")
+    board("I (30036) MICROPHONE: Sum SQ: 12.5, RMS pressure: 0.02, Normalized: 0.1, dB peak: 71.3")
+    assert runner.end.id == "mic_ok"
+
+
+def test_back_never_reenters_a_wait(rig):
+    engine, runner, clock, actions, board, _ = rig
+    runner.start("sensors")                      # route -> capture (wait, resets board)
+    assert runner.step.id == "capture" and actions == ["reset"]
+    clock.t += 46
+    runner.tick()                                # -> which_again -> end:red_unclear
+    runner.back()
+    assert actions == ["reset"]                  # no second reset
+
+
+def test_skip_wait_and_report_contains_technician_checks(rig):
+    engine, runner, clock, _, board, _ = rig
+    runner.start("update")
+    runner.proceed()                             # technician skips the wait
+    assert runner.end.id == "update_slow"
+    text = engine.report().to_text()
+    assert "Technician checks:" in text and "Update is taking very long" in text

tests/test_kota.py

@@ -0,0 +1,238 @@
+"""Firmware 1.0.16+ structured "KOTA:" lines and error IDs.
+
+The lines below are built from the exact format strings in the firmware
+source (boot_info.cpp, status.cpp, i2c.cpp, ds1307.cpp, sd_card.cpp,
+main.cpp, microphone.cpp, health.cpp); no hardware capture exists yet.
+"""
+
+from pathlib import Path
+
+from kota_tech.core.logfile import read_log_file
+from kota_tech.core.logline import LineKind, parse_line
+from kota_tech.diag.engine import DiagnosticsEngine, Severity
+from kota_tech.diag.firmware import same_build
+from kota_tech.matter.payload import payload_from_log
+from kota_tech.service.report import CONNECTIVITY, HARDWARE, service_status
+
+FIX = Path(__file__).parent / "fixtures"
+BANNER = ["ESP-ROM:esp32s3-20210327", "rst:0x15 (USB_UART_CHIP_RESET),boot:0x8 (SPI_FAST_FLASH_BOOT)"]
+I2C_OK = "I (1790) KOTA: i2c SDA=1 SCL=1 0x39=AS7341 0x68=DS1307 0x6B=SEN66 0x76=BME688"
+SD_OK = ("I (1990) KOTA: sd type=SDHC size=7.4GB fs=FAT32 free=7.3GB "
+         "env_keys=INFLUX_URL,INFLUX_TOKEN buffer_lines=0")
+BOOT = ("I (2310) KOTA: boot fw=1.0.16 build=4f10989e hw=2 mac=A4CB8FC946F8 reset=USB_UART_CHIP_RESET "
+        "mode=matter commissioned=1 last_restart={last}")
+
+
+def run(lines):
+    e = DiagnosticsEngine()
+    for i, text in enumerate(lines):
+        e.feed(parse_line(text, host_time=i * 0.01))
+    return e, e.report()
+
+
+def roots(report):
+    return {rc.finding.rule_id: rc for rc in report.roots}
+
+
+# ------------------------------------------------------------- parsing
+
+def test_kota_lines_are_parsed_into_fields():
+    ln = parse_line(BOOT.format(last="status_watchdog"))
+    assert ln.kind == LineKind.KOTA and ln.record == "boot" and ln.level == "I"
+    assert ln.fields["fw"] == "1.0.16" and ln.fields["last_restart"] == "status_watchdog"
+    st = parse_line("I (5) KOTA: status OK -> CONNECTION_ERROR code=1 reason=influx_rejected")
+    assert st.words == ("OK", "->", "CONNECTION_ERROR") and st.fields == {"code": "1", "reason": "influx_rejected"}
+    mic = parse_line("I (6) KOTA: mic enabled=0 (GPIO3=1, expected 0)")
+    assert mic.fields["enabled"] == "0" and mic.fields["GPIO3"] == "1"
+    i2c = parse_line("I (7) KOTA: i2c SDA=1 SCL=1 0x39=AS7341 0x68=DS1307(missing) 0x50=?")
+    assert i2c.fields["0x68"] == "DS1307(missing)" and i2c.fields["0x50"] == "?"
+    verify = parse_line("I (8) KOTA: rtc verify running=1 delta=2s ok=1")
+    assert verify.record == "rtc" and "verify" in verify.words and verify.fields["ok"] == "1"
+
+
+def test_error_id_is_split_off_but_kept_in_text():
+    ln = parse_line("E (1200) SD_CARD: [E-SD-03] Failed to initialize the card (ESP_ERR_TIMEOUT).")
+    assert ln.kind == LineKind.LOG and ln.error_id == "E-SD-03"
+    assert ln.message.startswith("Failed to initialize") and "[E-SD-03]" in ln.text
+    assert ln.match_text == "E (1200) SD_CARD: Failed to initialize the card (ESP_ERR_TIMEOUT)."
+
+
+def test_sd_line_with_secret_key_names_is_not_redacted():
+    ln = parse_line("I (9) KOTA: sd type=SDHC size=7.4GB fs=FAT32 free=7.3GB "
+                    "env_keys=INFLUX_URL,INFLUX_TOKEN,SSID,PASSWORD buffer_lines=0")
+    assert ln.fields["env_keys"] == "INFLUX_URL,INFLUX_TOKEN,SSID,PASSWORD"
+
+
+# -------------------------------------------------------------- engine
+
+def test_healthy_box_from_kota_lines():
+    e = DiagnosticsEngine()
+    for ln in read_log_file(FIX / "synthetic_fw1.0.16_healthy.txt"):
+        e.feed(ln)
+    r = e.report()
+    assert r.verdict.startswith("Healthy")
+    assert (r.led, r.led_pattern, r.led_exact, r.led_meaning) == ("GREEN", "solid", True, "OK")
+    assert "v1.0.16" in r.firmware.describe() and "4f10989e" in r.firmware.describe()
+    assert e.mac == "A4:CB:8F:C9:46:F8"
+    reached = {m for m, _, t in r.milestones if t is not None}
+    assert {"i2c_ok", "sd_mounted", "env_loaded", "matter_commissioned", "wifi_connected",
+            "time_synced", "clock_verified", "data_uploaded", "ota_registered"} <= reached
+    topics = {t: st for t, _, st in r.box}
+    assert topics["I2C"] == topics["SD card"] == topics["Health"] == "ok"
+    # The purple state before the tool's reset is shown, but only as information now.
+    prev = [f for f in r.earlier + [rc.finding for rc in r.roots] if f.rule_id == "boot.previous_status"]
+    assert not prev or prev[0].severity == Severity.INFO
+    assert "E-MAIN-04" not in r.to_text()           # MAC line is a benign ESP_LOGE
+
+
+def test_i2c_bus_stuck_is_root_of_blue_led():
+    _, r = run(BANNER + [
+        "I (1480) KOTA: led color=blue pattern=pulses n=2",
+        "I (1790) KOTA: i2c SDA=0 SCL=1 bus=stuck",
+        "I (1791) KOTA: status OK -> RTC_ERROR code=2 reason=i2c_bus_stuck",
+    ])
+    rs = roots(r)
+    assert "kota.i2c_stuck" in rs and rs["kota.i2c_stuck"].finding.severity == Severity.CRITICAL
+    assert "status.rtc.2" in {c.rule_id for c in rs["kota.i2c_stuck"].consequences}
+    assert (r.led, r.led_pattern) == ("BLUE", "2 pulses") and "I2C bus stuck" in r.led_meaning
+    assert service_status(r) == HARDWARE
+
+
+def test_missing_sensor_named_by_i2c_scan_and_red_pulses():
+    _, r = run(BANNER + [
+        "I (1790) KOTA: i2c SDA=1 SCL=1 0x39=AS7341 0x68=DS1307 0x6B=SEN66(missing) 0x76=BME688",
+        SD_OK,
+        "E (2100) MAIN: [E-MAIN-16] Failed to initialize SEN66: ESP_ERR_TIMEOUT",
+        "I (2101) KOTA: status OK -> ERROR code=2 reason=sen66_init_failed",
+        "I (2102) KOTA: led color=red pattern=pulses n=2",
+    ])
+    rs = roots(r)
+    root = rs["kota.sensor_missing"]
+    assert root.finding.title == "SEN66 does not answer on the I2C bus"
+    grouped = {c.rule_id for c in root.consequences}
+    assert {"status.error.2", "sensor.init_failed"} <= grouped
+    init = next(c for c in root.consequences if c.rule_id == "sensor.init_failed")
+    assert "E-MAIN-16" in init.error_ids and "SEN66" in init.error_ids["E-MAIN-16"]
+    assert r.led_meaning == "SEN66 failed"
+    assert "missing: SEN66" in dict((t, x) for t, x, _ in r.box)["I2C"]
+
+
+def test_server_rejected_box_is_purple_blinking():
+    _, r = run(BANNER + [I2C_OK, SD_OK, BOOT.format(last="none"),
+                         "I (70000) KOTA: status OK -> CONNECTION_ERROR code=1 reason=influx_rejected",
+                         "I (70001) KOTA: led color=purple pattern=blink period=1000ms"])
+    assert r.roots[0].finding.rule_id == "status.conn.1"
+    assert r.roots[0].finding.severity == Severity.CRITICAL
+    assert (r.led, r.led_pattern) == ("PURPLE", "blinking (1000 ms)")
+    assert "server rejected" in r.led_meaning
+    assert "influx_rejected" in r.led_reason
+    assert service_status(r) == CONNECTIVITY
+
+
+def test_status_back_to_ok_resolves_the_status_finding():
+    _, r = run(BANNER + [I2C_OK, "I (5000) KOTA: status OK -> CONNECTION_ERROR reason=influx_failed",
+                         "I (9000) KOTA: status CONNECTION_ERROR -> OK reason=influx_ok"])
+    assert "status.conn" not in roots(r)
+    assert any(f.rule_id == "status.conn" and f.resolved_by == "status -> OK" for f in r.resolved)
+
+
+def test_restart_reason_from_the_next_boot_line():
+    _, r = run(BANNER + [I2C_OK, BOOT.format(last="none"),
+                         "I (5000) KOTA: status OK -> ERROR code=3 reason=as7341_failed",
+                         "W (155000) KOTA: restart reason=status_watchdog",
+                         "I (155001) KOTA: led restart_flash color=red",
+                         "ESP-ROM:esp32s3-20210327", "rst:0xc (RTC_SW_CPU_RESET),boot:0x8 (SPI_FAST_FLASH_BOOT)",
+                         "I (1480) KOTA: led previous_boot status=ERROR code=3",
+                         I2C_OK, BOOT.format(last="status_watchdog")])
+    ids = {f.rule_id: f for rc in r.roots for f in [rc.finding, *rc.consequences]}
+    f = ids["reboot.status_watchdog"]
+    assert "150 s" in f.title and "state ERROR code=3" in f.meaning
+
+
+def test_brownout_restart_recorded_by_firmware():
+    _, r = run(BANNER + [I2C_OK, BOOT.format(last="none"), "I (90000) KOTA: health up=90s status=OK "
+                         "wifi=connected rssi=-60 time_valid=1 sd=ok buffer=0 heap=150000 psram=7.6M "
+                         "last_upload=10s ota=registered",
+                         "ESP-ROM:esp32s3-20210327", "rst:0xf (RTCWDT_BROWN_OUT_RESET),boot:0x8",
+                         I2C_OK, BOOT.format(last="brownout")])
+    assert r.roots[0].finding.rule_id == "reboot.brownout"
+
+
+def test_uncaptured_error_id_uses_the_csv_action():
+    _, r = run(BANNER + [I2C_OK, "E (3000) INFLUX_BUFFER: [E-INF-13] Failed to open buffer file for appending"])
+    f = next(f for rc in r.roots for f in [rc.finding, *rc.consequences] if "E-INF-13" in f.error_ids)
+    # A rule already knows this message, so the rule finding carries the code.
+    assert f.rule_id == "sd.write_fail"
+    _, r = run(BANNER + [I2C_OK, "E (3000) SPI: [E-SPI-01] Failed to take SPI mutex"])
+    f = roots(r)["eid.SPI"].finding
+    assert f.title == "SPI bus: Failed to take SPI mutex"
+    assert "firmware team" in f.actions[0] and f.error_ids == {"E-SPI-01": f.actions[0]}
+
+
+def test_legacy_rules_still_match_lines_with_error_ids():
+    _, r = run(BANNER + ["E (1200) MAIN: [E-MAIN-13] Failed to initialize RTC: ESP_ERR_TIMEOUT"])
+    assert "rtc.init_failed" in roots(r)
+
+
+def test_health_line_gives_status_when_connected_mid_run():
+    e, r = run(["I (600000) KOTA: health up=600s status=CONNECTION_ERROR wifi=disconnected rssi=0 "
+                "time_valid=1 sd=ok buffer=120 heap=150000 psram=7.6M last_upload=never ota=registered",
+                "I (660000) KOTA: health up=660s status=CONNECTION_ERROR wifi=disconnected rssi=0 "
+                "time_valid=1 sd=ok buffer=130 heap=150000 psram=7.6M last_upload=never ota=registered"])
+    assert (r.led, r.led_pattern) == ("PURPLE", "solid") and not r.led_exact
+    rs = roots(r)
+    assert "kota.wifi_down" in rs
+    assert "status.conn" in {c.rule_id for c in rs["kota.wifi_down"].consequences}
+    assert r.mid_run
+
+
+def test_sd_and_rtc_self_report():
+    _, r = run(BANNER + [
+        "I (1795) KOTA: rtc running=0 time=2000-01-01T00:00:00",
+        "I (1990) KOTA: sd type=SDHC size=7.4GB fs=FAT32 free=7.3GB env_keys=INFLUX_URL buffer_lines=0",
+        "I (8100) KOTA: rtc verify running=0 delta=0s ok=0",
+    ])
+    ids = {f.key for rc in r.roots for f in [rc.finding, *rc.consequences]}
+    assert {"influx.env_missing:INFLUX_TOKEN", "kota.rtc_stopped", "kota.rtc_not_ticking"} <= ids
+    _, r = run(BANNER + ["I (1990) KOTA: sd mounted=0 err=ESP_ERR_TIMEOUT",
+                         "I (1991) KOTA: status OK -> SD_ERROR reason=sd_mount_failed"])
+    rs = roots(r)
+    assert "kota.sd_unmounted" in rs and "ESP_ERR_TIMEOUT" in rs["kota.sd_unmounted"].finding.title
+    assert "status.sd" in {c.rule_id for c in rs["kota.sd_unmounted"].consequences}
+
+
+def test_matter_and_mic_lines():
+    e, r = run(BANNER + ["I (2315) KOTA: matter fabrics=0 window=open qr=MT:Y.K9042C00KA0648G00 manual=34970112332",
+                         "I (2400) KOTA: mic enabled=0 (GPIO3=1, expected 0)",
+                         "I (4481) KOTA: led color=cyan pattern=breathe period=3000ms"])
+    rs = roots(r)
+    assert "matter.not_commissioned" in rs and "mic.disabled" in rs
+    assert (r.led, r.led_meaning) == ("CYAN", "waiting to be paired in Matter")
+    p = payload_from_log([], e.matter_qr, e.matter_manual)
+    assert p.qr_text() == "MT:Y.K9042C00KA0648G00" and p.manual_code_pretty() == "3497-011-2332"
+    _, r = run(BANNER + ["I (2315) KOTA: matter fabrics=0 window=open qr=MT:Y.K9042C00KA0648G00 manual=34970112332",
+                         "I (90000) KOTA: matter fabrics=1 window=closed qr=MT:Y.K9042C00KA0648G00 manual=34970112332"])
+    assert "matter.not_commissioned" not in roots(r)
+
+
+def test_build_prefixes_of_different_length_match():
+    full = "4f10989e2b40c1d29fb3e8f8faaa50e5555997909c6d6b1db9d4e1e4d04555dc"
+    assert same_build("4f10989e", full) and same_build(full, "4f10989e2")
+    assert not same_build("4f10989f", full) and not same_build(None, full)
+
+
+def test_live_fw1016_uncommissioned_box():
+    # Real capture (2026-09-28) after flashing 1.0.16 App-only: not paired in Matter.
+    e = DiagnosticsEngine()
+    for ln in read_log_file(FIX / "live_boot_A4CB8FC946F8_fw1.0.16_uncommissioned.txt"):
+        e.feed(ln)
+    r = e.report()
+    assert r.firmware.version == "1.0.16" and same_build(r.firmware.elf_sha, "4f10989e")
+    assert (r.led, r.led_pattern, r.led_exact) == ("CYAN", "breathing", True)
+    rs = roots(r)
+    assert r.roots[0].finding.rule_id == "matter.not_commissioned"
+    grouped = {c.rule_id for c in rs["matter.not_commissioned"].consequences}
+    assert {"kota.wifi_down", "net.dns_fail", "status.conn", "kota.buffer_backlog"} <= grouped
+    assert "rtc.clock_not_running" in {c.rule_id for c in rs["kota.rtc_stopped"].consequences}
+    assert e.matter_qr == "MT:Y.K9042C00KA0648G00"
+    assert not any(f.rule_id.startswith("other.") for f in e.findings.values())

tests/test_matter.py

@@ -0,0 +1,42 @@
+"""Matter onboarding payload, checked against the real sticker of the bench box
+(QR decoded from matter_commissioning_qr.png: MT:Y.K9042C00KA0648G00)."""
+
+from pathlib import Path
+
+import segno
+
+from kota_tech.core.logfile import read_log_file
+from kota_tech.matter.payload import SetupPayload, payload_from_log, verhoeff_check
+
+STICKER_QR = "MT:Y.K9042C00KA0648G00"
+STICKER_MANUAL = "34970112332"          # printed as 3497-011-2332
+
+
+def test_default_payload_matches_sticker():
+    p = SetupPayload()
+    assert p.qr_text() == STICKER_QR
+    assert p.manual_code() == STICKER_MANUAL
+    assert p.manual_code_pretty() == "3497-011-2332"
+
+
+def test_payload_from_real_boot_log():
+    lines = [ln.text for ln in read_log_file(Path(__file__).parent / "fixtures" / "serial_log_20260917_162548.txt")]
+    p = payload_from_log(lines)
+    assert p.from_log and (p.vendor_id, p.product_id, p.discriminator) == (0xFFF1, 0x8000, 3840)
+    assert p.qr_text() == STICKER_QR
+
+
+def test_other_discriminator_changes_both_codes():
+    p = SetupPayload(discriminator=1234)
+    assert p.qr_text() != STICKER_QR and p.manual_code() != STICKER_MANUAL
+    assert p.qr_text().startswith("MT:") and len(p.qr_text()) == 3 + 19
+
+
+def test_verhoeff():
+    assert verhoeff_check("3497011233") == 2
+    assert verhoeff_check("236") == 3          # textbook example
+
+
+def test_qr_renders():
+    qr = segno.make(STICKER_QR, error="m")
+    assert qr.symbol_size(border=0)[0] >= 21

tests/test_ports.py

@@ -12,3 +12,15 @@ def test_other_ports_not_sensorbox():
     bt = PortInfo("COM3", "Standard Serial over Bluetooth link", None, None, None)
     assert not bt.is_sensorbox and bt.mac is None
     assert bt.label == "COM3 - Standard Serial over Bluetooth link"
+
+
+def test_macos_lists_only_callout_devices(monkeypatch):
+    from types import SimpleNamespace
+
+    from kota_tech.serialio import ports
+    fake = [SimpleNamespace(device=d, description="USB JTAG/serial debug unit", vid=0x303A, pid=0x1001,
+                            serial_number="A4:CB:8F:C9:46:F8")
+            for d in ("/dev/tty.usbmodem1101", "/dev/cu.usbmodem1101")]
+    monkeypatch.setattr(ports.sys, "platform", "darwin")
+    monkeypatch.setattr(ports.list_ports, "comports", lambda: fake)
+    assert [p.device for p in ports.list_serial_ports()] == ["/dev/cu.usbmodem1101"]

tests/test_sd.py

@@ -0,0 +1,183 @@
+"""SD provisioning: ENV.TXT (firmware-exact parsing), disk discovery parsers,
+the elevated Windows format script, and write/check on a stand-in card."""
+
+import plistlib
+
+import pytest
+
+import sys
+from pathlib import Path
+
+from kota_tech.sd.disks import MAX_CARD_BYTES, Disk, Volume, parse_macos, parse_windows
+from kota_tech.sd.envfile import EnvConfig, parse_env
+from kota_tech.sd.provision import check_card, win_format_command, write_env
+
+URL = "https://influx.kota-app.com/api/v2/write?bucket=sensorbox&org=kota"
+TOKEN = "T" * 86 + "=="          # shape of an InfluxDB token, not a real one
+
+
+def cfg(**kw):
+    base = dict(influx_url=URL, influx_token=TOKEN)
+    base.update(kw)
+    return EnvConfig(**base)
+
+
+# ------------------------------------------------------------------ ENV.TXT
+
+def test_render_matches_the_factory_file_format():
+    raw = cfg().render()
+    assert raw == f"INFLUX_TOKEN={TOKEN}\nINFLUX_URL={URL}\n".encode()
+    assert not raw.startswith(b"\xef\xbb\xbf") and b"\r" not in raw
+    assert parse_env(raw).ok
+
+
+def test_wifi_only_written_when_both_set():
+    raw = cfg(ssid="Site WiFi", password="correct horse").render().decode()
+    assert "SSID=Site WiFi\n" in raw and "PASSWORD=correct horse\n" in raw
+    assert any("both SSID and PASSWORD" in i.text for i in cfg(ssid="x").problems())
+
+
+@pytest.mark.parametrize("kw,fragment", [
+    (dict(influx_url="influx.kota-app.com"), "https://"),
+    (dict(influx_url="https://influx.kota-app.com/"), "write URL"),
+    (dict(influx_token=""), "INFLUX_TOKEN is empty"),
+    (dict(influx_token="abc def" * 5), "spaces"),
+    (dict(influx_token=TOKEN + " "), "space"),
+    (dict(ssid="s" * 33, password="12345678"), "32 bytes"),
+    (dict(ssid="net", password="short"), "8-63"),
+])
+def test_invalid_settings_are_errors(kw, fragment):
+    errors = [i.text for i in cfg(**kw).problems() if i.level == "error"]
+    assert any(fragment in e for e in errors), errors
+
+
+def test_parser_mirrors_firmware():
+    raw = b"\xef\xbb\xbfINFLUX_TOKEN=abc\r\nINFLUX_URL = x\nINFLUX_URL=u1\nINFLUX_URL=u2\nHTTP_SERVER=true\n"
+    chk = parse_env(raw)
+    texts = " ".join(i.text for i in chk.issues)
+    assert "BOM" in texts                                   # first key unreadable
+    assert "spaces around the key 'INFLUX_URL'" in texts
+    assert chk.values["INFLUX_URL"] == "u1"                 # first match wins
+    assert "appears twice" in texts and "setup mode" in texts
+    assert "INFLUX_TOKEN is missing" in texts               # hidden behind the BOM
+    assert not chk.ok
+
+
+def test_masking():
+    chk = parse_env(cfg(ssid="net", password="secretpassword").render())
+    m = chk.masked()
+    assert TOKEN not in m["INFLUX_TOKEN"] and m["INFLUX_TOKEN"].startswith("TTTT")
+    assert "secret" not in m["PASSWORD"]
+
+
+# ------------------------------------------------------------- disk lists
+
+WIN_JSON = """[{"Number":0,"FriendlyName":"ST500DM002-1BC142","Size":500107862016,"BusType":"SATA",
+ "Volumes":[{"DriveLetter":"D","FileSystem":"NTFS","Label":"WINRE"}]},
+ {"Number":4,"FriendlyName":"Mass Storage Device","Size":0,"BusType":"USB","Volumes":[]},
+ {"Number":5,"FriendlyName":"SDXC Card","Size":31914983424,"BusType":"SD",
+  "Volumes":{"DriveLetter":"E","FileSystem":"FAT32","Label":"KOTA"}}]"""
+
+
+def test_parse_windows_keeps_only_card_buses():
+    disks = parse_windows(WIN_JSON)
+    assert [d.id for d in disks] == ["4", "5"]              # SATA data disk never listed
+    reader, card = disks
+    assert not reader.has_media and reader.size_text == "no card"
+    assert card.volumes[0].mount == "E:\\" and card.volumes[0].filesystem == "FAT32"
+
+
+def test_parse_windows_single_object_quirk():
+    one = '{"Number":5,"FriendlyName":"SD","Size":8000000000,"BusType":"USB","Volumes":null}'
+    assert [d.id for d in parse_windows(one)] == ["5"]
+
+
+def test_parse_macos_excludes_system_disk():
+    listing = plistlib.dumps({"AllDisksAndPartitions": [
+        {"DeviceIdentifier": "disk0", "Size": 500_000_000_000, "Partitions": []},
+        {"DeviceIdentifier": "disk3", "Size": 994_000_000_000, "Partitions": [], "APFSVolumes": [{"MountPoint": "/"}]},
+        {"DeviceIdentifier": "disk4", "Size": 15_931_539_456,
+         "Partitions": [{"DeviceIdentifier": "disk4s1", "MountPoint": "/Volumes/KOTA", "Content": "DOS_FAT_32",
+                         "VolumeName": "KOTA"}]},
+    ]})
+    infos = {"disk0": plistlib.dumps({"Internal": True, "BusProtocol": "PCI-Express"}),
+             "disk3": plistlib.dumps({"Internal": True}),
+             "disk4": plistlib.dumps({"Internal": True, "RemovableMedia": True, "BusProtocol": "Secure Digital",
+                                      "MediaName": "SD Card Reader"})}
+    disks = parse_macos(listing, infos)
+    assert [d.id for d in disks] == ["/dev/disk4"] and disks[0].bus == "SD"
+    assert disks[0].volumes[0].mount == "/Volumes/KOTA"
+
+
+# -------------------------------------------------------- format script
+
+def test_elevated_helper_command(tmp_path):
+    disk = Disk("5", "SDXC Card", 63_864_569_856, "SD")
+    prog, params, cwd = win_format_command(disk, tmp_path / "r.json")
+    assert params.startswith("-m kota_tech.sd.win_format --disk 5 --size 63864569856 --label KOTA")
+    assert (Path(cwd) / "kota_tech").is_dir()                 # helper is importable from there
+
+
+@pytest.mark.skipif(sys.platform != "win32", reason="Windows formatter")
+@pytest.mark.parametrize("disks,msg", [
+    ([], "not a USB/SD/MMC"),                                                     # disk vanished / internal
+    ([Disk("5", "SD", 1_000, "SD")], "changed since it was selected"),              # swapped card
+    ([Disk("5", "SD", 31_457_280_000, "SD", [Volume("C:\\", "NTFS", "")])], "Windows drive"),
+])
+def test_formatter_guard_refuses_before_writing(monkeypatch, disks, msg):
+    from kota_tech.sd import win_format
+    monkeypatch.setattr(win_format.win_disks, "list_disks", lambda buses: disks)
+    monkeypatch.setattr(win_format, "RawDisk", lambda *a: pytest.fail("must not open the disk for writing"))
+    with pytest.raises(win_format.FormatError, match=msg):
+        win_format.format_card(5, 31_457_280_000, "KOTA", {})
+
+
+def test_large_disks_are_not_cards():
+    assert MAX_CARD_BYTES == 256 * 1024**3
+
+
+# ----------------------------------------------- write / check on a card
+
+def test_write_env_replaces_variants_and_keeps_buffered_data(tmp_path):
+    card = tmp_path / "card"
+    card.mkdir()
+    (card / "env.txt").write_bytes(b"INFLUX_URL=old\n")
+    (card / "BUFFER.TXT").write_bytes(b"line1\nline2\n\n")
+    out = write_env(str(card), cfg())
+    assert out.ok, out.message
+    names = sorted(p.name for p in card.iterdir())
+    assert names == ["BUFFER.TXT", "ENV.TXT"]
+    rep = check_card(str(card), "FAT32")
+    assert rep.env.ok and rep.problems == [] and rep.buffered_lines == 2
+
+
+def test_write_env_refuses_invalid_settings(tmp_path):
+    assert not write_env(str(tmp_path), cfg(influx_token="")).ok
+    assert not (tmp_path / "ENV.TXT").exists()
+
+
+def test_check_card_reports_missing_env_and_wrong_fs(tmp_path):
+    rep = check_card(str(tmp_path), "exFAT")
+    texts = " ".join(rep.problems)
+    assert "needs FAT32" in texts and "No ENV.TXT" in texts
+
+
+def test_elevated_result_folder_is_not_owner_only(tmp_path, monkeypatch):
+    # Regression: tempfile.mkdtemp() made the elevated script's result unreadable.
+    import kota_tech.sd.provision as prov
+    monkeypatch.setattr(prov, "WORK_ROOT", tmp_path / "tmp")
+    work = prov._workdir()
+    assert work.parent == tmp_path / "tmp" and work.is_dir()
+    (work / "result.json").write_text('{"ok": true}', encoding="utf-8")
+    assert (work / "result.json").read_text(encoding="utf-8")
+
+
+@pytest.mark.parametrize("fs", ["FAT32", "DOS_FAT_32", "Windows_FAT_32", "MS-DOS FAT32"])
+def test_fat32_names_from_windows_and_macos_are_accepted(tmp_path, fs):
+    (tmp_path / "ENV.TXT").write_bytes(b"INFLUX_URL=https://x\nINFLUX_TOKEN=abc\n")
+    assert not any("File system" in p for p in check_card(str(tmp_path), fs).problems)
+
+
+def test_exfat_is_flagged(tmp_path):
+    (tmp_path / "ENV.TXT").write_bytes(b"INFLUX_URL=https://x\nINFLUX_TOKEN=abc\n")
+    assert any("File system" in p for p in check_card(str(tmp_path), "ExFAT").problems)

tests/test_service.py

@@ -0,0 +1,107 @@
+"""Service-system hand-off: status mapping, note, and the #kota-report fragment
+(decoded exactly as the v1.1.0 service page does: base64url + UTF-8 JSON)."""
+
+import base64
+import json
+from pathlib import Path
+
+import pytest
+
+from kota_tech.core.logfile import read_log_file
+from kota_tech.core.logline import parse_line
+from kota_tech.diag.engine import DiagnosticsEngine
+from kota_tech.service.report import (
+    CONNECTIVITY, HARDWARE, OK, decode_fragment, normalize_mac, report_url, service_note, service_status,
+)
+
+FIX = Path(__file__).parent / "fixtures"
+
+
+def bench():
+    e = DiagnosticsEngine()
+    for ln in read_log_file(FIX / "live_boot_A4CB8FC946F8_fw1.0.txt"):
+        e.feed(ln)
+    return e
+
+
+def test_engine_reads_mac_from_boot_log():
+    assert bench().mac == "A4:CB:8F:C9:46:F8"
+
+
+def test_bench_box_is_a_connectivity_problem():
+    e = bench()
+    assert service_status(e.report()) == CONNECTIVITY
+    note = service_note(e.report())
+    assert note.startswith("[KOTA Technician Tool")
+    assert "not commissioned in Matter" in note and "↳ [Error] No Internet" in note
+    assert "Firmware: v1.0" in note
+
+
+def test_hardware_and_healthy_statuses():
+    e = DiagnosticsEngine()
+    for ln in ["ESP-ROM:esp32s3-20210327", "I (1299) app_init: Project name:     kota-sensorboard",
+               "E (3511) MAIN: Failed to initialize RTC: ESP_ERR_TIMEOUT"]:
+        e.feed(parse_line(ln))
+    assert service_status(e.report()) == HARDWARE
+    ok = DiagnosticsEngine()
+    for ln in ["ESP-ROM:esp32s3-20210327", "I (1299) app_init: Project name:     kota-sensorboard",
+               "I (31000) INFLUX: HTTP request performed, status code: 204"]:
+        ok.feed(parse_line(ln))
+    assert service_status(ok.report()) == OK
+
+
+def test_url_shape_and_payload_roundtrip():
+    e = bench()
+    url = report_url(e.mac, e.report(), "https://service.kota-app.com")
+    assert url.startswith("https://service.kota-app.com/A4CB8FC946F8#kota-report=")
+    assert "?" not in url                       # nothing in the query: the fragment is never sent to a server
+    data = decode_fragment(url)
+    assert data["v"] == 1 and data["mac"] == "A4CB8FC946F8" and data["status"] == CONNECTIVITY
+
+
+def test_fragment_decodes_like_the_service_page():
+    # Mirror of index.html applyToolPrefill: base64url -> pad -> bytes -> UTF-8 -> JSON
+    e = bench()
+    e.note_technician("Zażółć gęślą jaźń -> Purple")        # non-ASCII survives
+    url = report_url("a4:cb:8f:c9:46:f8", e.report())
+    frag = url.split("#kota-report=")[1]
+    assert set(frag) <= set("ABCDEFGHIJKLMNOPQRSTUVWXYZabcdefghijklmnopqrstuvwxyz0123456789-_")   # page regex
+    padded = frag.replace("-", "+").replace("_", "/")
+    padded += "==="[(len(padded) + 3) % 4:]
+    data = json.loads(base64.b64decode(padded).decode("utf-8"))
+    assert "Zażółć gęślą jaźń" in data["note"]
+
+
+def test_note_is_limited_and_no_secrets():
+    e = bench()
+    for i in range(400):
+        e.note_technician(f"check {i} " + "x" * 50)
+    note = service_note(e.report(), limit=4000)
+    assert len(note) <= 4000
+    assert "INFLUX_TOKEN" not in note
+
+
+@pytest.mark.parametrize("bad", ["", "A4CB8F", "zz:cb:8f:c9:46:f8"])
+def test_invalid_mac_rejected(bad):
+    with pytest.raises(ValueError):
+        report_url(bad, bench().report())
+
+
+def test_normalize_mac():
+    assert normalize_mac("a4:cb:8f:c9:46:f8") == "A4CB8FC946F8"
+
+
+def test_note_mirrors_the_diagnosis_panel():
+    from pathlib import Path
+    from kota_tech.core.logfile import read_log_file
+    e = DiagnosticsEngine()
+    for ln in read_log_file(Path(__file__).parent / "fixtures" / "live_boot_A4CB8FC946F8_fw1.0.16_uncommissioned.txt"):
+        e.feed(ln)
+    note = service_note(e.report())
+    assert len(note) <= 5000
+    for part in ("Status LED should be: Cyan, breathing", "Box self-report (KOTA lines):",
+                 "✔ I2C: found: AS7341, DS1307, SEN66, BME688", "Start-up progress (current boot):",
+                 "✔ SD card mounted (1.7 s)", "○ Connected to Wi-Fi", "What to do:",
+                 "Seen 12x, first at 21.6 s after start, last at 126.8 s",
+                 "↳ [Error] No Internet: server names cannot be resolved"):
+        assert part in note, part

uv.lock

@@ -1,6 +1,138 @@
 version = 1
 revision = 3
 requires-python = ">=3.11, <3.14"
+resolution-markers = [
+    "platform_machine == 'x86_64' and sys_platform == 'darwin'",
+    "platform_machine != 'x86_64' or sys_platform != 'darwin'",
+]
+
+[[package]]
+name = "appdirs"
+version = "1.4.4"
+source = { registry = "https://pypi.org/simple" }
+sdist = { url = "https://files.pythonhosted.org/packages/d7/d8/05696357e0311f5b5c316d7b95f46c669dd9c15aaeecbb48c7d0aeb88c40/appdirs-1.4.4.tar.gz", hash = "sha256:7d5d0167b2b1ba821647616af46a749d1c653740dd0d2415100fe26e27afdf41", size = 13470, upload-time = "2020-05-11T07:59:51.037Z" }
+wheels = [
+    { url = "https://files.pythonhosted.org/packages/3b/00/2344469e2084fb287c2e0b57b72910309874c3245463acd6cf5e3db69324/appdirs-1.4.4-py2.py3-none-any.whl", hash = "sha256:a841dacd6b99318a741b166adb07e19ee71a274450e68237b4650ca1055ab128", size = 9566, upload-time = "2020-05-11T07:59:49.499Z" },
+]
+
+[[package]]
+name = "argcomplete"
+version = "3.7.2"
+source = { registry = "https://pypi.org/simple" }
+sdist = { url = "https://files.pythonhosted.org/packages/87/6f/5a73f04007ca950701765949209f068da628bd11f9c2da287278ce91e0ee/argcomplete-3.7.2.tar.gz", hash = "sha256:aad8b69a0b9969edb62db0d1752354c0d50717b10e0cbb00e2a958381b9fc6b9", size = 74473, upload-time = "2026-08-06T04:53:21.662Z" }
+wheels = [
+    { url = "https://files.pythonhosted.org/packages/46/bd/551ee6af426af84ca33e02622be722925c196608e9127d731ef17c47f06e/argcomplete-3.7.2-py3-none-any.whl", hash = "sha256:6029205678bdd9c1c728a155f5f9ecf5812393f969eef58807641a2bc2aa5b19", size = 43294, upload-time = "2026-08-06T04:53:20.246Z" },
+]
+
+[[package]]
+name = "bitarray"
+version = "3.11.0"
+source = { registry = "https://pypi.org/simple" }
+sdist = { url = "https://files.pythonhosted.org/packages/04/f7/6765577df59e2345036e435f7e983e1c291d67b7d76a51918eff04ad1494/bitarray-3.11.0.tar.gz", hash = "sha256:bf19437ec00ec3d40aef82eaeedc14cf4000be9b635c4f5049796506e6630dd8", size = 174911, upload-time = "2026-09-01T15:21:52.076Z" }
+wheels = [
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