Oleksandr ShyshatskyiandClaude Opus 5
91604c2dfb
Twelve gates, most of them the weaker copy of a gate that survives. What is
left: pytest for the Klipper config, and three replica gates -- the end-to-end
install, MCU bring-up, and stock recovery.
Fix first, because the cut depends on it: a skip counted as a pass. Every
launcher exits 0 when it decides it cannot run, and sub() reported that as
`ok`. That is how test-abi.sh sat in the suite printing green while checking
nothing -- run-tests.sh deleted work/modpayload immediately before it ran and
CI set KLIPPER_FORK="", so it had no targets on any run, ever. Skips are now
counted apart, the summary says so, and the suite exits non-zero unless
ALLOW_SKIP=1 says the gap is deliberate. With four gates instead of twelve, a
gate that silently does not run is the failure mode that matters most.
Dropped, each because something else already does the job properly:
test-abi.sh bin/patch.sh refuses to build a non-nan2008
c_helper.so, bin/verify.sh re-checks the packaged
one, and case-install.sh reads the ELF header of
the file that actually landed on the machine.
test-ash-conformance.sh case-install.sh runs `sh -n` over every installed
script with the same qemu'd busybox and then greps
the boot log for "Syntax error".
test-model-gate.sh verify.sh SS8b/SS9 checks the same invariant and
pack.sh exits on MODEL MISMATCH before a package
exists. Its header claimed it proved the two models
ship different files; no such check was in it.
test-macros.py It used jinja2.Environment() -- default '{{ }}'.
The configs have no '{{' at all, only single-brace
expressions, so it checked '{% %}' block structure
and never looked inside an expression. Folded into
the chamber tests, which had the delimiters right.
test-base-cfg.py It read work/software/klipper/config/printer.base.cfg
as its stock reference -- the file bin/patch.sh
overwrites with ours. It was diffing our file
against itself: green on a cold tree, red on a
second run, blind to real drift either way. The
comparison moves to bin/unpack.sh, where a pristine
tree exists, as a warning rather than a gate.
lint-danger.sh Its structural greps were satisfiable by comments:
firmwareExe:44 and S80ui:16 *mention* helix and
SAFE-MODE, so they passed with the logic deleted.
case-ui.sh Goes with the helix-only decision.
applets.allow Ten entries, none of which the extractor had asked
about in a long time.
The command-word half of test-applets went too. It extracted only the first
word of a simple unprefixed command, so `if timeout 5 foo; then` yielded
['if','echo','fi'] -- the one failure its docstring named was invisible to it.
The absolute-path half survives: S50wifi's binaries sit behind a
[ -d /sys/class/net/wlan0 ] guard no simulation ever reaches, so nothing else
checks they exist.
The Python half is pytest now. Real assertions instead of hand-rolled
PASS/FAIL counters, underscored filenames so the modules import normally
(ffcfg keeps only the parser; the dash in test-macros.py was why one test used
to reach the other's parser through importlib), and a `rootfs` marker that
splits the tests needing the proprietary package from those that do not --
deselected in the PR lane, run in the replica half, so neither lane reports
skips it did not expect. test_default_delimiters_are_blind pins the jinja2 bug
so it cannot come back.
The config gate also moves out of the replica half into the half that runs on
a plain pull request. It needs python3, jinja2 and files in the repo, and it
is the only safety-relevant check in the suite -- a chamber heater declared on
a Creator 5 that has no element for it -- so it had no business being gated
behind the proprietary firmware.
Verified: pytest 21 passed / 5 rootfs-marked; the fixture pipeline
(unpack, patch, pack, verify) passes end to end; injecting a broken
single-brace expression fails test_every_macro_parses with the exact line, and
parses clean under the old defaults; the skip path reports SKIP and exits 1,
and ALLOW_SKIP=1 accepts it.
Also drops the CI `abi` job, which ran on a bare checkout with no binaries and
so was permanently green.
Co-Authored-By: Claude Opus 5 (1M context) <noreply@anthropic.com>
7.3 KiB
Hardware testing
CI installs the package into a replica of the printer -- the real
rootfs.squashfs running under qemu-mipsel, on the printer's own busybox and
unTar (see printer-replica.md) -- and proves the
machine would still boot. What it cannot do is drive the screen, the MCUs, the
toolchanger or a print. This is the on-hardware procedure.
There is one flash: the firmware package for your model.
Rule: have the stock FlashForge package for your model on a spare stick
before you flash anything. Flashing it back is the uninstall, and it is the
only recovery step that needs nothing but a USB port — no ssh, no screen. It
is proven by make test-recovery, which installs the mod into the printer
replica and then flashes the stock package over it.
Step zero: check the model gate
Every package carries a gate. Its runFirmwareExe.sh has MACHINE= / PID=
baked in, and compares them against the values app_startup.sh passes from
the firmware already on the printer. A mismatch is refused with
"Firmware does not match machine type" — it will not install, and it is not a
valid recovery image either.
| Model | MACHINE | PID |
|---|---|---|
| Creator 5 | Creator5 |
0028 |
| Creator 5 Pro | Creator5Pro |
0029 |
The gate is not cosmetic: the two models ship different firmwareExe
binaries, so a package must be built from the stock package for its own
model. make release builds both.
Find yours in Settings → About, or in
/usr/data/firmwareRes/config/general.json (machineName), and set
TARGET_MACHINE in config.env. Then:
make build && make verify # one model
make release # both, into dist/
verify.sh fails loudly on a mismatch. You must start from a stock package
built for your own model — the mod inherits the gate from whatever package
you unpack.
Before the first flash
- Put a copy of the stock FlashForge package for your model on a spare
USB stick and keep it physically separate. That is your recovery image:
flashing it restores every file the mod touches (proven by
make test-recovery). Check it is the right model first — see above. - Note your printer's serial number (Settings → About). The factory image restores a placeholder serial and you may need to put yours back.
- Confirm you can reach the printer's IP.
make testpasses.make rootfs && make test-installpasses — this parses every script that will run on the printer using the printer's own busybox ash.
Two USB sticks, FAT32, both packages at the root of the stick (not in a
folder). Ship both filenames (Creator5-* and Creator5Pro-*): the Pro's
boot script globs Creator5Pro-*.tgz, the non-Pro globs Creator5-*.tgz.
The flash (make build)
One flash brings up everything: a root password you know, Mainsail and moonraker, the forked Klipper with the toolchanger extras, and HelixScreen on the touchscreen in place of FlashForge's UI.
The root password is generated on the printer. Nothing is baked into the
package: the installer picks a random one, sets it, and writes it to
anvil-password.txt on the USB stick you flashed from. Pull the stick after
the flash and read it — then save the password somewhere safe and delete the
file. If the stick is not writable no password is set at all, and the install
log says so.
To choose your own instead, set it before you build:
openssl passwd -6 'your-password' # paste into ROOT_PW_HASH in config.env
ssh works because the stock rootfs already ships /usr/sbin/dropbear and an
enabled /etc/init.d/S50dropbear — port 22 is already open on a stock
printer, there is simply no published password. That shell is your recovery
channel, so confirm it before you touch anything else.
Before flashing, re-read the warnings about Z offsets in docs/toolchange.md. A wrong offset drives the nozzle into the plate.
Understand the safety net first, because FlashForge's UI is gone from the screen and there is nothing to fall back to:
- ssh and Mainsail do not depend on the screen.
/etc/init.d/S50dropbearis stock and runs long before the UI, andinit.d/S60webstarts nginx and moonraker independently. They are your way in when the screen is dark. init.d/S70klipperowns Klipper startup, because on stock firmware it wasfirmwareExe— not any init script — that ran/usr/prog/klipper/start.sh. Without this the printer would boot to a working screen and be unable to move.- If the UI dies repeatedly,
SAFE-MODElatches after 3 boots and the printer boots headless — no UI started at all — rather than crash-looping. ssh and Mainsail stay up. Delete/usr/data/anvil/SAFE-MODEto try again.
Go/no-go, in this order — with the emergency stop within reach:
Access first, so that everything below is diagnosable:
ssh root@PRINTERgets you a shell (password fromanvil-password.txton the stick)http://PRINTER/loads Mainsail- Mainsail shows the printer as ready, not "Klipper reports: ERROR"
If Mainsail loads but Klipper errors, stop here and read
/usr/data/logs/printer.log over ssh. Do not go on to motion.
Then the screen:
- HelixScreen appears on the touchscreen
- Klipper is still running — this is the one people miss
- heaters and motion respond from the touchscreen
Then motion, which is the part that can damage the machine:
ssh root@PRINTER 'grep -i error /usr/data/logs/printer.log | tail'is cleanTOOLCHANGE_STATUSresponds in the Mainsail console- home all axes — watch the first Z move
- one tool change, by hand, at temperature
- a single-tool test print
- a multi-tool test print
The .cfg includes are not wired up automatically — a tuned printer.cfg
is never modified. New files arrive as *.mod-new. Add the includes by hand
in the order given in the toolchanger README, then run
FF_IMPORT_FIRMWARE_CONFIG once.
Recovering from a bad UI, in increasing severity:
ssh root@PRINTER
/usr/data/anvil/init.d/S80ui status # what did it choose, and why
touch /usr/data/anvil/SAFE-MODE # boot headless next time (ssh + Mainsail only)
reboot
If ssh is gone too, flash the stock FlashForge package for your model.
If something goes wrong
| Symptom | Do this |
|---|---|
| Printer boots, screen blank | ssh in; /usr/data/anvil/init.d/S80ui status; touch /usr/data/anvil/SAFE-MODE; reboot |
| No ssh, no screen | flash the stock package for your model |
| Recovery stick does not help | try a newer stock FlashForge package for your model |
| Still broken | factory package (Creator5Pro-factory-*.tgz plus the separate Creator5Pro-factory.tar.xz on the same stick; needs 800 MB free) |
The mod never creates a mount point named like a mod, specifically so that FlashForge's factory-restore package — which greps the mount table for a known community mod's name and refuses to run when it matches — remains usable as a last resort.
Logs worth reading, all on the data partition and all surviving a reboot:
/usr/data/anvil-install.log what the installer did
/usr/data/logs/anvil-boot.log services + UI choice at each boot
/usr/data/logs/printer.log klipper
/usr/data/logs/helixscreen.log helixscreen