Technician tool v0.7

Imported from the Google Drive folder 004-technician_tool/v0.7.

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.

environment.yml

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

firmware/firmware.toml

@@ -1,11 +0,0 @@
-# Official firmware images the technician tool may flash.
-# Boxes normally receive new firmware over OTA; this is the factory image a
-# box updates itself from once it is online. Add a new image only when the
-# firmware team releases one: copy the .bin here and add an entry with its
-# SHA-256 (the tool refuses files that do not match).
-
-[[image]]
-file = "new_system.bin"
-sha256 = "1d58a8f4bb60f66009bd6df32e6e860c545c0c668de955af60d049ee3b9a212d"
-name = "v1.0 factory image (built Jun 29 2026)"
-notes = "Official factory image. Once online, the box registers for OTA and updates itself."

kota_tech/__init__.py

@@ -1,3 +1,3 @@
 """KOTA sensorbox technician tool."""
 
-__version__ = "0.5.0"
+__version__ = "0.7.0"

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.
@@ -22,6 +26,7 @@ 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")
@@ -48,6 +53,7 @@ LED = {
     "PURPLE": ("Purple", "#8e44ad"),
     "RED": ("Red", "#d64541"),
     "BLUE": ("Blue", "#2f6fd6"),
+    "CYAN": ("Cyan", "#1fc8d8"),
     "YELLOW": ("Yellow", "#e6c229"),
     "ORANGE": ("Orange", "#f08c1a"),
     "WHITE": ("White", "#f4f4f4"),
@@ -62,9 +68,11 @@ MILESTONES = [
     ("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),
@@ -77,11 +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
 
@@ -98,7 +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 = ""
@@ -119,7 +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", ""),
@@ -145,7 +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:
@@ -172,11 +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:
@@ -189,8 +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
@@ -218,14 +252,27 @@ class Report:
     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)}",
+               f"Boots seen: {max(len(self.boots) - (0 if self.boots and self.boots[0].explicit else 1), 0)}"]
-               "", "Milestones (current boot):"]
+        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 ""))
@@ -256,6 +303,8 @@ class Report:
 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
@@ -265,6 +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
@@ -280,6 +331,16 @@ class DiagnosticsEngine:
         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:
@@ -292,6 +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
@@ -301,7 +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).
@@ -318,12 +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:
+        hit: list[Finding] = []
-            m = rule.pattern.search(text)
+        rule_text = line.match_text
+        for rule in self._pattern_rules:
+            m = rule.pattern.search(rule_text)
             if not m:
                 continue
             matched = True
@@ -332,7 +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():
@@ -342,12 +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:
@@ -361,7 +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:
@@ -379,8 +458,12 @@ 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, list(self.technician))
+                      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:
@@ -415,6 +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:
@@ -432,6 +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
@@ -464,7 +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
@@ -490,35 +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.",)
@@ -537,10 +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
+Up to firmware 1.0 the app version string was "1.0" in every build, so
-told apart by the ELF SHA256 prefix printed by app_init. Boxes receive new
+builds are told apart by the ELF SHA256 prefix printed by app_init. Boxes
-firmware over OTA; an unknown SHA usually means a box has already updated.
+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

@@ -21,7 +21,7 @@ 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", "OFF", "CYCLING"]
+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"}
@@ -57,6 +57,7 @@ class Step:
     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())
@@ -101,7 +102,7 @@ def load_guides(path: Path = GUIDES_PATH) -> dict[str, Guide]:
                 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"),
+                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", [])}

kota_tech/diag/guides.toml

@@ -33,7 +33,7 @@ start = "led"
 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", OFF = "guide:power", CYCLING = "guide:reboot_loop" }
+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"
@@ -72,7 +72,8 @@ actions = [
 id = "network"
 title = "Purple LED / no Internet"
 summary = "Pairing in Matter, site Wi-Fi and Internet checks, with live confirmation."
-recommend = ["led:PURPLE", "matter.not_commissioned", "net.dns_fail", "influx.buffer_fail", "ota.registration_failed"]
+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]]
@@ -113,7 +114,8 @@ next = "pair_start"
 [[guide.step]]
 id = "pair_start"
 type = "wait"
-text = "In the Matter app choose 'Add device' and scan the QR code on the sticker (or type the 11-digit code printed under it). Keep the phone within 1 m of the box."
+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"
@@ -248,7 +250,7 @@ actions = ["Keep the tool connected a few more minutes and watch the Diagnosis t
 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"]
+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]]
@@ -309,7 +311,8 @@ actions = ["Replace the RTC module, or send the box for repair with the session
 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"]
+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]]
@@ -388,7 +391,9 @@ actions = [
 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"]
+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]]
@@ -469,7 +474,8 @@ actions = ["Save the session log and send it to the firmware team."]
 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"]
+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]]
@@ -605,7 +611,7 @@ actions = [
 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"]
+recommend = ["rtc.clock_not_running", "rtc.lost_after_sync", "kota.rtc_stopped", "kota.rtc_not_ticking", "kota.time_invalid"]
 start = "internet"
 
 [[guide.step]]

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
@@ -121,7 +124,7 @@ led_from = "PURPLE"
 
 [[rule]]
 id = "benign.mac"
-pattern = 'ID: Device MAC address'
+pattern = 'Device MAC address'
 severity = "ignore"
 
 [[rule]]
@@ -222,7 +225,7 @@ 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.",
@@ -340,6 +343,7 @@ 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]]
@@ -353,6 +357,7 @@ 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"
@@ -362,6 +367,7 @@ 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
 
@@ -376,6 +382,7 @@ 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]]
@@ -570,3 +577,148 @@ 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

@@ -1,14 +1,16 @@
-"""Firmware images: validation, integrity and layout.
+"""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 origins:
-  * factory   - bundled with the tool (firmware/firmware.toml), SHA-256 locked;
-  * developer - a newer build the firmware team sends to technicians,
-                imported into a per-user library (~/KotaTechnicianTool/firmware).
 Two kinds:
-  * merged - bootloader at 0x0 + partition table + app (like new_system.bin);
+  * 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 the factory image.
+             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
@@ -19,17 +21,11 @@ from __future__ import annotations
 
 import datetime as dt
 import hashlib
-import json
-import shutil
 import struct
-import tomllib
 from dataclasses import dataclass
 from pathlib import Path
 
 FIRMWARE_DIR = Path(__file__).resolve().parents[2] / "firmware"
-MANIFEST = FIRMWARE_DIR / "firmware.toml"
-LIBRARY_DIR = Path.home() / "KotaTechnicianTool" / "firmware"
-LIBRARY_INDEX = "library.json"
 
 PT_OFFSET = 0x8000
 PT_SIZE = 0xC00
@@ -58,7 +54,7 @@ class Partition:
 class AppInfo:
     project: str
     version: str
-    built: str          # "Jun 29 2026 11:03:32" as in the app descriptor
+    built: str          # "Sep 28 2026 15:07:57" as in the app descriptor
     idf: str
     elf_sha: str        # hex
 
@@ -71,13 +67,16 @@ class AppInfo:
         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
-    name: str
-    notes: str
-    origin: str                      # "factory" | "developer"
     kind: str                        # "merged" | "app"
     sha256: str
     flash_size: str
@@ -88,12 +87,12 @@ class FirmwareImage:
     app: AppInfo
 
     @property
-    def data(self) -> bytes:
+    def name(self) -> str:
-        return self.path.read_bytes()
+        return self.path.name
 
     @property
-    def is_developer(self) -> bool:
+    def data(self) -> bytes:
-        return self.origin == "developer"
+        return self.path.read_bytes()
 
     def partition(self, label: str) -> Partition:
         for p in self.partitions:
@@ -109,8 +108,9 @@ class FirmwareImage:
         return b"\xff" * self.partition("otadata").size
 
     def label(self) -> str:
-        tag = "factory" if self.origin == "factory" else "developer build"
+        """Choice text: compile date first (that is what the technician picks by)."""
-        return f"{self.app.version} built {self.app.built} [{self.app.elf_sha[:9]}] - {tag}"
+        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
@@ -180,10 +180,10 @@ def _app_info(data: bytes, offset: int) -> AppInfo:
     return info
 
 
-def inspect_image(path: Path, name: str = "", notes: str = "", origin: str = "factory",
+
-                  reference: FirmwareImage | None = None) -> FirmwareImage:
+def inspect_image(path: Path, reference: FirmwareImage | None = None) -> FirmwareImage:
     """Validate a merged or app-only image. App-only images need a `reference`
-    (the factory image) that provides the flash layout."""
+    (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
@@ -197,7 +197,8 @@ def inspect_image(path: Path, name: str = "", notes: str = "", origin: str = "fa
         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 image needs the factory image as layout reference")
+            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")
@@ -207,80 +208,53 @@ def inspect_image(path: Path, name: str = "", notes: str = "", origin: str = "fa
     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, name or path.name, notes, origin, kind, hashlib.sha256(data).hexdigest(),
+    return FirmwareImage(path, kind, hashlib.sha256(data).hexdigest(),
                          flash_size, parts, table, app_off, length, app)
 
 
 # ------------------------------------------------------------- catalogue
 
-def factory_images(manifest: Path = MANIFEST) -> list[FirmwareImage]:
+def folder_images(folder: Path = FIRMWARE_DIR) -> tuple[list[FirmwareImage], list[str]]:
-    """Bundled images whose file exists and matches the SHA-256 in the manifest."""
+    """(valid images newest-compiled first, problems) for the .bin files in `folder`.
-    if not manifest.exists():
-        return []
-    out = []
-    for e in tomllib.loads(manifest.read_text(encoding="utf-8")).get("image", []):
-        path = manifest.parent / e["file"]
-        if not path.exists():
-            continue
-        img = inspect_image(path, e.get("name", ""), e.get("notes", ""), "factory")
-        if img.sha256 != e["sha256"].lower():
-            raise ImageError(f"{path.name}: SHA-256 does not match the manifest - file changed or corrupt")
-        out.append(img)
-    return out
 
-
+    A broken or foreign file is reported, never offered. The same build
-class FirmwareLibrary:
+    under two file names is offered once.
-    """Developer builds imported by the technician (persist across tool versions)."""
+    """
-
+    if not folder.is_dir():
-    def __init__(self, root: Path = LIBRARY_DIR):
+        return [], [f"firmware folder not found: {folder}"]
-        self.root = root
+    files = sorted(p for p in folder.iterdir() if p.is_file() and p.suffix.lower() == ".bin")
-
+    merged: list[FirmwareImage] = []
-    def _index(self) -> list[dict]:
+    app_only: list[Path] = []
-        f = self.root / LIBRARY_INDEX
+    problems: list[str] = []
-        return json.loads(f.read_text(encoding="utf-8")) if f.exists() else []
+    for f in files:
-
-    def _save(self, entries: list[dict]) -> None:
-        self.root.mkdir(parents=True, exist_ok=True)
-        (self.root / LIBRARY_INDEX).write_text(json.dumps(entries, indent=2), encoding="utf-8")
-
-    def images(self, reference: FirmwareImage | None) -> tuple[list[FirmwareImage], list[str]]:
-        """(valid images, problems) - a changed or broken file is reported, not offered."""
-        imgs, problems = [], []
-        for e in self._index():
-            path = self.root / e["file"]
         try:
-                img = inspect_image(path, e.get("name", ""), e.get("notes", ""), "developer", reference)
+            merged.append(inspect_image(f))
-                if img.sha256 != e["sha256"]:
+        except ImageError as exc:
-                    raise ImageError("file changed since it was imported")
+            if "app-only" in str(exc):
-                imgs.append(img)
+                app_only.append(f)
-            except (OSError, ImageError) as exc:
+            else:
-                problems.append(f"{e.get('original', e['file'])}: {exc}")
+                problems.append(f"{f.name}: {exc}")
-        return imgs, problems
+        except OSError as exc:
-
+            problems.append(f"{f.name}: cannot read ({exc})")
-    def import_file(self, src: Path, reference: FirmwareImage | None, notes: str = "") -> FirmwareImage:
+    merged.sort(key=_newest_first)
-        img = inspect_image(src, origin="developer", reference=reference)   # validate before copying
+    reference = merged[0] if merged else None
-        entries = self._index()
+    images = list(merged)
-        existing = next((e for e in entries if e["sha256"] == img.sha256), None)
+    for f in app_only:
-        if existing:
+        try:
-            return inspect_image(self.root / existing["file"], existing["name"], existing["notes"],
+            images.append(inspect_image(f, reference))
-                                 "developer", reference)
+        except (ImageError, OSError) as exc:
-        self.root.mkdir(parents=True, exist_ok=True)
+            problems.append(f"{f.name}: {exc}")
-        fname = f"{img.app.elf_sha[:9]}_{img.sha256[:8]}.bin"
+    images.sort(key=_newest_first)
-        shutil.copyfile(src, self.root / fname)
+    unique: dict[str, FirmwareImage] = {}
-        name = f"Developer build {img.app.version} ({img.app.built})"
+    for img in images:
-        entries.append({"file": fname, "sha256": img.sha256, "name": name, "original": src.name,
+        if img.sha256 in unique:
-                        "imported": dt.datetime.now().isoformat(timespec="seconds"), "notes": notes})
+            problems.append(f"{img.name}: same file as {unique[img.sha256].name} (listed once)")
-        self._save(entries)
+        else:
-        return inspect_image(self.root / fname, name, notes, "developer", reference)
+            unique[img.sha256] = img
-
+    return list(unique.values()), problems
-    def remove(self, sha256: str) -> None:
-        entries = self._index()
-        keep = [e for e in entries if e["sha256"] != sha256]
-        for e in entries:
-            if e["sha256"] == sha256:
-                (self.root / e["file"]).unlink(missing_ok=True)
-        self._save(keep)
 
 
-# Backwards-compatible name used by earlier callers/tests.
+def _newest_first(img: FirmwareImage) -> tuple:
-official_images = factory_images
+    # 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/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

@@ -111,10 +111,10 @@ def parse_macos(list_plist: bytes, infos: dict[str, bytes]) -> list[Disk]:
 def list_cards() -> tuple[list[Disk], list[Disk]]:
     """(cards that may be formatted, readers/disks shown but not offered)."""
     if sys.platform == "win32":
-        out = subprocess.run(["powershell", "-NoProfile", "-NonInteractive", "-Command", WIN_LIST_PS],
+        # Driver-level listing (milliseconds, 1.5 s worst case) instead of
-                             capture_output=True, text=True, timeout=90,
+        # Get-Disk/WMI, which stalled 5-21 s on an empty card-reader slot.
-                             creationflags=subprocess.CREATE_NO_WINDOW).stdout
+        from .win_disks import list_disks
-        disks = parse_windows(out)
+        disks = list_disks(CARD_BUSES)
     elif sys.platform == "darwin":
         lst = subprocess.run(["diskutil", "list", "-plist", "physical"], capture_output=True, timeout=30).stdout
         infos = {}

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

@@ -3,11 +3,12 @@
 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 a generated PowerShell
+Windows: formatting needs administrator rights, so kota_tech.sd.win_format
-script runs elevated (UAC prompt). The script re-checks the disk (number,
+runs elevated (UAC prompt). It re-checks the disk (number, size, bus, not the
-size, bus, not system/boot) right before erasing it, so a card swapped
+Windows drive) right before erasing it, so a card swapped after the
-after the technician confirmed is not touched. Windows cannot format FAT32
+technician confirmed is not touched, and it writes MBR + FAT32 itself
-above 32 GB, so larger cards get a 32 GB partition (plenty for the box).
+(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).
 """
 
@@ -23,11 +24,10 @@ import uuid
 from dataclasses import dataclass, field
 from pathlib import Path
 
-from .disks import CARD_BUSES, Disk
+from .disks import Disk
 from .envfile import BUFFER_NAME, ENV_NAME, EnvCheck, EnvConfig, find_case_insensitive, parse_env
 
 VOLUME_LABEL = "KOTA"
-FAT32_MAX = 32 * 1024**3
 
 
 @dataclass
@@ -49,31 +49,6 @@ class CardReport:
 
 # ----------------------------------------------------------------- Windows
 
-def windows_format_script(disk: Disk, result_file: Path) -> str:
-    buses = ",".join(f"'{b}'" for b in sorted(CARD_BUSES))
-    return f"""
-$ErrorActionPreference = 'Stop'
-$result = @{{ ok = $false; message = ''; drive = '' }}
-try {{
-  $n = {int(disk.id)}
-  $d = Get-Disk -Number $n
-  if ($d.IsSystem -or $d.IsBoot) {{ throw 'Refusing: this is a system/boot disk.' }}
-  if (@({buses}) -notcontains [string]$d.BusType) {{ throw "Refusing: disk bus is $($d.BusType), not an SD/USB card." }}
-  if ([int64]$d.Size -ne {int(disk.size)}) {{ throw 'Refusing: the disk changed since it was selected (card swapped?).' }}
-  if ($d.PartitionStyle -ne 'RAW') {{ Clear-Disk -Number $n -RemoveData -RemoveOEM -Confirm:$false }}
-  Initialize-Disk -Number $n -PartitionStyle MBR -ErrorAction SilentlyContinue
-  $size = [Math]::Min([int64]$d.Size - 2MB, [int64]{FAT32_MAX})
-  $p = New-Partition -DiskNumber $n -Size $size -MbrType FAT32 -AssignDriveLetter
-  Format-Volume -Partition $p -FileSystem FAT32 -NewFileSystemLabel '{VOLUME_LABEL}' -Confirm:$false -Force | Out-Null
-  Start-Sleep -Seconds 2
-  $letter = (Get-Partition -DiskNumber $n -PartitionNumber $p.PartitionNumber).DriveLetter
-  if (-not $letter) {{ throw 'Formatted, but Windows gave the card no drive letter.' }}
-  $result.ok = $true; $result.drive = "$($letter):\\"; $result.message = 'Formatted FAT32 (MBR).'
-}} catch {{ $result.message = $_.Exception.Message }}
-$result | ConvertTo-Json | Out-File -FilePath '{result_file}' -Encoding utf8
-"""
-
-
 WORK_ROOT = Path.home() / "KotaTechnicianTool" / "tmp"
 
 
@@ -86,42 +61,54 @@ def _workdir() -> Path:
     return work
 
 
-def _query_windows_card(number: int) -> tuple[str, str, str]:
+def win_format_command(disk: Disk, result: Path) -> tuple[str, str, str]:
-    """(drive, filesystem, label) of the card's first partition - no admin rights needed."""
+    """(program, parameters, working dir) for the elevated helper."""
-    ps = (f"$p = Get-Partition -DiskNumber {number} -ErrorAction SilentlyContinue | Select-Object -First 1; "
+    root = Path(__file__).resolve().parents[2]            # the version folder holding kota_tech/
-          "if ($p) { $v = $p | Get-Volume -ErrorAction SilentlyContinue; "
+    params = f'-m kota_tech.sd.win_format --disk {int(disk.id)} --size {int(disk.size)} ' \
-          "\"$($p.DriveLetter)|$($v.FileSystem)|$($v.FileSystemLabel)\" }")
+             f'--label {VOLUME_LABEL} --result "{result}"'
-    out = subprocess.run(["powershell", "-NoProfile", "-Command", ps], capture_output=True, text=True,
+    return sys.executable, params, str(root)
-                         timeout=90, creationflags=subprocess.CREATE_NO_WINDOW).stdout.strip()
+
-    drive, fs, label = (out.split("|") + ["", "", ""])[:3]
+
-    return (f"{drive}:\\" if drive.strip() else ""), fs, label
+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:
-    work = _workdir()
+    result = _workdir() / "result.json"
-    script, result = work / "format_card.ps1", work / "result.json"
-    script.write_text(windows_format_script(disk, result), encoding="utf-8-sig")
     log.append("Asking Windows for administrator rights to format the card (UAC prompt)...")
-    launcher = ("$p = Start-Process powershell -Verb RunAs -Wait -PassThru -WindowStyle Hidden "
+    t = time.perf_counter()
-                f"-ArgumentList '-NoProfile -ExecutionPolicy Bypass -File \"{script}\"'; exit $p.ExitCode")
+    code = _run_elevated(*win_format_command(disk, result))
-    proc = subprocess.run(["powershell", "-NoProfile", "-Command", launcher], capture_output=True, text=True,
+    if code is None:
-                          timeout=600, creationflags=subprocess.CREATE_NO_WINDOW)
+        return Outcome(False, "Administrator permission was refused - the card was not formatted.", log=log)
-    if not result.exists():
-        err = (proc.stderr or "").strip().splitlines()
-        cancelled = any("canceled" in e.lower() or "cancelled" in e.lower() for e in err)
-        return Outcome(False, "Administrator permission was refused - the card was not formatted." if cancelled
-                       else "Formatting did not run: " + (err[-1] if err else "unknown error"), log=log)
     try:
-        res = json.loads(result.read_text(encoding="utf-8-sig"))
+        res = json.loads(result.read_text(encoding="utf-8"))
     except (OSError, ValueError) as exc:
-        # The script ran but its report is unreadable: judge by the card itself.
+        return Outcome(False, f"The formatter did not report back ({exc.__class__.__name__}, exit {code}). "
-        log.append(f"Could not read the format result ({exc.__class__.__name__}); checking the card directly.")
+                              "Check the card with 'Check card'.", log=log)
-        drive, fs, label = _query_windows_card(int(disk.id))
+    steps = ", ".join(f"{k} {v:.1f} s" for k, v in res.get("timings", {}).items())
-        ok = bool(drive) and fs.upper() == "FAT32" and label == VOLUME_LABEL
+    log.append(f"{res.get('message', '')} ({time.perf_counter() - t:.1f} s incl. permission prompt; {steps})")
-        res = {"ok": ok, "drive": drive,
-               "message": "Formatted FAT32 (MBR)." if ok else f"Card state after formatting: {fs or 'no file system'} "
-                                                              f"'{label}' - formatting probably failed."}
-    log.append(res.get("message", ""))
     return Outcome(bool(res.get("ok")), res.get("message", ""), res.get("drive", ""), log)
 
 

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

@@ -18,7 +18,7 @@ from .. import __version__
 from ..diag.engine import Report, Severity
 
 DEFAULT_BASE = "https://service.kota-app.com/"
-NOTE_LIMIT = 4000        # the service form accepts 5000; leave room for the technician
+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"
@@ -40,6 +40,17 @@ _STATUS_BY_RULE = [
     ("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}$")
@@ -61,26 +72,69 @@ def service_status(report: Report) -> str:
     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:
-    lines = [f"[KOTA Technician Tool {__version__}] {report.verdict}",
+    """The Diagnosis panel as text: verdict, LED, firmware, box self-report,
-             f"Firmware: {report.firmware.describe()}",
+    start-up progress with times, findings with details and when they were seen.
-             f"Expected LED: {report.led.capitalize()}"]
+
-    reached = [label for _, label, t in report.milestones if t is not None]
+    Falls back to shorter finding details when the full text does not fit the
-    missing = [label for _, label, t in report.milestones if t is None]
+    service form (consequences' explanations first, then all), then truncates.
-    if reached:
+    """
-        lines.append("OK: " + ", ".join(reached))
+    for detail in ("all", "roots", "none"):
-    if missing:
+        text = _note(report, detail)
-        lines.append("Not reached: " + ", ".join(missing))
+        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:
-        f = rc.finding
+        lines += _finding(rc.finding, "", detail in ("all", "roots"))
-        lines.append(f"- [{f.severity.label}] {f.title}")
         for c in rc.consequences:
-            lines.append(f"    -> {c.title}")
+            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.append("Technician checks:")
+        lines += ["", "Technician checks:"]
         lines += [f"  * {t}" for t in report.technician[-12:]]
-    text = "\n".join(lines)
+    return "\n".join(lines)
-    return text if len(text) <= limit else text[:limit - 20].rstrip() + "\n...(shortened)"
+
+
+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:

kota_tech/ui/cheatsheet.py

@@ -1,53 +1,55 @@
 """Quick-start cheat sheet shown on launch.
 
-Targets the DEPLOYED firmware: new_system.bin, app "kota-sensorboard"
+LED table for firmware 1.0.16+ (firmware-diagnostics-what-changed.md,
-1.0, built Jun 29 2026 11:03:32, ELF SHA256 45fa9d5b9... (verified on a
+status.cpp Status::pattern_for): colour AND pattern name the fault. Older
-live board). That build has no Wi-Fi setup portal / SSID-on-SD support;
+boxes (v1.0, built Jun 29 2026) show the same colours, always solid.
-those exist only in the newer, unbuilt source. The status LED is always
-SOLID; the separate small LED toggles every second while alive.
 """
 
-# (swatch colour, LED name, meaning, first action)
+# (swatch colour, LED name, pattern -> meaning, first action)
 LED_TABLE = [
-    ("#2e9e44", "Green", "Everything OK.", "Nothing to do."),
+    ("#2e9e44", "Green", "solid: everything OK.", "Nothing to do."),
-    ("#8e44ad", "Purple",
+    ("#1fc8d8", "Cyan",
-     "No Internet / InfluxDB or OTA server unreachable.",
+     "breathing: not paired in Matter yet<br>fast blink: a phone is connected for pairing.",
-     "Check the box is commissioned in the Matter app (sticker QR code) and the "
+     "Pair the box in the Matter app (QR sticker or the QR code in the tool)."),
-     "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)."),
     ("#f4f4f4", "White",
-     "SD card missing/unreadable or ENV.TXT incomplete - or a factory reset is "
+     "fast blink: SD card or ENV.TXT error<br>solid: factory reset (Matter button held 5 s)<br>"
-     "in progress (Matter button held 5 s).",
+     "breathing: Wi-Fi setup portal.",
-     "If nobody pressed the Matter button: the SD card is inside the case - "
+     "SD card is inside the case: re-seat or re-provision it. Setup portal: short-press the button to leave."),
-     "unscrew, re-seat or re-provision it."),
+    ("#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. "
+    "<b>Before a self-restart</b> the LED flashes the error colour 3 times; <b>after the restart</b> it "
-    "Connect serial and press <i>Reset &amp; capture</i>: the last lines before the "
+    "shows the previous error for 3 s. So a reboot loop shows its cause. Connect serial and press "
-    "reboot name the cause.",
+    "<i>Reset &amp; capture</i>: the tool reads the restart reason from the box.",
-    "<b>Small LED next to the RGB LED</b> blinks once per second while the "
+    "<b>Small LED next to the RGB LED</b> (heartbeat): blinks once per second while online, "
-    "firmware runs. Not blinking = firmware hung or not running.",
+    "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 "
+    "<b>Flashing</b> uses only the firmware files in the tool's <b>firmware</b> folder; choose the build "
-    "(the air-quality sensor warms up for 120 s).",
+    "by its compile date.",
 ]
 
 STEPS = [
@@ -73,10 +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
+Layout: verdict banner, expected LED (colour + pattern + meaning when the
-findings tree (root causes; their consequences as children; titles only)
+box reports it), firmware, the box's own self-report (KOTA lines), start-up
-and a wrapped detail pane for the selected finding.
+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"
+    seen = _esc(f.seen_text())
-    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)})"
     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

@@ -1,4 +1,5 @@
-"""Flash firmware tab: factory image or imported developer builds; App-only by default."""
+"""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
 
@@ -6,11 +7,11 @@ import datetime as dt
 import tempfile
 from pathlib import Path
 
-from PySide6.QtCore import QObject, Qt, QTimer, Signal
+from PySide6.QtCore import QObject, Qt, QTimer, QUrl, Signal
+from PySide6.QtGui import QDesktopServices
 from PySide6.QtWidgets import (
     QButtonGroup,
     QCheckBox,
-    QFileDialog,
     QComboBox,
     QGroupBox,
     QHBoxLayout,
@@ -25,7 +26,8 @@ from PySide6.QtWidgets import (
 )
 
 from ..core.session import SESSIONS_DIR
-from ..flash.image import FirmwareImage, FirmwareLibrary, ImageError, factory_images
+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
@@ -71,32 +73,32 @@ class FlashTab(QWidget):
         bl.addLayout(row)
         bl.addWidget(self.box_fw)
 
-        # 2. firmware
+        # 2. firmware - only files in the tool's firmware/ folder
-        fwbox = QGroupBox("2. Firmware")
+        fwbox = QGroupBox("2. Firmware (by compile date)")
         self.image_combo = QComboBox(minimumWidth=360)
-        self.import_btn = QPushButton("Import firmware file...")
+        self.image_combo.setToolTip(f"Firmware files in {FIRMWARE_DIR}")
-        self.import_btn.setToolTip("Add a newer build the firmware team sent you (.bin)")
+        self.reload_btn = QPushButton("Refresh list")
-        self.import_btn.clicked.connect(self._import)
+        self.reload_btn.setToolTip("Read the firmware folder again (after the firmware team added a file)")
-        self.remove_btn = QPushButton("Remove from list")
+        self.reload_btn.clicked.connect(lambda: self._load_images(self._selected_sha()))
-        self.remove_btn.clicked.connect(self._remove)
+        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.import_btn)
+        brow.addWidget(self.reload_btn)
-        brow.addWidget(self.remove_btn)
+        brow.addWidget(self.folder_btn)
         brow.addStretch(1)
         fl.addLayout(brow)
         fl.addWidget(self.image_info)
-        self._library = FirmwareLibrary()
-        self._reference: FirmwareImage | None = None
         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 factory image  (new or completely wiped boards)")
+        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)
@@ -166,54 +168,23 @@ class FlashTab(QWidget):
 
     # ------------------------------------------------------------ setup
     def _load_images(self, select_sha: str | None = None) -> None:
-        self._problems = []
+        self._images, self._problems = folder_images()
-        try:
+        for img in self._images:     # lets the Serial monitor show a box build's compile date
-            factory = factory_images()
+            register_local_build(img.app.elf_sha, img.app.version, img.app.built, img.name)
-        except ImageError as exc:
-            factory = []
-            self._problems.append(f"factory image: {exc}")
-        self._reference = factory[0] if factory else None
-        dev, problems = self._library.images(self._reference)
-        self._problems += problems
-        # Newest developer builds first, then the factory image.
-        dev.sort(key=lambda i: i.app.built_at or dt.datetime.min, reverse=True)
-        self._images = dev + factory
         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 image available - import one")
+            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), None)
+        idx = next((i for i, im in enumerate(self._images) if im.sha256 == select_sha), 0)
-        if idx is None:
+        self.image_combo.setCurrentIndex(idx)             # default: newest compile date
-            idx = len(dev) if factory else 0          # default: the factory image
-        self.image_combo.setCurrentIndex(idx)
         self.image_combo.blockSignals(False)
         self._update()
 
-    def _import(self) -> None:
+    def _selected_sha(self) -> str | None:
-        path, _ = QFileDialog.getOpenFileName(self, "Import firmware from the firmware team", str(Path.home()),
-                                              "Firmware (*.bin);;All files (*)")
-        if not path:
-            return
-        try:
-            img = self._library.import_file(Path(path), self._reference)
-        except (ImageError, OSError) as exc:
-            QMessageBox.warning(self, "Cannot use this file", f"This file cannot be flashed:\n\n{exc}")
-            return
-        self._load_images(select_sha=img.sha256)
-        kind = "complete image" if img.kind == "merged" else "app only"
-        QMessageBox.information(
-            self, "Firmware imported",
-            f"{img.name}\nbuild {img.app.elf_sha[:9]}, {kind}\n\nFile fingerprint (SHA-256):\n{img.sha256}\n\n"
-            "Compare it with the fingerprint the firmware team sent you before flashing.")
-
-    def _remove(self) -> None:
         img = self._selected_image()
-        if img and img.is_developer and QMessageBox.question(
+        return img.sha256 if img else None
-                self, "Remove firmware", f"Remove {img.name} from this computer?") == QMessageBox.StandardButton.Yes:
-            self._library.remove(img.sha256)
-            self._load_images()
 
     def refresh_ports(self) -> None:
         current = self.port_combo.currentData()
@@ -244,18 +215,17 @@ class FlashTab(QWidget):
         info = ""
         if img:
             a = img.app
-            origin = ("<b>Factory image</b> (bundled with the tool)" if not img.is_developer else
-                      "<b style='color:#c77c02'>Developer build</b> - only flash builds you received "
-                      "from the firmware team")
             kind = "complete image (bootloader + layout + app)" if img.kind == "merged" else "app only"
-            info = (f"{origin}<br>{a.project} {a.version}, built {a.built}, ESP-IDF {a.idf}, {kind}<br>"
+            info = (f"<b>Compiled {a.built}</b> &middot; {a.project} v{a.version}, ESP-IDF {a.idf}, {kind}<br>"
-                    f"<small>build {a.elf_sha[:9]} &middot; file SHA-256 {img.sha256[:16]}... "
+                    f"<small>file firmware/{img.name} &middot; build {a.elf_sha[:8]} &middot; "
-                    f"&middot; checksum OK</small>" + (f"<br><small>{img.notes}</small>" if img.notes else ""))
+                    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)
-        self.remove_btn.setEnabled(bool(img and img.is_developer) and self._runner is None)
         # 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)
@@ -273,7 +243,7 @@ class FlashTab(QWidget):
             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 factory image (~25 s)"]
+                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:
@@ -283,12 +253,13 @@ class FlashTab(QWidget):
         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()}" + (f", built {fw.built}" if fw.built else "")
+        msg = f"Box currently runs: {fw.describe()}"
         if not img:
             return msg
-        if fw.elf_sha.startswith(img.app.elf_sha[:9]) or img.app.elf_sha.startswith(fw.elf_sha):
+        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>"
-        box_built, img_built = _parse_built(fw.built), img.app.built_at
+        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:
@@ -303,9 +274,10 @@ class FlashTab(QWidget):
             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 factory image (pairing and OTA registration are erased)")
+                else "the COMPLETE image (pairing and OTA registration are erased)")
         if QMessageBox.question(self, "Flash firmware",
-                                f"Write {what}\n\nImage: {img.name}\nBox: {port.label}\n\n"
+                                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:
@@ -328,7 +300,8 @@ class FlashTab(QWidget):
         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.import_btn):
+        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()
 
@@ -356,8 +329,8 @@ class FlashTab(QWidget):
         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[:9]
+        want = self._image.app.elf_sha[:8]
-        done = fw.elf_sha is not None and fw.elf_sha.startswith(want)
+        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)
@@ -367,7 +340,7 @@ class FlashTab(QWidget):
                 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[:9] if fw.elf_sha else "no boot seen"
+                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")
 

kota_tech/ui/guide_panel.py

@@ -18,6 +18,8 @@ from PySide6.QtWidgets import (
 
 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"),
@@ -52,9 +54,11 @@ def _esc(s: str) -> str:
 
 
 class GuidePanel(QWidget):
-    def __init__(self, runner: GuideRunner, engine: DiagnosticsEngine, parent: QWidget | None = None):
+    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)
@@ -93,7 +97,8 @@ class GuidePanel(QWidget):
         self.end_box = QLabel(wordWrap=True)
         self.end_box.setTextFormat(Qt.TextFormat.RichText)
         self.end_box.setMargin(10)
-        for w in (self.guide_title, self.step_text):
+        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):
@@ -192,6 +197,10 @@ class GuidePanel(QWidget):
         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)

kota_tech/ui/main_window.py

@@ -30,15 +30,19 @@ 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",
@@ -47,6 +51,7 @@ COLORS = {
     LineKind.RESET: "#6fc3ff",
     LineKind.PANIC: "#ff4dd2",
     LineKind.HOST: "#7ee07e",
+    LineKind.KOTA: "#5fd7e8",
     LineKind.RAW: "#a8a8a8",
 }
 
@@ -118,7 +123,7 @@ class SerialTab(QWidget):
         self.view.setStyleSheet("QPlainTextEdit { background:#1e1e1e; color:#d4d4d4; }")
 
         self.diag = DiagnosticsPanel()
-        self.guide = GuidePanel(self._runner, self._engine)
+        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")
@@ -147,6 +152,7 @@ class SerialTab(QWidget):
         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)
@@ -205,6 +211,11 @@ class SerialTab(QWidget):
         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))
@@ -289,19 +300,24 @@ class SerialTab(QWidget):
             self._counts[line.level] += 1
         self._update_status()
 
-        allowed = LEVEL_FILTERS[self.filter_combo.currentText()]
+        if self._visible(line):
-        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)
 
+    def _visible(self, line: LogLine) -> bool:
+        allowed = LEVEL_FILTERS[self.filter_combo.currentText()]
+        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")))
+        colour = COLORS.get(line.kind) if line.kind == LineKind.KOTA and line.level == "I" else None
-        if line.kind in (LineKind.PANIC, LineKind.BOOT, LineKind.HOST):
+        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)

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

@@ -7,7 +7,6 @@ from pathlib import Path
 
 from PySide6.QtCore import QObject, QSettings, Qt, Signal
 from PySide6.QtWidgets import (
-    QApplication,
     QCheckBox,
     QFileDialog,
     QFormLayout,
@@ -34,6 +33,7 @@ DEFAULT_TEMPLATE = Path(__file__).resolve().parents[4] / "002-SD_card_format" /
 
 class _Bridge(QObject):
     done = Signal(object)
+    listed = Signal(object)
 
 
 def _secret_field() -> tuple[QLineEdit, QCheckBox]:
@@ -52,6 +52,7 @@ class SdTab(QWidget):
         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)")
@@ -135,6 +136,7 @@ class SdTab(QWidget):
 
         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)
@@ -199,13 +201,28 @@ class SdTab(QWidget):
         super().showEvent(event)
 
     def refresh_cards(self) -> None:
-        if self._busy:
+        """List cards in the background: the UI never waits for a slow card reader."""
+        if self._busy or self._listing:
             return
-        QApplication.setOverrideCursor(Qt.CursorShape.WaitCursor)
+        self._listing = True
+        self.others.setText("Looking for SD cards...")
+
+        def worker():
             try:
-            self._cards, others = list_cards()
+                result = list_cards()
-        finally:
+            except Exception as exc:        # show it, never leave the tab stuck
-            QApplication.restoreOverrideCursor()
+                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))

pyproject.toml

@@ -1,16 +1,17 @@
 [project]
 name = "kota-technician-tool"
-version = "0.5.0"
+version = "0.7.0"
 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

@@ -3,7 +3,7 @@
 cd "$(dirname "$0")" || exit 1
 
 # Keep the virtual environment out of the (Google Drive) tool folder.
-export UV_PROJECT_ENVIRONMENT="$HOME/Library/Caches/KotaTechnicianTool/venv-0.5"
+export UV_PROJECT_ENVIRONMENT="$HOME/Library/Caches/KotaTechnicianTool/venv-0.7"
 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-0.5"
+set "UV_PROJECT_ENVIRONMENT=%LOCALAPPDATA%\KotaTechnicianTool\venv-0.7"
 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()
+    from kota_tech.diag import kota
-    by_id = {r.id: r for r in rules}
+    graph = {r.id: r.explained_by for r in load_rules()}
-    for r in rules:
+    for st in ("ERROR", "OUT_OF_RESOURCES", "CONNECTION_ERROR", "RTC_ERROR", "SD_ERROR", "RESETING", "HTTP_SERVER"):
-        seen, todo = set(), list(r.explained_by)
+        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 +237,13 @@ 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")

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

@@ -1,5 +1,6 @@
-"""Flashing: image validation on the real official image, plan building,
+"""Flashing: image validation on the real image in firmware/, the folder
-and the runner against a fake esptool (no hardware)."""
+catalogue (compile-date order), plan building, and the runner against a fake
+esptool (no hardware)."""
 
 import hashlib
 import sys
@@ -8,31 +9,39 @@ from pathlib import Path
 
 import pytest
 
-from kota_tech.flash.image import ImageError, inspect_image, official_images
+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 = Path(__file__).resolve().parents[1] / "firmware" / "new_system.bin"
+FW_DIR = Path(__file__).resolve().parents[1] / "firmware"
+FW = sorted(FW_DIR.glob("*.bin"))[0]
 
 
 @pytest.fixture(scope="module")
 def image():
-    imgs = official_images()
+    imgs, problems = folder_images()
-    assert len(imgs) == 1
+    assert imgs and problems == []
     return imgs[0]
 
 
 # ------------------------------------------------------------------ image
 
-def test_official_image_is_the_deployed_v1_build(image):
+def test_folder_image_is_a_kota_build(image):
     assert image.app.project == "kota-sensorboard"
-    assert image.app.elf_sha.startswith("45fa9d5b9")       # same as the live board
+    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
@@ -40,17 +49,6 @@ def test_app_bytes_are_a_complete_app_image(image):
     assert len(image.blank_otadata()) == 0x2000 and set(image.blank_otadata()) == {0xFF}
 
 
-def test_modified_image_is_refused(tmp_path):
-    data = bytearray(FW.read_bytes())
-    data[-1] ^= 0xFF
-    bad = tmp_path / "new_system.bin"
-    bad.write_bytes(data)
-    manifest = tmp_path / "firmware.toml"
-    manifest.write_text(f'[[image]]\nfile = "new_system.bin"\nsha256 = "{hashlib.sha256(FW.read_bytes()).hexdigest()}"\n')
-    with pytest.raises(ImageError, match="SHA-256"):
-        official_images(manifest)
-
-
 @pytest.mark.parametrize("patch,msg", [
     ((0, 0x00), "not an ESP32 firmware"),
     ((12, 0x05), "not ESP32-S3"),
@@ -64,6 +62,93 @@ def test_wrong_images_are_rejected(tmp_path, patch, 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):
@@ -160,87 +245,3 @@ def test_runner_reports_connect_failure_with_hint(image, tmp_path):
     res, *_ = _run(plan, cmd)
     assert not res.ok and res.failed_step == 0
     assert "BOOT" in res.hint
-
-
-# ------------------------------------------------- developer builds (v0.5)
-
-from kota_tech.flash.image import FirmwareLibrary, app_image_length  # noqa: E402
-
-
-def _app_only_file(image, tmp_path, name="kota-sensorboard.bin"):
-    p = tmp_path / name
-    p.write_bytes(image.app_bytes())          # what a developer build/ folder contains
-    return p
-
-
-def test_integrity_check_on_factory_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, origin="developer")
-
-
-def test_import_app_only_developer_build(image, tmp_path):
-    lib = FirmwareLibrary(tmp_path / "lib")
-    src = _app_only_file(image, tmp_path)
-    img = lib.import_file(src, reference=image)
-    assert img.is_developer and img.kind == "app"
-    assert img.partition("ota_0").offset == 0x40000            # layout from the factory image
-    assert img.app_bytes() == image.app_bytes()
-    listed, problems = lib.images(image)
-    assert [i.sha256 for i in listed] == [img.sha256] and problems == []
-    assert lib.import_file(src, reference=image).sha256 == img.sha256   # re-import: no duplicate
-    assert len(lib.images(image)[0]) == 1
-
-
-def test_app_only_build_cannot_be_flashed_full(image, tmp_path):
-    lib = FirmwareLibrary(tmp_path / "lib")
-    img = lib.import_file(_app_only_file(image, tmp_path), reference=image)
-    plan = build_plan(img, Mode.APP_ONLY, "COM5", tmp_path / "w")
-    assert [s.kind for s in plan.steps] == ["read_pt", "write"]
-    with pytest.raises(ValueError, match="app only"):
-        build_plan(img, Mode.FULL, "COM5", tmp_path / "w")
-
-
-def test_import_merged_developer_build(image, tmp_path):
-    lib = FirmwareLibrary(tmp_path / "lib")
-    src = tmp_path / "dev_full.bin"
-    src.write_bytes(image.data)
-    img = lib.import_file(src, reference=image)
-    assert img.kind == "merged" and img.is_developer
-    assert [s.kind for s in build_plan(img, Mode.FULL, "COM5", tmp_path / "w").steps] == ["write"]
-
-
-def test_library_detects_file_changed_after_import(image, tmp_path):
-    lib = FirmwareLibrary(tmp_path / "lib")
-    img = lib.import_file(_app_only_file(image, tmp_path), reference=image)
-    stored = tmp_path / "lib" / img.path.name
-    data = bytearray(stored.read_bytes())
-    data[-40] ^= 1
-    stored.write_bytes(data)
-    listed, problems = lib.images(image)
-    assert listed == [] and problems
-
-
-def test_library_remove(image, tmp_path):
-    lib = FirmwareLibrary(tmp_path / "lib")
-    img = lib.import_file(_app_only_file(image, tmp_path), reference=image)
-    lib.remove(img.sha256)
-    assert lib.images(image) == ([], []) and not img.path.exists()
-
-
-def test_non_firmware_file_refused(tmp_path, image):
-    p = tmp_path / "notes.bin"
-    p.write_bytes(b"hello firmware team")
-    with pytest.raises(ImageError, match="not an ESP32 firmware"):
-        FirmwareLibrary(tmp_path / "lib").import_file(p, reference=image)

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_sd.py

@@ -5,9 +5,12 @@ import plistlib
 
 import pytest
 
-from kota_tech.sd.disks import MAX_CARD_BYTES, Disk, parse_macos, parse_windows
+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, windows_format_script, write_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
@@ -108,15 +111,25 @@ def test_parse_macos_excludes_system_disk():
 
 # -------------------------------------------------------- format script
 
-def test_windows_script_rechecks_disk_before_erasing(tmp_path):
+def test_elevated_helper_command(tmp_path):
     disk = Disk("5", "SDXC Card", 63_864_569_856, "SD")
-    ps = windows_format_script(disk, tmp_path / "r.json")
+    prog, params, cwd = win_format_command(disk, tmp_path / "r.json")
-    erase = ps.index("Clear-Disk")
+    assert params.startswith("-m kota_tech.sd.win_format --disk 5 --size 63864569856 --label KOTA")
-    for guard in ("IsSystem -or $d.IsBoot", "'MMC','SD','USB'", "-ne 63864569856"):
+    assert (Path(cwd) / "kota_tech").is_dir()                 # helper is importable from there
-        assert guard in ps and ps.index(guard) < erase
+
-    assert "-PartitionStyle MBR" in ps and "-FileSystem FAT32" in ps
+
-    assert str(32 * 1024**3) in ps                          # FAT32 partition capped at 32 GB
+@pytest.mark.skipif(sys.platform != "win32", reason="Windows formatter")
-    assert "NewFileSystemLabel 'KOTA'" in ps
+@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():

tests/test_service.py

@@ -33,7 +33,7 @@ def test_bench_box_is_a_connectivity_problem():
     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 "-> No Internet" in note
+    assert "not commissioned in Matter" in note and "↳ [Error] No Internet" in note
     assert "Firmware: v1.0" in note
 
 
@@ -89,3 +89,19 @@ def test_invalid_mac_rejected(bad):
 
 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

@@ -6,6 +6,15 @@ resolution-markers = [
     "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"
@@ -207,6 +216,20 @@ dependencies = [
 ]
 sdist = { url = "https://files.pythonhosted.org/packages/84/19/f68b27fd43564d69277e956d13b8c2b352e7f1af4fb5d6e5c43e5419e61c/esptool-4.12.0.tar.gz", hash = "sha256:d797f6529d582173508baf0572542ddadf53aae8c92c84ea9f420f242464103c", size = 463840, upload-time = "2026-07-14T08:36:51.891Z" }
 
+[[package]]
+name = "fs"
+version = "2.4.16"
+source = { registry = "https://pypi.org/simple" }
+dependencies = [
+    { name = "appdirs" },
+    { name = "setuptools" },
+    { name = "six" },
+]
+sdist = { url = "https://files.pythonhosted.org/packages/5d/a9/af5bfd5a92592c16cdae5c04f68187a309be8a146b528eac3c6e30edbad2/fs-2.4.16.tar.gz", hash = "sha256:ae97c7d51213f4b70b6a958292530289090de3a7e15841e108fbe144f069d313", size = 187441, upload-time = "2022-05-02T09:25:54.22Z" }
+wheels = [
+    { url = "https://files.pythonhosted.org/packages/b9/5c/a3d95dc1ec6cdeb032d789b552ecc76effa3557ea9186e1566df6aac18df/fs-2.4.16-py2.py3-none-any.whl", hash = "sha256:660064febbccda264ae0b6bace80a8d1be9e089e0a5eb2427b7d517f9a91545c", size = 135261, upload-time = "2022-05-02T09:25:52.363Z" },
+]
+
 [[package]]
 name = "iniconfig"
 version = "2.3.0"
@@ -227,17 +250,20 @@ wheels = [
 
 [[package]]
 name = "kota-technician-tool"
-version = "0.4.0"
+version = "0.7.0"
 source = { virtual = "." }
 dependencies = [
     { name = "esptool" },
     { name = "pyserial" },
     { name = "pyside6-essentials" },
+    { name = "segno" },
 ]
 
 [package.dev-dependencies]
 dev = [
+    { name = "pyfatfs" },
     { name = "pytest" },
+    { name = "setuptools" },
 ]
 
 [package.metadata]
@@ -245,10 +271,15 @@ requires-dist = [
     { name = "esptool", specifier = "~=4.8" },
     { name = "pyserial", specifier = ">=3.5" },
     { name = "pyside6-essentials", specifier = ">=6.7" },
+    { name = "segno", specifier = ">=1.6" },
 ]
 
 [package.metadata.requires-dev]
-dev = [{ name = "pytest", specifier = ">=8" }]
+dev = [
+    { name = "pyfatfs", specifier = ">=1.0" },
+    { name = "pytest", specifier = ">=8" },
+    { name = "setuptools", specifier = "<81" },
+]
 
 [[package]]
 name = "packaging"
@@ -277,6 +308,18 @@ wheels = [
     { url = "https://files.pythonhosted.org/packages/0c/c3/44f3fbbfa403ea2a7c779186dc20772604442dde72947e7d01069cbe98e3/pycparser-3.0-py3-none-any.whl", hash = "sha256:b727414169a36b7d524c1c3e31839a521725078d7b2ff038656844266160a992", size = 48172, upload-time = "2026-01-21T14:26:50.693Z" },
 ]
 
+[[package]]
+name = "pyfatfs"
+version = "1.1.0"
+source = { registry = "https://pypi.org/simple" }
+dependencies = [
+    { name = "fs" },
+]
+sdist = { url = "https://files.pythonhosted.org/packages/44/3f/d08f1dbc44a7eef9c7fb355b83423fbd15bb3e487c250479a2c179cb39bf/pyfatfs-1.1.0.tar.gz", hash = "sha256:9725ccd0a4da1c09c27358abbf10f08c043ac84210af576803e087f51a2b30e0", size = 55459, upload-time = "2024-03-03T20:50:43.227Z" }
+wheels = [
+    { url = "https://files.pythonhosted.org/packages/cb/de/feb531b25eb2315aa73a7dba335c253ee0075ff7f55b6fe742fb6d492ade/pyfatfs-1.1.0-py3-none-any.whl", hash = "sha256:7401fd39d9e92f531b2abea5b5d1d2c19d5461f4ba9ce8819b1ba35aea73c65d", size = 37932, upload-time = "2024-03-03T20:50:41.426Z" },
+]
+
 [[package]]
 name = "pygments"
 version = "2.21.0"
@@ -372,6 +415,24 @@ wheels = [
     { url = "https://files.pythonhosted.org/packages/09/19/1bb346c0e581557c88946d2bb979b2bee8992e72314cfb418b5440e383db/reedsolo-1.7.0-py3-none-any.whl", hash = "sha256:2b6a3e402a1ee3e1eea3f932f81e6c0b7bbc615588074dca1dbbcdeb055002bd", size = 32360, upload-time = "2023-01-17T05:10:17.652Z" },
 ]
 
+[[package]]
+name = "segno"
+version = "1.6.6"
+source = { registry = "https://pypi.org/simple" }
+sdist = { url = "https://files.pythonhosted.org/packages/1c/2e/b396f750c53f570055bf5a9fc1ace09bed2dff013c73b7afec5702a581ba/segno-1.6.6.tar.gz", hash = "sha256:e60933afc4b52137d323a4434c8340e0ce1e58cec71439e46680d4db188f11b3", size = 1628586, upload-time = "2025-03-12T22:12:53.324Z" }
+wheels = [
+    { url = "https://files.pythonhosted.org/packages/d6/02/12c73fd423eb9577b97fc1924966b929eff7074ae6b2e15dd3d30cb9e4ae/segno-1.6.6-py3-none-any.whl", hash = "sha256:28c7d081ed0cf935e0411293a465efd4d500704072cdb039778a2ab8736190c7", size = 76503, upload-time = "2025-03-12T22:12:48.106Z" },
+]
+
+[[package]]
+name = "setuptools"
+version = "80.10.2"
+source = { registry = "https://pypi.org/simple" }
+sdist = { url = "https://files.pythonhosted.org/packages/76/95/faf61eb8363f26aa7e1d762267a8d602a1b26d4f3a1e758e92cb3cb8b054/setuptools-80.10.2.tar.gz", hash = "sha256:8b0e9d10c784bf7d262c4e5ec5d4ec94127ce206e8738f29a437945fbc219b70", size = 1200343, upload-time = "2026-01-25T22:38:17.252Z" }
+wheels = [
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+]
+
 [[package]]
 name = "shiboken6"
 version = "6.11.2"