Gate Controller — QA Test Procedure

Pre-publish functional verification covering every feature of the gate controller. Work through the sections in order — the sequence minimises unnecessary gate trips and builds on state established in prior sections.

Before You Start

Requirement	Notes
Firmware flashed to ESP32
`secrets.yaml` populated	WiFi, OTA password, API key
Device connected to Home Assistant	API active
`input_number.entry_gate_duration` created in HA	min: 1, max: 300, step: 1, unit: s
Gate wired and physically operational	H-bridge, endstops, motor connected
ESPHome web server accessible	`http://<device-ip>` for log inspection

Reset state: Hold the panel Reboot/Reset button for 10+ seconds to clear any previously learned travel times and reboot clean. Manually position the gate at the closed endstop before starting.

1 — Initial State Detection on Boot

The controller checks both endstops on boot and sets the FSM to the correct starting state automatically.

Scenario 1.1 — Boot at closed endstop

Boot the device with the gate physically at the closed endstop.

Check	Expected	Pass
Close endstop binary sensor	ON	[ ]
FSM state (within 2s of boot)	CLOSED	[ ]
Open LED / Close LED	Off / Solid	[ ]
Cover position	0%	[ ]

Scenario 1.2 — Boot at open endstop

Manually position the gate at the open endstop, then reboot.

Check	Expected	Pass
Open endstop binary sensor	ON	[ ]
FSM state (within 2s of boot)	OPEN	[ ]
Open LED / Close LED	Solid / Off	[ ]
Cover position	100%	[ ]

Scenario 1.3 — Boot mid-travel (position unknown)

Manually position the gate mid-travel so neither endstop is active, then reboot.

Check	Expected	Pass
Both endstop sensors	OFF	[ ]
FSM state	STOPPED_UNKNOWN	[ ]
Open LED / Close LED	Alternating fast flash (opposite phase)	[ ]

2 — Timing Learning (First Run)

The controller measures full travel time on the first run and stores it in flash. This calibration is required before position control (Section 7) and soft stop (Section 8) are meaningful. Both directions are learned in this combined run.

During a learning run, soft start is intentionally disabled so speed is constant and the timing is accurate.

Scenario 2.1 — Learn open time

Precondition: Learned times cleared (see Before You Start). State = CLOSED.

Send OPEN from the HA cover entity.

Check	Expected	Pass
FSM state	OPENING	[ ]
Log message	"Timing not learned: using default open time"	[ ]
Log message	"TIMING RUN ARMED"	[ ]
Soft Start Active sensor	Stays OFF for entire run	[ ]
Motor current	Steady from start (no soft ramp)	[ ]
Open LED / Close LED	Fast flash / Off	[ ]

Gate travels to open endstop and stops.

Check	Expected	Pass
Log message	"ENDSTOP: OPEN — emergency motor kill"	[ ]
FSM state	OPEN	[ ]
Learned Open Time sensor	Non-zero value (measured seconds)	[ ]
Gate Position sensor	~100%	[ ]
Open LED / Close LED	Solid / Off	[ ]

Scenario 2.2 — Learn close time

Precondition: State = OPEN (from 2.1).

Send CLOSE from HA.

Check	Expected	Pass
FSM state	CLOSING	[ ]
Log message	"TIMING RUN ARMED"	[ ]
Soft Start Active sensor	Stays OFF for entire run	[ ]

Gate travels to close endstop and stops.

Check	Expected	Pass
FSM state	CLOSED	[ ]
Learned Close Time sensor	Non-zero value	[ ]
Open LED / Close LED	Off / Solid	[ ]

Scenario 2.3 — Learned times survive reboot

Note the learned open and close times, then reboot the device.

Check	Expected	Pass
Learned Open Time after reboot	Same as before	[ ]
Learned Close Time after reboot	Same as before	[ ]
"Timing not learned" warning on next motion	Does NOT appear	[ ]

3 — Basic Open / Close / Direction Reversal

Precondition: Timing learned. Gate at closed endstop. State = CLOSED.

Scenario 3.1 — Open via HA with soft start

Send OPEN from the HA cover entity.

Check	Expected	Pass
FSM state	OPENING	[ ]
Soft Start Active sensor	ON at start, transitions OFF mid-travel	[ ]
Log message	"Ramp complete at X% travel"	[ ]
FSM state at open endstop	OPEN (no countdown)	[ ]
Gate Position sensor	~100%	[ ]

Scenario 3.2 — Close via HA

Precondition: State = OPEN.

Check	Expected	Pass
FSM state after CLOSE command	CLOSING	[ ]
Open LED / Close LED	Off / Fast flash	[ ]
FSM state at close endstop	CLOSED	[ ]
Gate Position sensor	~0%	[ ]

Scenario 3.3 — Direction reversal mid-travel (CLOSE while OPENING)

Send OPEN, wait until gate is 30–50% open, then send CLOSE.

Check	Expected	Pass
FSM state after CLOSE command	CLOSING immediately (no pause)	[ ]
Gate reverses without stopping	Yes	[ ]
Gate reaches close endstop	State = CLOSED	[ ]

Scenario 3.4 — Direction reversal mid-travel (OPEN while CLOSING)

Send CLOSE, wait until 30–50% closed, then send OPEN.

Check	Expected	Pass
FSM state after OPEN command	OPENING immediately	[ ]
Gate reaches open endstop	State = OPEN	[ ]

4 — Cycle Button & Auto-Close

Scenario 4.1 — Full auto-close cycle

Precondition: State = CLOSED. Set input_number.entry_gate_duration = 10 seconds.

Press Cycle (panel button or HA button entity).

Check	Expected	Pass
FSM state	OPENING_CYCLE	[ ]
Open LED / Close LED	Fast flash / Off	[ ]

Gate reaches open endstop.

Check	Expected	Pass
FSM state	OPEN_CYCLE	[ ]
Open LED / Close LED	Slow pulse (1 Hz) / Off	[ ]
Close Countdown sensor	Counting down from 10	[ ]
Auto Close Armed sensor	ON	[ ]

Countdown expires.

Check	Expected	Pass
FSM state	CLOSING	[ ]
Gate closes to endstop	State = CLOSED	[ ]
Close Countdown sensor	Resets to 10	[ ]
Auto Close Armed sensor	OFF	[ ]

Scenario 4.2 — Cancel auto-close with Cycle button

Precondition: State = OPEN_CYCLE, countdown active.

Check after pressing Cycle	Expected	Pass
FSM state	OPEN (countdown cancelled)	[ ]
Open LED	Solid	[ ]
Auto Close Armed sensor	OFF	[ ]

Scenario 4.3 — Cancel auto-close with OPEN command

Precondition: State = OPEN_CYCLE, countdown active.

Check after sending OPEN	Expected	Pass
FSM state	OPEN	[ ]
Countdown	Stopped	[ ]

Scenario 4.4 — CLOSE command during auto-close countdown

Precondition: State = OPEN_CYCLE, countdown active.

Check after sending CLOSE	Expected	Pass
FSM state	CLOSING immediately	[ ]
Auto Close Armed sensor	OFF	[ ]

Scenario 4.5 — CYCLE from OPEN closes directly (no auto-close)

Precondition: State = OPEN (arrived via OPEN command, no countdown armed).

Check	Expected	Pass
FSM state after Cycle	CLOSING	[ ]
Gate closes to endstop	State = CLOSED	[ ]

Scenario 4.6 — Countdown pauses when gate leaves open endstop

Precondition: State = OPEN_CYCLE, countdown active (set to 30s for this test).

Note the current countdown value, then briefly jog the gate away from the open endstop.

Check	Expected	Pass
Countdown while off endstop	Stops decrementing	[ ]
Countdown after returning to endstop	Resumes from where it paused	[ ]

Scenario 4.7 — Pause mid-OPENING_CYCLE with Cycle, then resume with Cycle

Precondition: State = CLOSED.

Press Cycle, wait until mid-travel, press Cycle again.

Check	Expected	Pass
FSM state after second Cycle	PAUSED_FROM_OPENING	[ ]
Gate	Stopped	[ ]
Both LEDs	Fast flash	[ ]

Press Cycle a third time.

Check	Expected	Pass
FSM state	CLOSING	[ ]
Gate closes to endstop	State = CLOSED	[ ]

Scenario 4.8 — Pause mid-CLOSING, resume with Cycle arms auto-close

Precondition: State = OPEN.

Send CLOSE, wait until mid-travel, press Cycle.

Check	Expected	Pass
FSM state after Cycle	PAUSED_FROM_CLOSING	[ ]
Both LEDs	Fast flash	[ ]

Press Cycle again.

Check	Expected	Pass
FSM state	OPENING_CYCLE	[ ]
Gate reaches open endstop	State = OPEN_CYCLE	[ ]
Countdown starts	Yes	[ ]

5 — Hold-to-Operate (Jog)

Jog is a dead man's switch — the gate moves only while the button is held. It bypasses the FSM entirely; the FSM state does not change during a jog.

Scenario 5.1 — Jog open, verify FSM unchanged

Precondition: State = CLOSED.

Check while holding OPEN jog button	Expected	Pass
Gate movement	Moving open	[ ]
Open LED / Close LED	Fast flash / Off	[ ]
FSM state	Still CLOSED	[ ]
Motor Current sensor	Positive value	[ ]

Check after releasing OPEN jog button	Expected	Pass
Gate	Stops immediately	[ ]
FSM state	Still CLOSED	[ ]

Scenario 5.2 — Jog close, verify FSM unchanged

Precondition: State = OPEN.

Check while holding CLOSE jog button	Expected	Pass
Gate movement	Moving close	[ ]
Open LED / Close LED	Off / Fast flash	[ ]
FSM state	Still OPEN	[ ]

Check after releasing	Expected	Pass
Gate	Stops immediately	[ ]
FSM state	Still OPEN	[ ]

Scenario 5.3 — Jog stops at endstop

Position the gate within a few seconds of the open endstop, then hold the OPEN jog button.

Check	Expected	Pass
Gate at/approaching open endstop	Motor stops (endstop lockout)	[ ]
FSM state	Unchanged	[ ]

Scenario 5.4 — Jog does not disrupt auto-close countdown

Precondition: State = OPEN_CYCLE, countdown active.

Briefly hold CLOSE jog button (gate moves off endstop), then release.

Check	Expected	Pass
Countdown while off endstop	Paused (not decrementing)	[ ]
FSM state after releasing jog	Still OPEN_CYCLE	[ ]
Countdown after gate returns to endstop	Resumes	[ ]

6 — Stop & Pause Mid-Travel

Scenario 6.1 — Stop button during opening

Send OPEN, wait until mid-travel, then press the Stop button.

Check	Expected	Pass
Gate	Stops immediately	[ ]
FSM state	STOPPED	[ ]
Both LEDs	Fast flash	[ ]
Gate resumes on OPEN command	Yes, State = OPENING	[ ]

Scenario 6.2 — Stop button during closing

Send CLOSE, wait until mid-travel, then press Stop.

Check	Expected	Pass
FSM state	STOPPED	[ ]
Gate resumes on CLOSE command	Yes, State = CLOSING	[ ]

Scenario 6.3 — Stop from HA cover entity

During any motion, click Stop on the HA cover entity.

Check	Expected	Pass
Gate	Stops immediately	[ ]
FSM state	STOPPED	[ ]

Scenario 6.4 — Stop has no effect from a resting state

Precondition: State = CLOSED.

Check after pressing Stop	Expected	Pass
Gate	No movement	[ ]
FSM state	Still CLOSED	[ ]

Scenario 6.5 — Resume from PAUSED_FROM_OPENING

Precondition: State = PAUSED_FROM_OPENING (paused while opening).

Check after OPEN command	Expected	Pass
FSM state	OPENING	[ ]
Gate	Continues toward open endstop	[ ]

Check after CLOSE command (from PAUSED_FROM_OPENING)	Expected	Pass
FSM state	CLOSING	[ ]

Scenario 6.6 — Resume from PAUSED_FROM_CLOSING

Precondition: State = PAUSED_FROM_CLOSING (paused while closing).

Check after CLOSE command	Expected	Pass
FSM state	CLOSING	[ ]
Gate	Continues toward close endstop	[ ]

Check after OPEN command (from PAUSED_FROM_CLOSING)	Expected	Pass
FSM state	OPENING	[ ]

7 — Position Control

Precondition: Timing is learned (Section 2 complete).

Scenario 7.1 — Move to 50% from closed

Precondition: State = CLOSED. Set the HA cover slider to 50%.

Check	Expected	Pass
FSM state during travel	OPENING	[ ]
Gate Position sensor	Increases during travel	[ ]
Soft Stop Active sensor	ON as gate approaches target	[ ]
Gate stops at	~50% (±5% acceptable)	[ ]
FSM state after stop	STOPPED	[ ]

Scenario 7.2 — Move to 75% from 50%, then 25% from 75%

Check	Expected	Pass
Slider to 75% from STOPPED at 50%	Gate opens to ~75% and stops	[ ]
Slider to 25% from STOPPED at 75%	Gate closes to ~25% and stops	[ ]

Scenario 7.3 — Position command cancels auto-close countdown

Precondition: State = OPEN_CYCLE, countdown active.

Check after setting slider to 50%	Expected	Pass
Auto Close Armed sensor	OFF	[ ]
FSM state	CLOSING	[ ]
Gate stops at	~50%	[ ]

8 — Soft Start & Soft Stop

Scenario 8.1 — Soft start ramp in normal operation

Precondition: Timing learned. State = CLOSED. Send OPEN.

Check	Expected	Pass
Soft Start Active sensor at motion start	ON	[ ]
Motor Current sensor at start	Gradual increase (not instant)	[ ]
Log message	"Ramp complete at X% travel"	[ ]
Soft Start Active sensor after ramp	OFF	[ ]

Scenario 8.2 — Soft stop ramp approaching endstop

Observe the gate in the final approach to the open endstop.

Check	Expected	Pass
Soft Stop Active sensor (last ~1% of travel)	ON	[ ]
Motor Current sensor near endstop	Reduces before endstop triggers	[ ]
Gate arrival at endstop	Clean stop, no audible slam	[ ]

Scenario 8.3 — Soft stop ramp for position target

Observe the gate approaching a 50% position target.

Check	Expected	Pass
Soft Stop Active sensor (last ~5% before target)	ON	[ ]
Gate	Visibly slows before stopping	[ ]
Gate stops at	~50%	[ ]

Scenario 8.4 — Soft start disabled during timing learning run

Precondition: Learned times reset. State = CLOSED. Send OPEN.

Check	Expected	Pass
Log message	"TIMING RUN ARMED"	[ ]
Soft Start Active sensor	Stays OFF entire run	[ ]
Motor current at start	Full power from the first moment	[ ]

9 — Obstacle Detection

Safety: Use a test object that will not be damaged and that the gate can safely contact. Test at 30–70% travel (well clear of the 0–10% and 90–100% near-endstop zones). Keep a hand near the Stop button throughout.

Scenario 9.1 — First obstacle hit: gate reverses then stops

Precondition: Timing learned. Place obstacle in the gate path at approximately 50%.

Send OPEN and allow gate to contact the obstacle.

Check	Expected	Pass
Gate stops after contact	Within 50ms (one check cycle)	[ ]
Log message	"OBSTACLE HIT: X.XXA > threshold at pos XX% → reversing"	[ ]
Gate reverses direction	Yes	[ ]
Reversal distance	Approximately equal to Obstacle Reverse Distance setting	[ ]
Log message after reversal	"Reverse complete at XX% → STOP"	[ ]
FSM state after reversal	STOPPED	[ ]

Scenario 9.2 — Second obstacle during reverse → FAULT

Position an obstacle that also blocks the reverse path (or quickly place a second object after the first hit).

Allow the gate to hit the obstacle during its reversal.

Check	Expected	Pass
Log message	"OBSTACLE DURING REVERSE: X.XXA > threshold → FAULT"	[ ]
Motor	Stops immediately	[ ]
FSM state	FAULT	[ ]
Open LED / Close LED	Both solid	[ ]

Scenario 9.3 — Clear FAULT and resume after obstacle

Precondition: State = FAULT. Remove all obstacles.

Check	Expected	Pass
After pressing Cycle	State = STOPPED	[ ]
Both LEDs	Fast flash	[ ]
After pressing Cycle again	State = OPENING_CYCLE, gate moves normally	[ ]

Scenario 9.4 — Near-endstop threshold automatically increases

Trigger an obstacle hit while the gate is in the last 10% of travel (position > 90% or < 10%).

Check	Expected	Pass
Log shows threshold when hit	Base threshold × 1.15	[ ]
Gate did not false-trigger on normal mechanical resistance near endstop	Yes	[ ]

If the gate does false-trigger on normal resistance near the endstop, raise the base threshold via the Obstacle Threshold number entity in HA.

Scenario 9.5 — Grace period absorbs startup inrush current

Precondition: Reduce the Obstacle Threshold entity to a low value (e.g., 0.05 A) to expose this scenario. Restore it after the test.

Send OPEN and observe the motor current spike at startup.

Check	Expected	Pass
Obstacle triggered during first 300ms	No (grace period active)	[ ]
Log message at ~300ms	"Grace period ended, monitoring active"	[ ]

Scenario 9.6 — Obstacle suppressed during soft start

During soft start the current readings are unreliable at low PWM, so obstacle detection is suppressed.

Check during soft start ramp	Expected	Pass
Soft Start Active sensor	ON	[ ]
Obstacle triggered despite low threshold	No	[ ]
Obstacle detection activates	After Soft Start Active goes OFF	[ ]

10 — Movement Timeout & FAULT

To simulate a timeout, physically block or disconnect the open endstop sensor so it cannot trigger. The timeout fires at 1.5 × the learned travel time.

Scenario 10.1 — Movement timeout triggers FAULT

Precondition: Timing learned. Open endstop disabled.

Send OPEN.

Check	Expected	Pass
Log message	"Movement timeout armed: Xs (travel=Ys × 1.5)"	[ ]
After 1.5× travel time	"MOVEMENT TIMEOUT: Xs elapsed > Xs limit → FAULT"	[ ]
Motor	Stops immediately	[ ]
FSM state	FAULT	[ ]
Open LED / Close LED	Both solid	[ ]

Re-enable the endstop and clear FAULT (Cycle → STOPPED, Cycle → OPENING_CYCLE).

Scenario 10.2 — Timeout uses fallback when timing not learned

Precondition: Learned times reset. Send OPEN.

Check	Expected	Pass
Log message	"Timing not learned: using default open time"	[ ]
Timeout value in log	open_time_fallback × 1.5	[ ]
Gate completes travel normally	Endstop stops it before timeout	[ ]

Scenario 10.3 — Two-step FAULT recovery via OPEN or CLOSE command

Precondition: State = FAULT.

Check after first OPEN command	Expected	Pass
FSM state	STOPPED_UNKNOWN (not yet moving)	[ ]

Check after second OPEN command	Expected	Pass
FSM state	OPENING	[ ]
Gate moves normally	Yes	[ ]

11 — Reboot & Reset Button

Scenario 11.1 — Short press (under 3 seconds) is ignored

Check after holding for 1–2s and releasing	Expected	Pass
Log message	"too short, ignoring (need 3s+)"	[ ]
Device	Does not reboot	[ ]

Scenario 11.2 — Medium hold (3–9 seconds) reboots, times preserved

Note the current learned times before testing.

Check after holding ~4s and releasing	Expected	Pass
Log message	"REBOOT: Button held Xs — rebooting"	[ ]
Device reboots	Yes	[ ]
Learned times after reboot	Unchanged	[ ]

Scenario 11.3 — Long hold (10+ seconds) resets times and reboots

Check after holding 10+ seconds and releasing	Expected	Pass
Log message	"RESET: Button held Xs — resetting learned times + rebooting"	[ ]
Learned Open Time after reboot	0	[ ]
Learned Close Time after reboot	0	[ ]
Warning on next motion	"Timing not learned" in logs	[ ]

Scenario 11.4 — Reset Learned Times HA button

Check after pressing Reset Learned Times button in HA	Expected	Pass
Learned Open Time	0	[ ]
Learned Close Time	0	[ ]

12 — Home Assistant Entity Audit

Verify every entity is present, labelled correctly, and responsive. The entity prefix matches your friendly_name substitution (default: gate_controller).

Entity	Type	Present	Responds
cover.gate	Cover (open / close / stop / position slider)	[ ]	[ ]
sensor — State	FSM state string	[ ]	[ ]
sensor — Gate Position	0–100%	[ ]	[ ]
sensor — Learned Open Time	Seconds	[ ]	[ ]
sensor — Learned Close Time	Seconds	[ ]	[ ]
sensor — Close Countdown	Seconds remaining	[ ]	[ ]
sensor — Gate Motor Current	Amperes	[ ]	[ ]
binary_sensor — Open Endstop	Reflects physical switch	[ ]	[ ]
binary_sensor — Close Endstop	Reflects physical switch	[ ]	[ ]
binary_sensor — Auto Close Armed	ON during OPEN_CYCLE countdown	[ ]	[ ]
button — Reset Learned Times	Clears both learned times	[ ]	[ ]
button — Gate Cycle	Software Cycle trigger	[ ]	[ ]
number — Obstacle Threshold	Adjustable threshold (Amperes)	[ ]	[ ]
number — Obstacle Reverse Distance	Reverse distance (0.0–1.0)	[ ]	[ ]
sensor — WiFi Signal Strength	dBm (diagnostic)	[ ]	[ ]
sensor — Uptime	Human-readable (diagnostic)	[ ]	[ ]
binary_sensor — Status	Online / offline (diagnostic)	[ ]	[ ]
switch — Restart	Remote restart (diagnostic)	[ ]	[ ]

13 — LED Pattern Verification

Use the scenarios from prior sections to enter each state and verify the physical panel LEDs.

State	Open LED (GPB0)	Close LED (GPB1)	Pass
OPEN	Solid	Off	[ ]
CLOSED	Off	Solid	[ ]
OPENING	Fast flash (2 Hz)	Off	[ ]
OPENING_CYCLE	Fast flash (2 Hz)	Off	[ ]
CLOSING	Off	Fast flash (2 Hz)	[ ]
OPEN_CYCLE	Slow pulse (1 Hz)	Off	[ ]
STOPPED	Fast flash (2 Hz)	Fast flash (2 Hz)	[ ]
PAUSED_FROM_OPENING	Fast flash (2 Hz)	Fast flash (2 Hz)	[ ]
PAUSED_FROM_CLOSING	Fast flash (2 Hz)	Fast flash (2 Hz)	[ ]
FAULT	Solid	Solid	[ ]
STOPPED_UNKNOWN	Fast flash	Fast flash (opposite phase)	[ ]
Jog opening (any FSM state)	Fast flash (2 Hz)	Off	[ ]
Jog closing (any FSM state)	Off	Fast flash (2 Hz)	[ ]

14 — Safety Architecture

Scenario 14.1 — Endstop kills motor before FSM processes the transition

Allow the gate to open fully and trigger the open endstop normally.

Check	Expected	Pass
Log order	"emergency motor kill" appears before FSM transition message	[ ]
Motor Current sensor at endstop trigger	Drops to 0 immediately	[ ]
Visible gate overrun	None	[ ]

Scenario 14.2 — 100ms watchdog interval is independent of scripts

Manually trigger the open endstop signal (hold the switch closed) while the gate is moving open.

Check	Expected	Pass
Motor stops	Within 100ms of endstop activation	[ ]
Stop occurs independently	Even if scripts are mid-execution	[ ]

Scenario 14.3 — motor_kill flag holds zero PWM after a stop

Stop the gate mid-motion and watch the Motor Current sensor closely.

Check	Expected	Pass
Motor Current after stop	Drops to 0 and stays at 0	[ ]
Any brief current spike after stop	None (motor_kill interlock effective)	[ ]

Scenario 14.4 — Endstop terminates soft start / soft stop loops

Allow a stop event (endstop or emergency stop) to fire while a ramp script is mid-loop.

Check	Expected	Pass
Ramp scripts self-terminate	Yes (level-triggered check at top of each loop)	[ ]
No continued PWM after stop	Confirmed by current sensor	[ ]

15 — Connectivity & Status LED

The status LED is the onboard blue LED on the Wemos D1 Mini32 (GPIO2).

State	Status LED	Pass
WiFi disconnected	Fast blink (500ms on / 500ms off)	[ ]
WiFi connected, HA API disconnected	Solid ON	[ ]
WiFi connected, HA API connected	Slow breathing glow (~2s cycle)	[ ]

Scenario 15.4 — Fallback AP on WiFi failure

Boot the device with no configured WiFi available.

Check	Expected	Pass
SSID visible	`gate-controller`	[ ]
Captive portal at 192.168.4.1	Yes	[ ]

Scenario 15.5 — OTA firmware update

Trigger an OTA update from the ESPHome dashboard.

Check	Expected	Pass
Update completes	Yes	[ ]
Device reconnects after reboot	Yes	[ ]
FSM initial state correct after OTA	Matches gate physical position	[ ]

16 — Edge Cases

Scenario 16.1 — CYCLE from STOPPED_UNKNOWN sends gate to close endstop

Precondition: State = STOPPED_UNKNOWN (boot with gate mid-travel).

Check	Expected	Pass
FSM state after Cycle	CLOSING	[ ]
Gate travels to close endstop	State = CLOSED	[ ]
Position now known	Normal operation resumes	[ ]

Scenario 16.2 — Rapid Cycle presses remain predictable

Press Cycle 3 times in rapid succession (~200ms apart) from State = CLOSED.

Check	Expected	Pass
Each press advances through valid FSM transitions	Yes	[ ]
No double-motion, no stuck state, no crash	Yes	[ ]

Scenario 16.3 — Software Cycle button in HA is identical to panel button

Check from State = CLOSED	Expected	Pass
Press Gate Cycle button in HA	State = OPENING_CYCLE	[ ]

Scenario 16.4 — Position tracking corrects to exact values at endstops

Run gate mid-travel repeatedly to allow position drift, then close and open fully.

Check	Expected	Pass
Gate Position sensor at close endstop	Resets to exactly 0%	[ ]
Gate Position sensor at open endstop	Resets to exactly 100%	[ ]

Summary

Section	Description	Pass
1	Initial state detection on boot	[ ]
2	Timing learning	[ ]
3	Basic open / close / direction reversal	[ ]
4	Cycle button & auto-close	[ ]
5	Hold-to-operate (jog)	[ ]
6	Stop & pause mid-travel	[ ]
7	Position control	[ ]
8	Soft start & soft stop	[ ]
9	Obstacle detection	[ ]
10	Movement timeout & FAULT	[ ]
11	Reboot & reset button	[ ]
12	Home Assistant entity audit	[ ]
13	LED pattern verification	[ ]
14	Safety architecture	[ ]
15	Connectivity & status LED	[ ]
16	Edge cases	[ ]

Tester: _____________________________ Date: _______________ Firmware: _______________

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Gate Controller — QA Test Procedure

Before You Start

1 — Initial State Detection on Boot

Scenario 1.1 — Boot at closed endstop

Scenario 1.2 — Boot at open endstop

Scenario 1.3 — Boot mid-travel (position unknown)

2 — Timing Learning (First Run)

Scenario 2.1 — Learn open time

Scenario 2.2 — Learn close time

Scenario 2.3 — Learned times survive reboot

3 — Basic Open / Close / Direction Reversal

Scenario 3.1 — Open via HA with soft start

Scenario 3.2 — Close via HA

Scenario 3.3 — Direction reversal mid-travel (CLOSE while OPENING)

Scenario 3.4 — Direction reversal mid-travel (OPEN while CLOSING)

4 — Cycle Button & Auto-Close

Scenario 4.1 — Full auto-close cycle

Scenario 4.2 — Cancel auto-close with Cycle button

Scenario 4.3 — Cancel auto-close with OPEN command

Scenario 4.4 — CLOSE command during auto-close countdown

Scenario 4.5 — CYCLE from OPEN closes directly (no auto-close)

Scenario 4.6 — Countdown pauses when gate leaves open endstop

Scenario 4.7 — Pause mid-OPENING_CYCLE with Cycle, then resume with Cycle

Scenario 4.8 — Pause mid-CLOSING, resume with Cycle arms auto-close

5 — Hold-to-Operate (Jog)

Scenario 5.1 — Jog open, verify FSM unchanged

Scenario 5.2 — Jog close, verify FSM unchanged

Scenario 5.3 — Jog stops at endstop

Scenario 5.4 — Jog does not disrupt auto-close countdown

6 — Stop & Pause Mid-Travel

Scenario 6.1 — Stop button during opening

Scenario 6.2 — Stop button during closing

Scenario 6.3 — Stop from HA cover entity

Scenario 6.4 — Stop has no effect from a resting state

Scenario 6.5 — Resume from PAUSED_FROM_OPENING

Scenario 6.6 — Resume from PAUSED_FROM_CLOSING

7 — Position Control

Scenario 7.1 — Move to 50% from closed

Scenario 7.2 — Move to 75% from 50%, then 25% from 75%

Scenario 7.3 — Position command cancels auto-close countdown

8 — Soft Start & Soft Stop

Scenario 8.1 — Soft start ramp in normal operation

Scenario 8.2 — Soft stop ramp approaching endstop

Scenario 8.3 — Soft stop ramp for position target

Scenario 8.4 — Soft start disabled during timing learning run

9 — Obstacle Detection

Scenario 9.1 — First obstacle hit: gate reverses then stops

Scenario 9.2 — Second obstacle during reverse → FAULT

Scenario 9.3 — Clear FAULT and resume after obstacle

Scenario 9.4 — Near-endstop threshold automatically increases

Scenario 9.5 — Grace period absorbs startup inrush current

Scenario 9.6 — Obstacle suppressed during soft start

10 — Movement Timeout & FAULT

Scenario 10.1 — Movement timeout triggers FAULT

Scenario 10.2 — Timeout uses fallback when timing not learned

Scenario 10.3 — Two-step FAULT recovery via OPEN or CLOSE command

11 — Reboot & Reset Button

Scenario 11.1 — Short press (under 3 seconds) is ignored

Scenario 11.2 — Medium hold (3–9 seconds) reboots, times preserved

Scenario 11.3 — Long hold (10+ seconds) resets times and reboots

Scenario 11.4 — Reset Learned Times HA button

12 — Home Assistant Entity Audit

13 — LED Pattern Verification

14 — Safety Architecture

Scenario 14.1 — Endstop kills motor before FSM processes the transition

Scenario 14.2 — 100ms watchdog interval is independent of scripts

Scenario 14.3 — motor_kill flag holds zero PWM after a stop

Scenario 14.4 — Endstop terminates soft start / soft stop loops

15 — Connectivity & Status LED

Scenario 15.4 — Fallback AP on WiFi failure

Scenario 15.5 — OTA firmware update

16 — Edge Cases

Scenario 16.1 — CYCLE from STOPPED_UNKNOWN sends gate to close endstop

Scenario 16.2 — Rapid Cycle presses remain predictable