Build optimization: pre-built PM3 binaries, ARM64 CI, base image caching
Replace PM3 compile-from-source in pi-gen with pre-built tarball extraction (saves 43-58 min). Merge stagePM3 into stageDangerousPi as 02-pm3-install substage, renumber all subsequent substages. Switch CI PM3 build to native ARM64 runner (ubuntu-24.04-arm64) eliminating QEMU overhead. Add weekly base-image workflow for pre-baking stages 0-2. Support PM3_TARBALL, BASE_IMAGE, and APT_PROXY env vars in build-image.sh. Also includes prior Phase 5 work: theme system, design system integration, component update system, OS updates, CI build pipeline, and test results. Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
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michael
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TEST_RESULTS_2026-01-23.md
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TEST_RESULTS_2026-01-23.md
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# Dangerous Pi - Hardware Test Results
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**Test Date**: 2026-01-23
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**Tester**: Claude (via serial console)
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**Hardware**: Raspberry Pi Zero 2 W + Proxmark3 Easy + PiSugar 2 Zero
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**Image Version**: Custom pi-gen build (January 2026)
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**Pi IP**: 192.168.0.129 (on NETGEAR13 network)
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---
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## Test Summary
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| Component | Status | Notes |
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|-----------|--------|-------|
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| Serial Console | PASS | Connected via /dev/ttyUSB0 at 115200 baud |
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| Boot & Login | PASS | Logged in as dt/proxmark3 |
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| Backend Service | PASS | dangerous-pi.service running on port 8000 |
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| Frontend | PASS | Remix.js serving on port 3000, HTTP 200 |
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| PM3 Detection | PASS | Device at /dev/ttyACM0 detected |
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| PM3 Commands | PASS | hw version, hw tune working |
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| HF Card Search | PASS | MIFARE Classic 1K detected (UID: B9 78 42 3D) |
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| LF Card Search | PASS | FDX-B Animal tag detected (ID: 941-000019966456) |
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| WiFi Client Mode | PASS | Connected to NETGEAR13 (192.168.0.129) |
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| WiFi Manager API | **ISSUE** | See Issue #1 |
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| UPS Detection | **ISSUE** | See Issue #2 |
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| BLE Advertising | **ISSUE** | See Issue #3 |
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| Antenna Tuning | PASS | LF: 25.21V @ 126.32kHz, HF: 11.02V @ 13.56MHz |
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| LED Control | PASS | hw led command returns success |
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| Plugin System | PASS | Hello World plugin discovered |
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---
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## Issues Found
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### Issue #1: WiFi Connect API Returns Failure Despite Success (HIGH)
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**Component**: WiFi Manager API
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**Endpoint**: `POST /api/wifi/connect`
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**Severity**: High
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**Reproducible**: Yes
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**Description**:
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When calling the WiFi connect API, the connection actually succeeds (device gets IP address), but the API returns a 503 error and falls back to AP mode.
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**Steps to Reproduce**:
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```bash
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curl -X POST http://localhost:8000/api/wifi/connect \
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-H "Content-Type: application/json" \
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-d '{"ssid": "NETGEAR13", "password": "****"}'
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```
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**Expected**: `{"success": true, "ip_address": "192.168.0.129"}`
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**Actual**: `{"detail":"Failed to connect to NETGEAR13"}`
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**Log Evidence**:
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```
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[WiFi Connect] IP result: inet 192.168.0.129/24
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Device 'wlan0' successfully activated with 'f931b358-80a4-4f81-93d8-690a5cff910e'.
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Falling back to AP mode...
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[NM Management] Setting wlan0 as unmanaged...
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AP mode enabled
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```
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**Analysis**:
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The NetworkManager successfully connects and obtains an IP, but the verification logic incorrectly determines failure and triggers AP mode fallback.
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**Workaround**:
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After API call, manually run `sudo nmcli device set wlan0 managed yes` to complete the connection.
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---
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### Issue #2: PiSugar 2 UPS Not Detected at Startup (HIGH)
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**Component**: UPS Manager
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**Severity**: High
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**Hardware**: PiSugar 2 Zero at I2C address 0x75
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**Reproducible**: Yes
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**Description**:
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PiSugar 2 is physically connected and responds to I2C probes, but the UPS manager fails to detect it during service startup.
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**I2C Devices Detected**:
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- 0x32 - RTC (SD3078)
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- 0x75 - PiSugar 2 battery IC (IP5209)
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**Manual Detection Test** (Works):
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```python
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# This works when run manually after boot
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detected, driver = await PiSugarI2CDriver.detect(retries=3, retry_delay=1.0)
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# Result: PiSugar I2C: Found PiSugar 2 at 0x75 (voltage regs: 92, 23)
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# Detection result: True
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```
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**Service Startup Log** (Fails):
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```
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✅ UPS manager started
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Failed to initialize I2C fuel gauge: [Errno 5] Input/output error
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UPS not available: Failed to initialize I2C Fuel Gauge (MAX17040/MAX17048)
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```
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**Analysis**:
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The error message "MAX17040/MAX17048" indicates the auto-detection is falling through to the generic I2C fuel gauge driver instead of using the PiSugar I2C driver. Possible race condition with I2C bus availability at boot time.
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**Potential Fixes**:
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1. Add longer startup delay before UPS detection (UPS_STARTUP_DELAY env var?)
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2. Add retry logic in auto_detect_driver
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3. Check if PiSugar detection is being attempted before generic I2C
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---
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### Issue #3: BLE Advertisement Registration Failure (MEDIUM)
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**Component**: BLE Manager
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**Severity**: Medium
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**Reproducible**: Yes (at startup)
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**Description**:
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BLE advertising fails to register during service startup, falling back to "basic mode".
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**Log Evidence**:
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```
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Failed to start BLE server: Failed to register advertisement
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dbus_next.errors.DBusError: Failed to register advertisement
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Failed to start GATT server, falling back to basic mode
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✅ BLE manager started
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```
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**API Status** (Reports OK):
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```json
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{
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"enabled": true,
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"available": true,
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"advertising": true,
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"connected_devices": 0,
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"device_name": "DangerousPi"
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}
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```
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**Analysis**:
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The BLE manager reports success in "basic mode" despite the GATT server advertisement failure. The distinction between full mode and basic mode is unclear. Testing BLE advertising from a mobile device would help determine actual functionality.
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---
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### Issue #4: Missing i2c-tools Package (LOW)
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**Component**: System Image
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**Severity**: Low
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**Description**:
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The `i2cdetect` command is not available, making I2C debugging more difficult.
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```
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$ sudo i2cdetect -y 1
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sudo: i2cdetect: command not found
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```
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**Recommendation**:
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Add `i2c-tools` to the pi-gen package list.
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---
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### Issue #5: PM3 Firmware/Client Version Mismatch Warning (LOW)
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**Component**: Proxmark3 Integration
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**Severity**: Low (Cosmetic)
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**Description**:
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The PM3 hw version command shows a warning about firmware/client mismatch.
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**Output**:
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```
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[!] ARM firmware does not match the source at the time the client was compiled
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[!] Make sure to flash a correct and up-to-date version
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```
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**API Status**:
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```json
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"firmware_info": {
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"bootrom_version": "Iceman/DangerousPi/master/66c7374-dirty-suspect",
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"os_version": "Iceman/DangerousPi/master/66c7374-dirty-suspect",
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"compatible": false
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}
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```
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**Analysis**:
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The firmware (built 2026-01-04) and client (built 2026-01-13) were compiled at different times. This is expected when firmware and client are built separately, but the `compatible: false` flag may cause unnecessary warnings in the UI.
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---
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### Issue #6: Pydantic Protected Namespace Warning (LOW)
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**Component**: Backend Models
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**Severity**: Low (Cosmetic)
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**Description**:
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Pydantic logs a warning about field naming conflict.
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**Log**:
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```
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Field "model_short" in PiModelResponse has conflict with protected namespace "model_".
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You may be able to resolve this warning by setting `model_config['protected_namespaces'] = ()`.
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```
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**Recommendation**:
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Either rename the field or add the protected_namespaces config to the Pydantic model.
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---
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## Passing Tests Detail
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### Proxmark3 Hardware
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**hw version**:
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```
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[ Client ] Iceman/DangerousPi/master/v4.20728-299-g91263b...-suspect 2026-01-13
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[ ARM ] Iceman/DangerousPi/master/66c7374-dirty-suspect 2026-01-04
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[ FPGA ] fpga_pm3_hf.ncd, fpga_pm3_lf.ncd, fpga_pm3_felica.ncd images present
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[ Hardware ] AT91SAM7S512 Rev A, ARM7TDMI, 64K SRAM, 512K flash (71% used)
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```
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**hw tune**:
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- LF Antenna: 25.21V @ 126.32kHz (optimal), Q factor OK
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- HF Antenna: 11.02V @ 13.56MHz, OK
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**hf search** (Card on HF antenna):
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- Type: MIFARE Classic 1K
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- UID: B9 78 42 3D (ONUID, re-used)
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- Magic: Gen 1a
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- PRNG: weak
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**lf search** (Card on LF antenna):
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- Type: FDX-B / ISO 11784/5 Animal tag
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- Animal ID: 941-000019966456
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- Chipset: T55xx
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### System Info
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**API Response** (`/api/system/info`):
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```json
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{
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"hostname": "dangerous-pi",
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"uptime": 2995.86,
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"cpu_temp": 45.08,
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"cpu": {
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"count": 2,
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"percent": 3.4,
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"temperature": 45.08
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},
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"memory_used": 115757056,
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"memory_total": 436301824,
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"disk_used": 6584954880,
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"disk_total": 7116754944
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}
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```
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### WiFi Status (After manual fix)
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**API Response** (`/api/wifi/status`):
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```json
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{
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"mode": "client",
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"interfaces": [{
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"name": "wlan0",
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"mac": "2c:cf:67:87:db:13",
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"is_usb": false,
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"is_up": true,
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"connected": true,
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"ssid": "NETGEAR13",
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"ip_address": "192.168.0.129",
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"mode": "managed"
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}],
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"current_ssid": "NETGEAR13",
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"current_ip": "192.168.0.129",
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"ap_ssid": "Dangerous-Pi",
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"supports_dual": false
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}
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```
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### Plugins
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**API Response** (`/api/plugins/list`):
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```json
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[{
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"metadata": {
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"id": "hello_world",
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"name": "Hello World Plugin",
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"version": "1.0.0",
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"description": "Example plugin demonstrating the plugin framework"
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},
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"status": "loaded",
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"enabled": false
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}]
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```
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---
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## Recommendations
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### Priority 1 (Critical for User Experience)
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1. **Fix WiFi Connect API** - Investigate why verification fails after successful connection
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2. **Fix UPS Detection** - Add retry logic or increase startup delay for I2C initialization
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### Priority 2 (Quality Improvements)
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3. **Investigate BLE Basic Mode** - Document what features are available in basic vs full mode
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4. **Add i2c-tools** - Include in pi-gen image for easier debugging
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### Priority 3 (Nice to Have)
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5. **Fix Pydantic Warning** - Clean up model namespace conflict
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6. **Document PM3 Version Mismatch** - Either sync builds or suppress cosmetic warning
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---
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## Test Environment
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```
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Pi Model: Raspberry Pi Zero 2 W
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Kernel: 6.12.62+rpt-rpi-v8 aarch64
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Debian: Trixie
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Python: 3.13.5
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Serial: /dev/ttyUSB0 @ 115200 baud
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PM3: /dev/ttyACM0 (Proxmark3 Easy)
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I2C Bus: 1 (devices at 0x32, 0x75)
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```
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---
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*Test conducted via serial console using Python pyserial library*
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Reference in New Issue
Block a user