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Add SEN54/NOX detection to AIR-1 factory test #113

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Add SEN54/NOX detection to AIR-1 factory test #113

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33 changes: 30 additions & 3 deletions Integrations/ESPHome/Core.yaml
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Original file line number Diff line number Diff line change
@@ -1,6 +1,6 @@
substitutions:
name: apollo-air-1
version: "26.7.1.1"
version: "26.7.15.1"
device_description: ${name} made by Apollo Automation - version ${version}.
# Default OTA password. Override in your device YAML by re-declaring
# `substitutions: { ota_password: !secret <name>_ota_password }` so each
Expand Down Expand Up @@ -71,6 +71,10 @@ globals:
restore_value: no
type: bool
initial_value: "false"
- id: noxPassed
restore_value: no
type: bool
initial_value: "false"


i2c:
Expand Down Expand Up @@ -575,6 +579,7 @@ script:
then:
- lambda: "id(runTest) = false;"
- lambda: "id(testCycleCount) = 0;"
- lambda: "id(noxPassed) = false;"
- while:
condition:
- lambda: "return id(testCycleCount) < 5;"
Expand All @@ -597,11 +602,33 @@ script:
- lambda: "id(runTest) = false;"
- delay: 1s
- lambda: "id(testCycleCount) += 1;"


# SEN54 detection: when the SEN5x chip reports itself as a SEN54 the
# component nulls the NOX sensor, so its state stays NaN forever. A
# healthy SEN55 publishes a NOX index within a couple of update cycles,
# so wait up to 30s for a value before deciding.
- wait_until:
condition:
- lambda: "return !isnan(id(sen55_nox).state);"
timeout: 30s
Comment on lines +606 to +613

@coderabbitai coderabbitai Bot Jul 15, 2026

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🎯 Functional Correctness | 🟠 Major | ⚡ Quick win

Increase NOX timeout to account for the sensor's warm-up period.

The SEN55 datasheet specifies that both VOC and NOX index values require a 45-second warm-up period after power-on before they return valid data (outputting 0x7FFF, translated to NaN by ESPHome, in the meantime).

Since testScript runs on boot (via AIR-1_Factory.yaml), the device will have been powered on for just a few seconds. The maximum 5-second wait for the DPS310 plus this 30-second NOX timeout totals around 35 seconds. This falls short of the 45-second hardware warm-up time, meaning the factory test will likely time out and falsely fail healthy SEN55 units.

Please consider increasing the timeout to at least 45-50 seconds.

🕒 Proposed timeout fix 
           - wait_until:
               condition:
                 - lambda: "return !isnan(id(sen55_nox).state);"
-              timeout: 30s
+              timeout: 45s
📝 Committable suggestion

‼️ IMPORTANT
Carefully review the code before committing. Ensure that it accurately replaces the highlighted code, contains no missing lines, and has no issues with indentation. Thoroughly test & benchmark the code to ensure it meets the requirements.

Suggested change
# SEN54 detection: when the SEN5x chip reports itself as a SEN54 the
# component nulls the NOX sensor, so its state stays NaN forever. A
# healthy SEN55 publishes a NOX index within a couple of update cycles,
# so wait up to 30s for a value before deciding.
- wait_until:
condition:
- lambda: "return !isnan(id(sen55_nox).state);"
timeout: 30s
# SEN54 detection: when the SEN5x chip reports itself as a SEN54 the
# component nulls the NOX sensor, so its state stays NaN forever. A
# healthy SEN55 publishes a NOX index within a couple of update cycles,
# so wait up to 30s for a value before deciding.
- wait_until:
condition:
- lambda: "return !isnan(id(sen55_nox).state);"
timeout: 45s
🤖 Prompt for AI Agents 
Verify each finding against current code. Fix only still-valid issues, skip the
rest with a brief reason, keep changes minimal, and validate.

In `@Integrations/ESPHome/Core.yaml` around lines 606 - 613, Increase the timeout
in the SEN54/SEN55 NOX wait_until block from 30 seconds to at least 45–50
seconds so testScript accommodates the sensor’s documented warm-up period. Keep
the existing !isnan(id(sen55_nox).state) condition unchanged.

- if:
condition:
- lambda: "return !isnan(id(sen55_nox).state);"
then:
- lambda: "id(noxPassed) = true;"
- logger.log:
format: "TEST: NOX OK - SEN55 confirmed (nox index %.1f)"
args: ["id(sen55_nox).state"]
level: INFO
else:
- logger.log:
format: "TEST FAIL: NOX unavailable - SEN55 is reporting as SEN54"
level: ERROR

#Check If Test Passed To Trigger Lights
- if:
condition:
- lambda: "return id(dps310Passed);"
- lambda: "return id(dps310Passed) && id(noxPassed);"
then:
- lambda: "id(runTest) = false;"
- light.turn_on:
Expand Down