fix(paths): centralize file:// URL handling to fix broken save-dir paths

- QUrl.toLocalFile() prevents leading slash on Windows drive letters (e.g.
  "/C:/Users/...") that was causing Path operations to fail
- remove docs/ from .gitignore so document revisions are tracked in Git

.gitea/workflows/ci.yml

@@ -0,0 +1,35 @@
+name: CI
+
+on:
+  push:
+    branches: ["**"]
+  pull_request:
+
+env:
+  QT_QPA_PLATFORM: offscreen
+
+jobs:
+  preflight:
+    runs-on: ubuntu-latest
+    steps:
+      - uses: actions/checkout@v4
+
+      - name: Install Qt runtime libs
+        run: sudo apt-get update && sudo apt-get install -y libegl1 libgl1 libxkbcommon0 libfontconfig1 libdbus-1-3
+
+      - name: Install uv
+        uses: astral-sh/setup-uv@v3
+        with:
+          python-version: "3.11"
+
+      - name: Install dependencies
+        run: uv sync
+
+      - name: Lint
+        run: make lint
+
+      - name: Typecheck
+        run: make typecheck
+
+      - name: Test
+        run: make test

.gitignore

@@ -21,7 +21,6 @@ env/
 *.swp
 *.swo
 *~
-docs
 
 # OS
 .DS_Store
@@ -37,9 +36,7 @@ moc_*.cpp
 # Build / packaging artifacts
 build/
 dist/
-*.spec
-*.icns
-*.ico
+
 
 # Runtime scratch data
 tmp/
@@ -58,3 +55,4 @@ AGENTS.md
 CONVENTIONS.md
 specs/
 graphify-out/
+.personal-docs/

Makefile

@@ -18,6 +18,9 @@ typecheck:
 run:
 	uv run python -m pygui
 
+package:
+	uv run pyinstaller packaging/isc.spec
+
 clean:
-	rm -rf .pytest_cache .ruff_cache .mypy_cache
+	rm -rf .pytest_cache .ruff_cache .mypy_cache build dist
 	find . -type d -name "__pycache__" -exec rm -rf {} +

packaging/isc.spec

@@ -0,0 +1,62 @@
+# -*- mode: python ; coding: utf-8 -*-
+# Run from the project root:  pyinstaller packaging/isc.spec
+
+import sys
+
+if sys.platform == "win32":
+    app_icon = "isc.ico"
+elif sys.platform == "darwin":
+    app_icon = "isc.icns"
+else:
+    app_icon = None
+
+a = Analysis(
+    ['../src/pygui/__main__.py'],
+    pathex=['src'],
+    binaries=[],
+    # Bundle the QML module so loadFromModule("ISC", "Main") resolves at runtime.
+    datas=[('../src/pygui/ISC', 'ISC')],
+    hiddenimports=[],
+    hookspath=[],
+    hooksconfig={},
+    runtime_hooks=[],
+    excludes=[],
+    noarchive=False,
+    optimize=0,
+)
+pyz = PYZ(a.pure)
+
+exe = EXE(
+    pyz,
+    a.scripts,
+    [],
+    exclude_binaries=True,
+    name='ISC',
+    debug=False,
+    bootloader_ignore_signals=False,
+    strip=False,
+    upx=True,
+    console=False,
+    disable_windowed_traceback=False,
+    argv_emulation=False,
+    target_arch=None,
+    codesign_identity=None,
+    entitlements_file=None,
+    icon=app_icon,
+)
+coll = COLLECT(
+    exe,
+    a.binaries,
+    a.datas,
+    strip=False,
+    upx=True,
+    upx_exclude=[],
+    name='ISC',
+)
+if sys.platform == "darwin":
+    app = BUNDLE(
+        coll,
+        name='ISC.app',
+        icon=app_icon,
+        bundle_identifier=None,
+    )

pyproject.toml

@@ -92,6 +92,7 @@ dev = [
     "pytest>=9.0.3",
     "ruff",
     "mypy",
+    "pyinstaller==6.21.0",
 ]
 
 [tool.uv]

src/pygui/ISC/AboutDialog.qml

@@ -3,6 +3,7 @@ import QtQuick.Controls
 import QtQuick.Dialogs
 import QtQuick.Layouts
 import ISC
+import ISC.Tabs.components
 
 Popup {
     id: root
@@ -133,13 +134,28 @@ Popup {
                         Label { text: modelData.mfgDate; font.pixelSize: Theme.fontMd; color: Theme.bodyColor; Layout.preferredWidth: 120 }
                         Label { text: modelData.level; font.pixelSize: Theme.fontMd; color: Theme.bodyColor; Layout.preferredWidth: 80 }
                         Label { text: modelData.licDate; font.pixelSize: Theme.fontMd; color: Theme.bodyColor; Layout.fillWidth: true }
-                        ToolButton {
+                        Button {
+                            id: removeLicenseBtn
                             Layout.preferredWidth: 28
-                            text: "✕"
-                            font.pixelSize: Theme.fontSm
-                            ToolTip.visible: hovered
-                            ToolTip.text: "Remove license"
+                            implicitHeight: 28
+                            hoverEnabled: true
+                            background: Rectangle {
+                                color: removeLicenseBtn.pressed ? Theme.buttonPressed : removeLicenseBtn.hovered ? Theme.buttonNeutralHover : "transparent"
+                                radius: Theme.radiusSm
+                            }
+                            contentItem: Text {
+                                text: "✕"
+                                font.pixelSize: Theme.fontSm
+                                color: Theme.bodyColor
+                                horizontalAlignment: Text.AlignHCenter
+                                verticalAlignment: Text.AlignVCenter
+                            }
                             onClicked: licenseModel.removeLicense(modelData.serial, modelData.level)
+
+                            AppToolTip {
+                                visible: removeLicenseBtn.hovered
+                                text: "Remove license"
+                            }
                         }
                     }
                 }

src/pygui/ISC/FirstLaunchWizard.qml

@@ -43,7 +43,7 @@ Popup {
         id: saveDirDialog
         title: "Choose a folder to save data"
         onAccepted: {
-            var dir = decodeURIComponent(String(selectedFolder).replace(/^file:\/\//, ""))
+            var dir = String(selectedFolder)
             deviceController.setSaveDataDir(dir)
             file_browser.setCurrentDirectory(dir)
             root.finished()

src/pygui/ISC/HomePage.qml

@@ -33,6 +33,9 @@ Rectangle {
     property string dataCompareFileB: ""
 
     onSelectedTabIndexChanged: {
+        // Time-based, so re-check on every switch rather than trusting a
+        // value computed at some earlier point in a possibly long-running session.
+        root.reviewBlocked = licenseModel.reviewAccessBlocked()
         if (selectedTabIndex === 2) {
             file_browser.refreshFiles();
             if (root.mapReviewFile !== "") {
@@ -68,6 +71,9 @@ Rectangle {
             if (root.selectedTabIndex === 2) root.mapReviewFile = streamController.loadedFile
             else if (root.selectedTabIndex === 3) root.graphReviewFile = streamController.loadedFile
         }
+        function onLiveError(message) {
+            deviceController.appendActivityLog("Live stream error — stream stopped: " + message)
+        }
     }
 
     // Data tab's Run A/B picks survive it being destroyed/recreated by its
@@ -84,6 +90,24 @@ Rectangle {
     property bool waferDetected: false
     property bool waferLicensed: false
 
+    // Data/Graph/Map-review are gated on the 30-day trial once it's actually
+    // expired (ADR-0005 "Deferred" item — the trigger existed, nothing ever
+    // checked it). Status stays free: hardware actions are gated separately,
+    // per-wafer-serial, via waferLicensed above.
+    property bool reviewBlocked: false
+    onReviewBlockedChanged: {
+        // Property change signals only fire on an actual value change, so
+        // this logs once per none/temporary → expired transition, not on
+        // every recompute in onSelectedTabIndexChanged/onLicensesChanged.
+        if (reviewBlocked) {
+            deviceController.appendActivityLog(
+                "Review trial expired — load a wafer license to continue using Data/Map/Graph (About dialog)")
+            if (root.selectedTabIndex !== 0) {
+                root.selectedTabIndex = 0
+            }
+        }
+    }
+
     Connections {
         target: deviceController
         function onDetectResult(result){
@@ -100,16 +124,22 @@ Rectangle {
                 licenseModel.startReplayTrial()
             }
         }
-        function onParsedDataReady(result) {
-            if (result.success && result.csv_path) {
-                streamController.loadFile(result.csv_path)
-                // Fires while still on Status(0), before the tab switch below —
-                // the generic per-tab tracker only attributes picks made while
-                // already on Map/Graph, so record this one explicitly.
-                root.mapReviewFile = result.csv_path
-                if (root.selectedTabIndex === 0 && licenseModel.licenses.length > 0) {
+    }
+    Connections {
+        // Deferred until the post-read metadata dialog (StatusTab.qml) closes —
+        // jumping tabs from onParsedDataReady directly would deactivate the
+        // Status Loader (StackLayout.index !== selectedTabIndex) and tear down
+        // the dialog before the technician could see or use it.
+        target: statusTabLoader.item
+        function onCsvMetadataDialogClosed(csvPath) {
+            if (!csvPath) return
+            streamController.loadFile(csvPath)
+            // Fires while still on Status(0), before the tab switch below —
+            // the generic per-tab tracker only attributes picks made while
+            // already on Map/Graph, so record this one explicitly.
+            root.mapReviewFile = csvPath
+            if (root.selectedTabIndex === 0 && licenseModel.licenses.length > 0) {
                 root.selectedTabIndex = 2
-                }
             }
         }
     }
@@ -124,6 +154,7 @@ Rectangle {
                 root.selectedTabIndex = 0
             }
             root.waferLicensed = root.waferDetected && deviceController.waferLicensed()
+            root.reviewBlocked = licenseModel.reviewAccessBlocked()
         }
     }
     Connections {
@@ -133,17 +164,13 @@ Rectangle {
                                result !== undefined &&
                                result.success === true)
             if (root.memoryRead) {
-                console.log("[P1.1] Memory read complete:", result.bytes, "bytes")
+                console.log("Memory read complete:", result.bytes, "bytes")
             } else {
-                console.log("[P1.1] Read failed:", result.error || "unknown")
+                console.log("Read failed:", result.error || "unknown")
             }
         }
     }
 
-    function cleanFolderUrl(url) {
-        return decodeURIComponent(String(url).replace(/^file:\/\//, ""))
-    }
-
     function _doDetect() {
         root.memoryRead = false
         root.waferDetected = false
@@ -156,7 +183,7 @@ Rectangle {
         id: saveDirDialog
         title: "Choose a folder to save Data"
         onAccepted: {
-            var dir = root.cleanFolderUrl(selectedFolder)
+            var dir = String(selectedFolder)
             deviceController.setSaveDataDir(dir)
             file_browser.setCurrentDirectory(dir)
             root._doDetect()
@@ -271,6 +298,7 @@ Rectangle {
         }
     }
     Component.onCompleted: {
+        root.reviewBlocked = licenseModel.reviewAccessBlocked()
         if (isFirstLaunch) {
             firstLaunchWizard.open()
         }
@@ -342,10 +370,13 @@ Rectangle {
                                 id: pillBtn
                                 checked: root.selectedTabIndex === index
                                 // MAP (index 2) is locked until a valid license .bin is installed.
+                                // DATA/MAP/GRAPH (index !== 0) also lock once the 30-day review
+                                // trial has actually expired with no permanent license (ADR-0005).
                                 // Stays enabled (not `enabled: false`) so hover still fires and the
                                 // tooltip can explain why — a disabled Item receives no mouse/hover
                                 // events at all, which would silently kill the tooltip below.
-                                property bool locked: index === 2 && licenseModel.licenses.length === 0
+                                property bool locked: (index === 2 && licenseModel.licenses.length === 0)
+                                    || (index !== 0 && root.reviewBlocked)
                                 flat: true
                                 Layout.fillWidth: true
                                 Layout.fillHeight: true
@@ -411,9 +442,15 @@ Rectangle {
 
                                 AppToolTip {
                                     visible: pillBtn.hovered
-                                    text: (index === 2 && licenseModel.licenses.length === 0)
-                                        ? "<b>MAP</b>: No license loaded — load one in About to unlock"
-                                        : "<b>" + model.label + "</b>: " + model.desc
+                                    // Trial-expired is checked first: it's the broader reason and
+                                    // applies identically to Data/Map/Graph, so when it's true it
+                                    // wins even for MAP — otherwise MAP's narrower "no license at
+                                    // all" case (trial not yet expired, still just unlicensed) shows.
+                                    text: (index !== 0 && root.reviewBlocked)
+                                        ? "<b>" + model.label + "</b>: Review trial expired — load a license in About to unlock"
+                                        : (index === 2 && licenseModel.licenses.length === 0)
+                                            ? "<b>MAP</b>: No license loaded — load one in About to unlock"
+                                            : "<b>" + model.label + "</b>: " + model.desc
                                 }
 
                                 onClicked: if (!pillBtn.locked) root.selectedTabIndex = index
@@ -729,6 +766,7 @@ Rectangle {
                 currentIndex: root.selectedTabIndex
 
                 Loader {
+                    id: statusTabLoader
                     source: "Tabs/StatusTab.qml"
                     active: StackLayout.index === root.selectedTabIndex
                 }

src/pygui/ISC/Tabs/StatusTab.qml

@@ -15,6 +15,12 @@ ColumnLayout {
     anchors.margins: Theme.panelPadding
     spacing: 8
 
+    // Fired once the post-read metadata dialog is dismissed (Save or Cancel),
+    // so HomePage can defer its auto-jump-to-Map until after the technician
+    // has had a chance to edit metadata — jumping tabs immediately would
+    // deactivate this Loader's item and kill the dialog mid-display.
+    signal csvMetadataDialogClosed(string csvPath)
+
     // ── Reusable Inline Components ──
     component StatCard : Rectangle {
         property alias value: valueText.text
@@ -107,9 +113,6 @@ ColumnLayout {
     readonly property bool isBusy: deviceController.connectionStatus.endsWith("...")
     readonly property string portName: deviceController.selectedPort || "—"
 
-    function cleanFolderUrl(url) {
-        return decodeURIComponent(String(url).replace(/^file:\/\//, ""));
-    }
     function currentFamilyCode() {
         var info = deviceController.lastWaferInfo;
         return info && info.length > 0 ? (info[0] || "") : "";
@@ -122,7 +125,7 @@ ColumnLayout {
         id: saveDirDialog
         title: "Choose a folder to save."
         onAccepted: {
-            var dir = root.cleanFolderUrl(selectedFolder);
+            var dir = String(selectedFolder);
             deviceController.setSaveDataDir(dir);
             file_browser.setCurrentDirectory(dir);
             root.parseAndSavePendingRead();
@@ -135,7 +138,7 @@ ColumnLayout {
         id: dirOnlyDialog
         title: "Choose a folder to save Data"
         onAccepted: {
-            var dir = root.cleanFolderUrl(selectedFolder);
+            var dir = String(selectedFolder);
             deviceController.setSaveDataDir(dir);
             file_browser.setCurrentDirectory(dir);
         }
@@ -147,31 +150,127 @@ ColumnLayout {
         id: editCsvDialog
         parent: Overlay.overlay
         modal: true
-        title: "Edit CSV Metadata"
         width: 460
         anchors.centerIn: parent
-        standardButtons: Dialog.Save | Dialog.Cancel
+        standardButtons: Dialog.NoButton
+        padding: 20
         onAccepted: file_browser.saveMetadata(root.csvPath, metaWafer.text, metaDate.text, metaChamber.text, metaNotes.text, false, "")
+        onClosed: root.csvMetadataDialogClosed(root.csvPath)
+
+        background: Rectangle {
+            radius: Theme.radiusLg
+            color: Theme.cardBackground
+            border.color: Theme.cardBorder
+            border.width: Theme.borderThin
+        }
+
+        component MetaField: TextField {
+            id: metaField
+            Layout.fillWidth: true
+            color: Theme.fieldText
+            placeholderTextColor: Theme.fieldPlaceholder
+            selectedTextColor: Theme.fieldBackground
+            selectionColor: Theme.fieldText
+            font.pixelSize: Theme.fontMd
+            background: Rectangle {
+                radius: Theme.radiusXs
+                color: Theme.fieldBackground
+                border.width: metaField.activeFocus ? Theme.borderStrong : Theme.borderThin
+                border.color: metaField.activeFocus ? Theme.fieldBorderFocus : Theme.fieldBorder
+                Behavior on border.color {
+                    ColorAnimation { duration: Theme.durationFast }
+                }
+            }
+        }
 
         ColumnLayout {
             anchors.fill: parent
             spacing: 6
 
+            // ── header ───────────────────────────────────────────────
+            Label {
+                text: "EDIT CSV METADATA"
+                color: Theme.headingColor
+                font.pixelSize: Theme.fontLg
+                font.bold: true
+                font.letterSpacing: 1
+                Layout.fillWidth: true
+            }
+
             Text {
                 text: root.csvPath.split("/").pop()
                 color: Theme.sideMutedText
                 font.pixelSize: Theme.fontXs
                 elide: Text.ElideMiddle
                 Layout.fillWidth: true
+                Layout.bottomMargin: 4
+            }
+
+            Rectangle {
+                Layout.fillWidth: true
+                Layout.bottomMargin: 8
+                height: 1
+                color: Theme.cardBorder
+            }
+
+            Label { text: "Wafer"; color: Theme.bodyColor; font.pixelSize: Theme.fontXs }
+            MetaField { id: metaWafer }
+            Label { text: "Date"; color: Theme.bodyColor; font.pixelSize: Theme.fontXs; Layout.topMargin: 6 }
+            MetaField { id: metaDate }
+            Label { text: "Chamber"; color: Theme.bodyColor; font.pixelSize: Theme.fontXs; Layout.topMargin: 6 }
+            MetaField { id: metaChamber }
+            Label { text: "Notes"; color: Theme.bodyColor; font.pixelSize: Theme.fontXs; Layout.topMargin: 6 }
+            MetaField { id: metaNotes }
+
+            // ── buttons ───────────────────────────────────────────────
+            RowLayout {
+                Layout.fillWidth: true
+                Layout.topMargin: 14
+                spacing: 8
+
+                Button {
+                    id: cancelCsvBtn
+                    text: "Cancel"
+                    Layout.fillWidth: true
+                    hoverEnabled: true
+                    background: Rectangle {
+                        radius: Theme.radiusSm
+                        color: cancelCsvBtn.down ? Theme.buttonNeutralPressed : cancelCsvBtn.hovered ? Theme.buttonNeutralHover : Theme.buttonNeutralBackground
+                        border.width: Theme.borderThin
+                        border.color: Theme.fieldBorder
+                    }
+                    contentItem: Text {
+                        text: cancelCsvBtn.text
+                        color: Theme.buttonNeutralText
+                        horizontalAlignment: Text.AlignHCenter
+                        verticalAlignment: Text.AlignVCenter
+                        font.bold: true
+                        font.pixelSize: Theme.fontSm
+                    }
+                    onClicked: editCsvDialog.reject()
+                }
+                Button {
+                    id: saveCsvBtn
+                    text: "Save"
+                    Layout.fillWidth: true
+                    hoverEnabled: true
+                    background: Rectangle {
+                        radius: Theme.radiusSm
+                        color: saveCsvBtn.hovered ? Qt.lighter(Theme.primaryAccent, 1.1) : Theme.primaryAccent
+                        border.width: Theme.borderThin
+                        border.color: Theme.primaryAccent
+                    }
+                    contentItem: Text {
+                        text: saveCsvBtn.text
+                        color: Theme.tone100
+                        horizontalAlignment: Text.AlignHCenter
+                        verticalAlignment: Text.AlignVCenter
+                        font.bold: true
+                        font.pixelSize: Theme.fontSm
+                    }
+                    onClicked: editCsvDialog.accept()
+                }
             }
-            Label { text: "Wafer" }
-            TextField { id: metaWafer; Layout.fillWidth: true }
-            Label { text: "Date" }
-            TextField { id: metaDate; Layout.fillWidth: true }
-            Label { text: "Chamber" }
-            TextField { id: metaChamber; Layout.fillWidth: true }
-            Label { text: "Notes" }
-            TextField { id: metaNotes; Layout.fillWidth: true }
         }
     }
 
@@ -214,74 +313,74 @@ ColumnLayout {
 
                 Item { Layout.fillHeight: true }
 
-                RowLayout {
+                // Badge cluster centers on the full card width; port name overlays
+                // the right edge independently so a long port string can't drag
+                // the centered badge off-center (was sharing width via RowLayout).
+                Item {
                     Layout.fillWidth: true
-                    spacing: 8
+                    Layout.preferredHeight: 22
 
-                    Item {
-                        Layout.fillWidth: true
-                        implicitHeight: 22
-
-                        Row {
-                            anchors.centerIn: parent
-                            spacing: 5
-
-                            Repeater {
-                                model: 4
-                                Rectangle {
-                                    width: 4; height: 4; radius: 2
-                                    anchors.verticalCenter: parent.verticalCenter
-                                    color: root.isConnected ? Theme.statusSuccessColor : (root.isBusy ? Theme.statusWarningColor : Theme.sideMutedText)
-                                    opacity: (root.isConnected || root.isBusy) ? 1.0 : 0.3
-
-                                    SequentialAnimation on opacity {
-                                        running: root.isConnected || root.isBusy
-                                        loops: Animation.Infinite
-                                        NumberAnimation { to: 0.3; duration: 1400 }
-                                        NumberAnimation { to: 1.0; duration: 1400 }
-                                    }
-                                }
-                            }
+                    Row {
+                        anchors.centerIn: parent
+                        spacing: 5
 
+                        Repeater {
+                            model: 4
                             Rectangle {
+                                width: 4; height: 4; radius: 2
                                 anchors.verticalCenter: parent.verticalCenter
-                                width: statusPillText.implicitWidth + 16
-                                height: 20
-                                radius: 10
-                                color: root.isConnected ? Theme.statusSuccessColor : (root.isBusy ? Theme.statusWarningColor : Theme.statusErrorColor)
+                                color: root.isConnected ? Theme.statusSuccessColor : (root.isBusy ? Theme.statusWarningColor : Theme.sideMutedText)
+                                opacity: (root.isConnected || root.isBusy) ? 1.0 : 0.3
 
-                                Text {
-                                    id: statusPillText
-                                    anchors.centerIn: parent
-                                    text: root.isConnected ? "ACTIVE" : (root.isBusy ? deviceController.connectionStatus.replace("...", "").toUpperCase() : "INACTIVE")
-                                    color: Theme.statusBadgeText
-                                    font.pixelSize: Theme.fontXs
-                                    font.weight: Font.Bold
-                                    font.family: Theme.uiFontFamily
-                                    font.letterSpacing: 0.6
+                                SequentialAnimation on opacity {
+                                    running: root.isConnected || root.isBusy
+                                    loops: Animation.Infinite
+                                    NumberAnimation { to: 0.3; duration: 1400 }
+                                    NumberAnimation { to: 1.0; duration: 1400 }
                                 }
                             }
+                        }
 
-                            Repeater {
-                                model: 4
-                                Rectangle {
-                                    width: 4; height: 4; radius: 2
-                                    anchors.verticalCenter: parent.verticalCenter
-                                    color: root.isConnected ? Theme.statusSuccessColor : (root.isBusy ? Theme.statusWarningColor : Theme.sideMutedText)
-                                    opacity: (root.isConnected || root.isBusy) ? 1.0 : 0.3
+                        Rectangle {
+                            anchors.verticalCenter: parent.verticalCenter
+                            width: statusPillText.implicitWidth + 16
+                            height: 20
+                            radius: 10
+                            color: root.isConnected ? Theme.statusSuccessColor : (root.isBusy ? Theme.statusWarningColor : Theme.statusErrorColor)
 
-                                    SequentialAnimation on opacity {
-                                        running: root.isConnected || root.isBusy
-                                        loops: Animation.Infinite
-                                        NumberAnimation { to: 0.3; duration: 1400 }
-                                        NumberAnimation { to: 1.0; duration: 1400 }
-                                    }
+                            Text {
+                                id: statusPillText
+                                anchors.centerIn: parent
+                                text: root.isConnected ? "ACTIVE" : (root.isBusy ? deviceController.connectionStatus.replace("...", "").toUpperCase() : "INACTIVE")
+                                color: Theme.statusBadgeText
+                                font.pixelSize: Theme.fontXs
+                                font.weight: Font.Bold
+                                font.family: Theme.uiFontFamily
+                                font.letterSpacing: 0.6
+                            }
+                        }
+
+                        Repeater {
+                            model: 4
+                            Rectangle {
+                                width: 4; height: 4; radius: 2
+                                anchors.verticalCenter: parent.verticalCenter
+                                color: root.isConnected ? Theme.statusSuccessColor : (root.isBusy ? Theme.statusWarningColor : Theme.sideMutedText)
+                                opacity: (root.isConnected || root.isBusy) ? 1.0 : 0.3
+
+                                SequentialAnimation on opacity {
+                                    running: root.isConnected || root.isBusy
+                                    loops: Animation.Infinite
+                                    NumberAnimation { to: 0.3; duration: 1400 }
+                                    NumberAnimation { to: 1.0; duration: 1400 }
                                 }
                             }
                         }
                     }
 
                     Text {
+                        anchors.right: parent.right
+                        anchors.verticalCenter: parent.verticalCenter
                         text: root.portName
                         color: root.isConnected ? Theme.statusSuccessColor : Theme.headingColor
                         font.pixelSize: Theme.fontMd
@@ -612,7 +711,7 @@ ColumnLayout {
             root.dataCols = 0;
             root.csvPath = "";
             if (result && result.success === true)
-                saveDirDialog.open();
+                root.parseAndSavePendingRead();
         }
     }
 

src/pygui/ISC/Tabs/components/OverlapMapCard.qml

@@ -53,6 +53,7 @@ PanelBox {
                 margin: 1.0
                 blend: card.blendAmount / 100
                 showLabels: true
+                showExtremes: false
                 ringColor: Theme.waferRingColor
                 axisColor: Theme.waferAxisColor
                 lowColor: Theme.sensorLow

src/pygui/ISC/Tabs/components/SourcePanel.qml

@@ -260,14 +260,14 @@ ColumnLayout {
         id: importFileDialog
         title: "Select Data File To Import"
         nameFilters: ["CSV files (*.csv)"]
-        onAccepted: file_browser.importZWaferCsv(String(selectedFile).replace(/^file:\/\//, ""))
+        onAccepted: file_browser.importZWaferCsv(String(selectedFile))
     }
 
     FolderDialog {
         id: batchExportDirDialog
         title: "Export Wafer Maps To…"
         onAccepted: {
-            var dir = String(selectedFolder).replace(/^file:\/\//, "");
+            var dir = String(selectedFolder);
             var paths = file_browser.files.map(function(row) { return row.fileName; });
             batchExportController.start(paths, dir);
         }

src/pygui/ISC/Tabs/components/StreamControlPanel.qml

@@ -110,8 +110,13 @@ Rectangle {
 
                 TabButton {
                     id: liveTab
+                    // Only X-family wafer firmware supports live streaming
+                    // (C# parity, Form1.cs btnConnect_Click) — other families
+                    // have no live-stream protocol to speak.
+                    readonly property string detectedFamily: (deviceController.lastWaferInfo && deviceController.lastWaferInfo.length > 0) ? deviceController.lastWaferInfo[0] : ""
+                    readonly property bool familySupportsStream: detectedFamily === "X"
                     text: "Live"
-                    enabled: deviceController.connectionStatus === "Connected"
+                    enabled: deviceController.connectionStatus === "Connected" && familySupportsStream
                     opacity: enabled ? 1.0 : 0.4
                     Layout.fillWidth: true
                     implicitHeight: 24
@@ -120,7 +125,9 @@ Rectangle {
 
                     AppToolTip {
                         visible: disabledHover.containsMouse && !liveTab.enabled
-                        text: "Connect a wafer to enable Live mode"
+                        text: deviceController.connectionStatus !== "Connected"
+                            ? "Connect a wafer to enable Live mode"
+                            : "Live mode is only supported on X-family wafers (detected " + liveTab.detectedFamily + ")"
                         delay: 300
                     }
 
@@ -359,12 +366,14 @@ Rectangle {
             text: streamController.mode === "live" ? "STOP" : "START"
             enabled: streamController.mode === "live"
                      ? true
-                     : deviceController.connectionStatus === "Connected"
+                     : (deviceController.connectionStatus === "Connected" && liveTab.familySupportsStream)
             opacity: enabled ? 1.0 : 0.4
 
             AppToolTip {
                 visible: primaryBtn.hovered && !primaryBtn.enabled
-                text: "Connect a wafer to enable Live mode"
+                text: deviceController.connectionStatus !== "Connected"
+                    ? "Connect a wafer to enable Live mode"
+                    : "Live mode is only supported on X-family wafers (detected " + liveTab.detectedFamily + ")"
                 delay: 300
             }
 

src/pygui/backend/controllers/batch_export_controller.py

@@ -5,7 +5,7 @@ import threading
 
 from PySide6.QtCore import Property, QObject, Qt, Signal, Slot
 
-from pygui.backend.utils import slot_error_boundary
+from pygui.backend.utils import slot_error_boundary, to_local_path
 from pygui.backend.wafer.batch_export import BatchExportResult, export_batch
 
 log = logging.getLogger(__name__)
@@ -33,7 +33,9 @@ class BatchExportController(QObject):
         self._busy = True
         self.busyChanged.emit()
         threading.Thread(
-            target=self._worker, args=(list(file_paths), output_dir), daemon=True
+            target=self._worker,
+            args=(list(file_paths), str(to_local_path(output_dir))),
+            daemon=True,
         ).start()
 
     def _worker(self, file_paths: list[str], output_dir: str) -> None:

src/pygui/backend/controllers/device_controller.py

@@ -15,7 +15,7 @@ from PySide6.QtCore import Property, QObject, Qt, Signal, Slot
 
 from pygui.backend.data.local_settings import LocalSettings
 from pygui.backend.models.data_model import TemperatureTableModel
-from pygui.backend.utils import slot_error_boundary
+from pygui.backend.utils import slot_error_boundary, to_local_path
 from pygui.backend.visualization.graph_view import GraphView
 from pygui.serialcomm.data_parser import (
     convert_to_debug_temperatures,
@@ -82,7 +82,8 @@ class DeviceController(QObject):
         self._operation_in_progress = False
         self._activity_log: list[str] = []
         self._raw_bytes: Optional[bytes] = None
-        self._save_data_dir: str = getattr(settings, 'save_data_dir', "") or str(Path(self._data_dir) / "csv")
+        saved_dir = getattr(settings, 'save_data_dir', "")
+        self._save_data_dir: str = str(to_local_path(saved_dir)) if saved_dir else str(Path(self._data_dir) / "csv")
         self._last_wafer_info: dict[str, Any] = {}
         self._wafer_detected: bool = False
         self._last_csv_path: str = ""
@@ -141,8 +142,8 @@ class DeviceController(QObject):
     @slot_error_boundary
     def setSaveDataDir(self, path: str) -> None:
         """Set the directory for saving parsed CSV data files."""
-        self._save_data_dir = path
-        self._append_log(f"Save data dir set to: {path}")
+        self._save_data_dir = str(to_local_path(path))
+        self._append_log(f"Save data dir set to: {self._save_data_dir}")
         self._save_status()
 
     @Slot(result=str)
@@ -303,6 +304,13 @@ class DeviceController(QObject):
             self._activity_log = self._activity_log[-200:]
         self.activityLogUpdated.emit("\n".join(self._activity_log))
 
+    @Slot(str)
+    @slot_error_boundary
+    def appendActivityLog(self, message: str) -> None:
+        """Public entry point for QML-side conditions (e.g. license/trial
+        state) to log into the same Activity Log as backend-triggered lines."""
+        self._append_log(message)
+
     @Slot()
     @slot_error_boundary
     def clearActivityLog(self) -> None:

src/pygui/backend/controllers/session_controller.py

@@ -21,6 +21,7 @@ from pygui.backend.models.sensor_editor import SensorEditor
 from pygui.backend.models.session_model import SessionModel, SessionUpdate
 from pygui.backend.models.threshold_classifier import ThresholdConfig
 from pygui.backend.utils import slot_error_boundary
+from pygui.backend.wafer.family_spec import sensor_count_for
 from pygui.backend.wafer.wafer_layouts import ec_pairs_for_wafer_id
 from pygui.backend.wafer.zwafer_models import Sensor
 from pygui.backend.wafer.zwafer_parser import ZWaferParser
@@ -43,6 +44,7 @@ class SessionController(QObject):
     loadFileError = Signal(str)
     clusterAveragingEnabledChanged = Signal()
     liveStatsChanged = Signal()  # emitted when receivedCount or errorCount change
+    liveError = Signal(str)  # fatal live-stream error message, for Activity Log
     # trend: per-frame avg for live graph
     trendDelta = Signal(str)  # JSON [[elapsed_s, avg]] — one new point per live frame
     trendReset = Signal()  # live trend buffer cleared (new stream started)
@@ -53,7 +55,7 @@ class SessionController(QObject):
     segmentExported = Signal(dict)  # dict with success, path | error
     # private: marshal a worker-thread frame onto the main thread
     _liveFrame = Signal(object)    # Frame
-    _liveError = Signal()          # worker-thread error ping
+    _liveError = Signal(str)       # worker-thread error ping, carries exception text
 
     def __init__(self, parent: QObject | None = None) -> None:
         super().__init__(parent)
@@ -685,6 +687,16 @@ class SessionController(QObject):
             log.warning("startStream: StreamReader is already running.")
             return
 
+        # C# parity (Form1.cs btnConnect_Click: "currently only X wafers
+        # support streaming"). Other families' firmware has no live-stream
+        # protocol — a D2 send on family A produced a burst of unrelated
+        # ASCII output for ~10s then went quiet, not real sensor telemetry.
+        if family_code and family_code != "X":
+            message = f"Live stream is only supported on X-family wafers (detected {family_code})"
+            log.warning(message)
+            self.liveError.emit(message)
+            return
+
         from pygui.backend.wafer.wafer_layouts import load_layout_for_wafer_id
         from pygui.serialcomm.serial_port import SerialPort  # transport open
 
@@ -700,9 +712,16 @@ class SessionController(QObject):
         if not self._active_clusters:
             self._active_clusters = group_sensors_by_radius(self._sensors)
 
-        # The new binary protocol sends payload of (sensorCount * 2) bytes
-        # Each sensor is a big-endian 16-bit value (Sign-Magnitude).
-        expected_sensors = 80 if (family_code or "") == "X" else 244
+        # The binary protocol's payload carries a fixed-size channel array
+        # (sensorCount * 2 bytes, big-endian Sign-Magnitude each) that's wider
+        # than any one wafer family's real sensor count — trailing channels
+        # are unpopulated hardware slots, not real readings. Bound decoding to
+        # the just-loaded layout's actual sensor count so those float/noise
+        # channels never reach values (and therefore never reach MIN/MAX/AVG
+        # in compute_stats, which has no sensor-count knowledge of its own).
+        # Fall back to the family YAML lookup only if no layout loaded yet
+        # (e.g. startStream called with an unknown family_code).
+        expected_sensors = len(self._sensors) or sensor_count_for(family_code or "")
 
         def parse_binary_frame(payload: bytes, seq: int) -> Frame:
             values = []
@@ -733,6 +752,13 @@ class SessionController(QObject):
         self.liveStatsChanged.emit()
 
         transport = SerialPort.open_port(port, timeout=1)
+        # Discard anything left over from a prior session (e.g. the device
+        # kept transmitting after our last D2S landed) — stale bytes here
+        # misalign the very first packet, corrupting every reading in it.
+        try:
+            transport.reset_input_buffer()
+        except Exception as exc:
+            log.warning("Could not reset input buffer before start: %s", exc)
         # Send 'D2' command padded to 512 bytes to start the stream
         cmd = b"D2" + SerialPort.COMMAND_PAD.encode()
         transport.write(cmd)
@@ -744,8 +770,11 @@ class SessionController(QObject):
             log.error("Live stream error: %s", exc)
             ref = weak_self()
             if ref is not None:
-                ref._liveError.emit()
-                ref.stopStream()
+                # Marshal onto the main thread via the queued signal — this
+                # callback runs on StreamReader's own worker thread, and
+                # stopStream() joins that same thread, so calling it directly
+                # here would deadlock/raise ("cannot join current thread").
+                ref._liveError.emit(str(exc))
 
         def on_frame(frame: Frame):
             ref = weak_self()
@@ -772,14 +801,24 @@ class SessionController(QObject):
         self.liveStatsChanged.emit()
         if self._reader:
             transport = self._reader._transport
+            reader_thread = self._reader._thread
+            # If the worker thread already exited on its own (e.g. a fatal
+            # stream error), it already closed the transport in its finally
+            # block — writing here races that close and raises EBADF. Nothing
+            # is listening for D2S anyway once the reader has given up.
+            reader_still_running = reader_thread is not None and reader_thread.is_alive()
 
             # Send 'D2S' command padded to 512 bytes to stop the stream
             # Send BEFORE stopping the reader which will close the port on thread exit
-            if transport and transport.is_open:
+            if reader_still_running and transport and transport.is_open:
                 try:
                     cmd = b"D2S" + (b"F" * 509)
                     transport.write(cmd)
                     transport.flush()
+                    # Device may keep transmitting a few more bytes after D2S
+                    # lands — discard them so they don't survive into the
+                    # next Live session and misalign its first packet.
+                    transport.reset_input_buffer()
                 except Exception as exc:
                     log.error("Error sending stop command: %s", exc)
 
@@ -815,10 +854,15 @@ class SessionController(QObject):
         self.frameUpdated.emit()
         self.stateChanged.emit()
 
-    def _on_live_error(self) -> None:
-        """Main-thread callback for worker-thread stream errors."""
+    def _on_live_error(self, message: str) -> None:
+        """Main-thread callback for worker-thread stream errors. StreamReader
+        only calls its on_error for resync exhaustion or an unhandled parse
+        exception — both unrecoverable for the current stream — so this ends
+        the session and surfaces the reason (Activity Log wiring in QML)."""
         self._error_count += 1
         self.liveStatsChanged.emit()
+        self.liveError.emit(message)
+        self.stopStream()
 
     # ---- recording ----
     @Slot(str, str)

src/pygui/backend/data/file_browser.py

@@ -10,6 +10,7 @@ from PySide6.QtWidgets import QFileDialog, QMessageBox
 
 from pygui.backend.data.constants import default_data_dir
 from pygui.backend.data.csv_file_metadata import CSVFileMetadata
+from pygui.backend.utils import to_local_path
 from pygui.backend.wafer.zwafer_parser import ZWaferParser
 
 
@@ -45,7 +46,7 @@ class FileBrowser(QObject):
         Used to keep this directory in sync with DeviceController.saveDataDir
         when the user picks a save folder elsewhere in the app.
         """
-        self._set_current_directory(Path(path))
+        self._set_current_directory(to_local_path(path))
         self._refresh_files(show_empty_message=False)
 
     @Slot()
@@ -124,7 +125,8 @@ class FileBrowser(QObject):
         date still gets a deterministic (if degenerate) filename, so the
         duplicate-import guard below still fires on a second attempt.
         """
-        source_path = Path(file_path)
+        source_path = to_local_path(file_path)
+        file_path = str(source_path)
         parser_data, _ = self._parser.parse(file_path)
         if parser_data is None:
             self.importFinished.emit("", f"Failed to parse CSV:\n{source_path.name}")

src/pygui/backend/license/license_model.py

@@ -4,7 +4,6 @@ import logging
 import shutil
 import time
 from pathlib import Path
-from urllib.parse import unquote, urlparse
 
 from PySide6.QtCore import Property, QObject, Signal, Slot
 
@@ -14,19 +13,13 @@ from pygui.backend.license.license_manager import (
     parse_license_blob,
     read_license_files,
 )
+from pygui.backend.utils import to_local_path as _to_local_path
 
 log = logging.getLogger(__name__)
 
 TRIAL_DAYS = 30
 
 
-def _to_local_path(path_or_url: str) -> Path:
-    """Accept both plain paths and file:// URLs (QML FileDialog gives URLs)."""
-    if path_or_url.startswith("file:"):
-        return Path(unquote(urlparse(path_or_url).path))
-    return Path(path_or_url)
-
-
 # ===== License Model =====
 class LicenseModel(QObject):
     """Context property backing the About dialog license grid.
@@ -207,3 +200,12 @@ class LicenseModel(QObject):
             return True
         age_days = (time.time() - marker.stat().st_mtime) / 86400.0
         return age_days > TRIAL_DAYS
+
+    @Slot(result=bool)
+    def reviewAccessBlocked(self) -> bool:
+        """True only once a started trial has actually expired (ADR-0005).
+
+        A "none" state (trial never started) is not a block — nothing to
+        enforce yet. "permanent" (a real license) never blocks.
+        """
+        return self.replayLicenseState() == "temporary" and self.replayTrialExpired()

src/pygui/backend/utils.py

@@ -1,5 +1,26 @@
 import logging
+import re
 from functools import wraps
+from pathlib import Path
+
+from PySide6.QtCore import QUrl
+
+_MANGLED_DRIVE_RE = re.compile(r"^/([A-Za-z]:)")
+
+
+def to_local_path(path_or_url: str) -> Path:
+    """Accept plain paths, file:// URLs, and already-mangled "/C:/..." strings
+    (persisted by old buggy code before it stripped file:// by hand).
+
+    Uses QUrl.toLocalFile() rather than a manual string strip — stripping
+    "file://" by hand leaves a leading slash before a Windows drive letter
+    (e.g. "/C:/Users/...", not a valid absolute path), which QUrl's
+    platform-aware conversion handles correctly.
+    """
+    if path_or_url.startswith("file:"):
+        return Path(QUrl(path_or_url).toLocalFile())
+    # ponytail: repair values saved by the old regex-stripping QML code
+    return Path(_MANGLED_DRIVE_RE.sub(r"\1", path_or_url))
 
 
 def slot_error_boundary(func):

src/pygui/backend/visualization/radial_metrics.py

@@ -0,0 +1,38 @@
+from __future__ import annotations
+
+import math
+
+from pygui.backend.wafer.zwafer_models import Sensor
+
+
+def ring_boundaries(sensors: list[Sensor]) -> list[float]:
+    """Distinct radial distances of sensor groups, sorted ascending, plus the outer boundary."""
+    if not sensors:
+        r = 150.0
+        return [r * f for f in (0.25, 0.50, 0.75, 1.0)]
+    # Cluster radii that are within 2 mm of each other into one ring; skip center point.
+    radii = sorted(r for r in {math.hypot(s.x, s.y) for s in sensors} if r > 1.0)
+    groups: list[float] = []
+    for r in radii:
+        if not groups or r - groups[-1] > 2.0:
+            groups.append(r)
+        else:
+            groups[-1] = (groups[-1] + r) / 2  # merge close values
+    # Always include the outer boundary ring so the wafer circle is drawn.
+    outer = max(math.hypot(s.x, s.y) for s in sensors) * 1.05
+    if not groups or outer - groups[-1] > 2.0:
+        groups.append(outer)
+    return groups
+
+
+def bucket_by_ring(sensors: list[Sensor], values: list[float]) -> dict[int, list[float]]:
+    """Group each sensor's value under the index of its nearest ring boundary."""
+    boundaries = ring_boundaries(sensors)
+    result: dict[int, list[float]] = {i: [] for i in range(len(boundaries))}
+    for i, s in enumerate(sensors):
+        if i >= len(values):
+            continue
+        r = math.hypot(s.x, s.y)
+        idx = min(range(len(boundaries)), key=lambda j: abs(boundaries[j] - r))
+        result[idx].append(values[i])
+    return result

src/pygui/backend/visualization/wafer_map_item.py

@@ -28,6 +28,7 @@ from PySide6.QtQml import QmlElement
 from PySide6.QtQuick import QQuickPaintedItem
 
 from pygui.backend.models.frame_stats import compute_stats
+from pygui.backend.visualization.radial_metrics import ring_boundaries
 from pygui.backend.visualization.rbf_heatmap import (
     ellipse_alpha,
     interpolate_field,
@@ -517,22 +518,7 @@ class WaferMapItem(QQuickPaintedItem):
 
     def _sensor_ring_radii_mm(self) -> list[float]:
         """Distinct radial distances of sensor groups, sorted ascending, plus the outer boundary."""
-        if not self._sensors:
-            r = self._wafer_radius_mm()
-            return [r * f for f in (0.25, 0.50, 0.75, 1.0)]
-        # Cluster radii that are within 2 mm of each other into one ring; skip center point.
-        radii = sorted(r for r in {math.hypot(s.x, s.y) for s in self._sensors} if r > 1.0)
-        groups: list[float] = []
-        for r in radii:
-            if not groups or r - groups[-1] > 2.0:
-                groups.append(r)
-            else:
-                groups[-1] = (groups[-1] + r) / 2  # merge close values
-        # Always include the outer boundary ring so the wafer circle is drawn.
-        outer = self._wafer_radius_mm()
-        if not groups or outer - groups[-1] > 2.0:
-            groups.append(outer)
-        return groups
+        return ring_boundaries(self._sensors)
 
     def _scale(self, ds: int, r_mm: float) -> float:
         """Pixels per mm. The wafer radius maps to ds//2 - 24 px."""

src/pygui/backend/wafer/family_spec.py

@@ -1,9 +1,14 @@
 """Single source of truth for the wafer sensor-count partition."""
+from __future__ import annotations
+
+from pygui.backend.wafer.wafer_layouts import load_layout_for_wafer_id
 
 
 def sensor_count_for(family_code: str) -> int:
-    """Return the number of valid sensor readings for a wafer family code.
+    """Real sensor count for a wafer family code, from its YAML layout.
 
-    Returns 80 for the "X" family. Returns 244 for every other family
-    code."""
-    return 80 if family_code == "X" else 244
+    0 for an unknown/empty family code."""
+    try:
+        return len(load_layout_for_wafer_id(family_code))
+    except KeyError:
+        return 0

src/pygui/serialcomm/data_parser.py

@@ -20,17 +20,7 @@ log = logging.getLogger(__name__)
 
 def csv_column_count(family_code: str) -> int:
     """Return the number of columns to display for a family code."""
-    mapping = {
-        "A": 48,
-        "E": 48,
-        "P": 48,
-        "B": 29,
-        "C": 29,
-        "D": 29,
-        "F": 22,
-        "X": 80,
-    }
-    return mapping.get(family_code, 0)
+    return sensor_count_for(family_code)
 
 
 def _hex_to_binary(hex_str: str) -> list[int]:
@@ -160,19 +150,19 @@ def parse_binary_data(data_bytes: bytes, family_code: str) -> Optional[list[list
         if family_code == "X":
             return _parse_x_binary(data_bytes)
         else:
-            return _parse_p_binary(data_bytes)
+            return _parse_p_binary(data_bytes, family_code)
     except Exception as exc:
         log.error("Binary parse failed: %s", exc)
         return None
 
 
-def _parse_p_binary(data_bytes: bytes) -> list[list[str]]:
+def _parse_p_binary(data_bytes: bytes, family_code: str = "P") -> list[list[str]]:
     """Parse P-family (and A/B/C/D/E/F) binary data.
 
     Each block of 256 readings has 244 valid + 12 overhead.
     Valid readings are chunked into rows of the family's sensor count (244).
     """
-    sensor_count = sensor_count_for("P")
+    sensor_count = sensor_count_for(family_code or "P")
     readings: list[str] = []
 
     # Read 2 bytes at a time (UInt16 little-endian)
@@ -190,7 +180,7 @@ def _parse_p_binary(data_bytes: bytes) -> list[list[str]]:
         result.append(readings[idx : idx + sensor_count])
         idx += sensor_count
 
-    log.info("Parsed P-family: %d rows × %d cols", len(result), sensor_count)
+    log.info("Parsed %s-family: %d rows × %d cols", family_code or "P", len(result), sensor_count)
     return result
 
 

src/pygui/serialcomm/stream_reader.py

@@ -14,8 +14,33 @@ log = logging.getLogger(__name__)
 
 ParseFrame = Callable[[bytes, int], Frame]
 
-# Max consecutive resync attempts before giving up on a corrupt stream.
-_MAX_RESYNC_ATTEMPTS = 50
+# Max garbage bytes discarded (no sync marker found) before giving up on a
+# corrupt stream. Counted in BYTES, not read attempts — attempts scale with
+# data rate (a slow trickle could take minutes to trip an attempt-count cap),
+# bytes don't. Real frames are <=500B, so a healthy stream never comes close;
+# 16KB is ~32 frames of slack, ~1.4s of pure garbage at 115200 baud. Empty
+# reads (idle port) never count — C#'s findMessageStart waits forever on quiet.
+_MAX_RESYNC_BYTES = 16384
+
+# Largest believable payload_len. Real frames are ≤ 488 bytes (244 words);
+# anything bigger means we latched onto a false 0xAA 0x88 inside data and
+# read garbage as a length — without this cap, _accumulate would swallow up
+# to 64KB of good frames waiting for a packet that doesn't exist.
+# ponytail: loose cap; exact per-family length check if false frames slip CRC.
+_MAX_PAYLOAD_LEN = 4096
+
+
+def _crc16(data: bytes) -> int:
+    """CRC16/MODBUS (poly 0xA001, init 0xFFFF) — mirrors C# CalculateCRC16."""
+    crc = 0xFFFF
+    for byte in data:
+        crc ^= byte
+        for _ in range(8):
+            if crc & 1:
+                crc = (crc >> 1) ^ 0xA001
+            else:
+                crc >>= 1
+    return crc
 
 class StreamReader:
 
@@ -63,43 +88,43 @@ class StreamReader:
 
     def _run(self) -> None:
         try:
-            # Peek at the first few bytes to determine protocol.
-            peek_buf = bytearray()
-            while not self._stop.is_set() and len(peek_buf) < 32:
-                b = self._transport.read(1)
-                if not b:
-                    continue
-                peek_buf.extend(b)
-                if b[0] == 10:  # newline
-                    break
-
-            if self._stop.is_set() or not peek_buf:
+            # Protocol is decided by the first byte: 0xAA is the binary sync
+            # marker's lead byte and can never appear in the ASCII hex-dump
+            # stream (0-9/A-F only) real hardware has been observed sending
+            # — see docs/adr/0007. Anything else is ASCII.
+            first = b""
+            while not first and not self._stop.is_set():
+                first = self._transport.read(1)
+            if self._stop.is_set() or not first:
                 return
 
-            raw = bytes(peek_buf)
-
-            # Binary sync bytes are the strongest signal.
-            if raw.startswith(b"\xaa\x88"):
-                self._run_binary(raw)
+            if first[0] == 0xAA:
+                second = b""
+                while not second and not self._stop.is_set():
+                    second = self._transport.read(1)
+                if self._stop.is_set():
+                    return
+                if second and second[0] == 0x88:
+                    self._run_binary(bytearray(first + second))
+                    return
+                # Lone 0xAA, not a real marker — feed both bytes into the
+                # ASCII path instead of discarding them.
+                self._run_ascii(bytes(first) + bytes(second))
                 return
 
-            # Text-lines (CSV) requires BOTH a newline AND commas in the
-            # pre-newline content.  This avoids misclassifying a binary
-            # payload that happens to contain 0x2C as text.
-            has_newline = b"\n" in raw or b"\r" in raw
-            line_before_nl = raw.split(b"\n")[0].split(b"\r")[0]
-            if has_newline and b"," in line_before_nl:
-                self._run_text_lines(raw)
-                return
-
-            # Default: ASCII hex dump stream.
-            self._run_ascii(raw)
+            self._run_ascii(bytes(first))
         except Exception as exc:
-            log.exception("StreamReader thread encountered error: %s", exc)
-            try:
-                self._on_error(exc)
-            except Exception:
-                pass
+            if self._stop.is_set():
+                # stop() closes the transport to unblock a pending read —
+                # that self-inflicted close raises here too (e.g. EBADF).
+                # Not a real stream fault, so don't report it as one.
+                log.debug("StreamReader thread exiting after stop(): %s", exc)
+            else:
+                log.exception("StreamReader thread encountered error: %s", exc)
+                try:
+                    self._on_error(exc)
+                except Exception:
+                    pass
         finally:
             try:
                 self._transport.close()
@@ -109,7 +134,8 @@ class StreamReader:
     def _run_binary(self, initial_bytes: bytes | bytearray) -> None:
         log.info("StreamReader: starting binary stream parsing")
         buf = bytearray(initial_bytes)
-        resync_attempts = 0
+        resync_bytes = 0
+        logged_head = False
 
         while not self._stop.is_set():
             # Find sync marker in buffer.
@@ -122,7 +148,11 @@ class StreamReader:
                 idx += 1
 
             if synced:
-                resync_attempts = 0
+                if not logged_head:
+                    log.debug("StreamReader: first bytes on wire: %s",
+                            bytes(buf[:64]).hex())
+                    logged_head = True
+                resync_bytes = 0
                 buf = buf[idx:]
                 # Accumulate header (5 bytes after sync).
                 while len(buf) < 7 and not self._stop.is_set():
@@ -133,6 +163,12 @@ class StreamReader:
                     return
 
                 payload_len = int.from_bytes(buf[5:7], byteorder='little')
+                if payload_len > _MAX_PAYLOAD_LEN:
+                    # False sync marker inside data — the "length" is garbage.
+                    # Skip past the marker and rescan what we already have.
+                    self.resync_count += 1
+                    buf = buf[2:]
+                    continue
                 total_packet_len = 2 + 5 + payload_len + 2
 
                 # Accumulate the rest of the packet in one buffered read.
@@ -144,6 +180,22 @@ class StreamReader:
                 if self._stop.is_set():
                     return
 
+                # CRC16 over sync+header+payload, trailing 2 bytes LE —
+                # mirrors C# VerifyData. A failed CRC is a corrupt or
+                # misframed packet: drop it, rescan, keep streaming.
+                received_crc = int.from_bytes(
+                    buf[7 + payload_len:9 + payload_len], byteorder='little'
+                )
+                if _crc16(bytes(buf[:7 + payload_len])) != received_crc:
+                    self.error_count += 1
+                    if self.error_count <= 10:
+                        log.warning(
+                            "CRC mismatch on binary packet (seq bytes %s) — dropped",
+                            bytes(buf[3:5]).hex(),
+                        )
+                    buf = buf[2:]
+                    continue
+
                 header = buf[2:7]
                 seq = int.from_bytes(header[1:3], byteorder='little')
                 payload = buf[7:7 + payload_len]
@@ -160,27 +212,46 @@ class StreamReader:
                 buf = buf[total_packet_len:]
             else:
                 # Resync: keep only trailing 0xAA if present, then read more.
-                resync_attempts += 1
-                self.resync_count += 1
-                if resync_attempts > _MAX_RESYNC_ATTEMPTS:
-                    log.error(
-                        "StreamReader: giving up after %d resync attempts "
-                        "(no 0xAA 0x88 sync marker found in stream)",
-                        resync_attempts,
-                    )
-                    self._on_error(
-                        TimeoutError("Binary stream resync failed: no sync marker")
-                    )
-                    return
                 if len(buf) > 0 and buf[-1] == 0xAA:
                     buf = bytearray([0xAA])
                 else:
                     buf.clear()
 
                 chunk = self._read_chunk()
+                if not chunk:
+                    # Quiet port — waiting for data is not a resync failure.
+                    # The device pauses between scans; C#'s findMessageStart
+                    # waits forever. Only actual garbage counts toward the cap.
+                    continue
+                if not logged_head:
+                    log.debug("StreamReader: first bytes on wire: %s",
+                            bytes((buf + chunk)[:64]).hex())
+                    logged_head = True
+                self.resync_count += 1
+                resync_bytes += len(chunk)
+                if resync_bytes > _MAX_RESYNC_BYTES:
+                    # buf was already cleared/reset at the top of this
+                    # iteration — the bytes worth dumping are in buf+chunk
+                    # (the carryover byte, if any, plus what was just read).
+                    # Raw wire content is DEBUG-only — never in the ERROR
+                    # line the terminal/Activity Log surface to the user.
+                    log.debug("StreamReader: discarded bytes before giving up: %s",
+                            bytes((buf + chunk)[:64]).hex())
+                    log.error(
+                        "StreamReader: giving up after %d garbage bytes "
+                        "(no 0xAA 0x88 sync marker found in stream)",
+                        resync_bytes,
+                    )
+                    self._on_error(
+                        TimeoutError("Binary stream resync failed: no sync marker")
+                    )
+                    return
                 buf.extend(chunk)
 
     def _run_ascii(self, initial_bytes: bytes) -> None:
+        """Parse the ASCII hex-dump live stream: fixed-width blocks of
+        4-char hex words, one word per channel slot (up to 256 slots; only
+        the family's real sensor_count are populated, see docs/adr/0007)."""
         log.info("StreamReader: starting ASCII hex dump stream parsing")
 
         valid_words = sensor_count_for(self._family_code)
@@ -189,12 +260,9 @@ class StreamReader:
         chars_needed = block_words * word_char_len  # total hex chars per block
 
         hex_chars = bytearray()
-        if initial_bytes:
-            for b in initial_bytes:
-                if chr(b) in "0123456789ABCDEFabcdef":
-                    hex_chars.append(b)
-                elif b == 0xAA:
-                    hex_chars.append(b)
+        for b in initial_bytes:
+            if chr(b) in "0123456789ABCDEFabcdef":
+                hex_chars.append(b)
 
         seq = 0
         while not self._stop.is_set():
@@ -202,24 +270,15 @@ class StreamReader:
             while len(hex_chars) < chars_needed and not self._stop.is_set():
                 chunk = self._read_chunk(min_bytes=chars_needed - len(hex_chars))
                 for byte in chunk:
-                    if byte == 0xAA:
-                        # Sync marker appeared – hand off to binary parser.
-                        hex_chars.append(byte)
-                        break
                     if chr(byte) in "0123456789ABCDEFabcdef":
                         hex_chars.append(byte)
-                else:
-                    continue
-                break  # broke out of inner loop due to 0xAA
 
-            # Check for early termination (0xAA sync marker anywhere in buffer).
-            aa_idx = hex_chars.find(bytes([0xAA]))
-            if aa_idx >= 0:
-                log.info("StreamReader: Detected 0xAA at position %d, switching to binary mode.", aa_idx)
-                self._run_binary(hex_chars[aa_idx:])
+            if self._stop.is_set():
                 return
 
-            # Parse words from the accumulated hex characters.
+            # Parse one block's worth of words (buffered reads may overshoot
+            # chars_needed — cap here so the remainder rolls into the next
+            # iteration instead of being folded into this frame and lost).
             word_buffer = []
             for i in range(0, min(len(hex_chars), chars_needed), word_char_len):
                 word_str = hex_chars[i:i + word_char_len]
@@ -228,7 +287,6 @@ class StreamReader:
                 word_buffer.append(bytes(word_str))
 
             if not word_buffer:
-                time.sleep(0.01)
                 continue
 
             hex_chars = hex_chars[len(word_buffer) * word_char_len:]
@@ -238,7 +296,7 @@ class StreamReader:
             for hex_val in valid_hex_words:
                 try:
                     swapped = hex_val[2:4] + hex_val[0:2]
-                    t = _convert_hex_to_temp(swapped, self._family_code)  # type: ignore[arg-type]
+                    t = _convert_hex_to_temp(swapped.decode(), self._family_code)
                     values.append(t)
                 except Exception:
                     values.append(0.0)
@@ -248,34 +306,29 @@ class StreamReader:
                 self._on_frame(frame)
                 seq += 1
             except Exception as exc:
-                log.error("Error emitting ASCII frame: %s", exc)
-
-    def _run_text_lines(self, initial_bytes: bytes) -> None:
-        log.info("StreamReader: starting line-by-line ASCII text parsing")
-        buf = bytearray(initial_bytes)
-        seq = 0
-
-        while not self._stop.is_set():
-            # Drain complete lines from the buffer.
-            while b"\n" in buf:
-                line_bytes, _, buf = buf.partition(b"\n")
-                line = line_bytes.decode('utf-8', errors='ignore').strip()
-                if line:
-                    try:
-                        frame = self._parse(line, seq)  # type: ignore[arg-type]
-                        if frame:
-                            self._on_frame(frame)
-                            seq += 1
-                    except Exception as exc:
-                        self.error_count += 1
-                        self._on_error(exc)
-
-            # Read more data using buffered reads.
-            chunk = self._read_chunk()
-            buf.extend(chunk)
+                self.error_count += 1
+                if self.error_count <= 10:
+                    log.warning("Error emitting ASCII frame: %s", exc)
+                self._on_error(exc)
 
     def stop(self) -> None:
         self._stop.set()
+        # Close the port out from under any blocked transport.read() call —
+        # relying on _stop alone means a thread stuck in a longer-than-
+        # expected read (or one the OS driver is slow to unblock) keeps the
+        # port open, and a subsequent startStream() then opens a *second*
+        # handle to the same port, racing the still-live old reader for
+        # bytes (garbled/duplicated frames on the next Live session).
+        try:
+            self._transport.close()
+        except Exception:
+            pass
         if self._thread is not None and self._thread.is_alive():
             self._thread.join(timeout = 2.0)
+            if self._thread.is_alive():
+                log.error(
+                    "StreamReader: worker thread still alive %.1fs after "
+                    "stop() — port may not be released for the next session",
+                    2.0,
+                )
             self._thread = None

tests/test_data_parser.py

@@ -42,8 +42,13 @@ class TestCsvColumnCount:
     def test_x_family(self):
         assert csv_column_count("X") == 80
 
+    def test_z_family(self):
+        # Z has a real YAML layout (zwafer.yaml) — not "unknown" like the
+        # old hardcoded table implied by omitting it.
+        assert csv_column_count("Z") == 65
+
     def test_unknown_family_returns_zero(self):
-        assert csv_column_count("Z") == 0
+        assert csv_column_count("Q") == 0
 
     def test_empty_string_returns_zero(self):
         assert csv_column_count("") == 0
@@ -134,11 +139,11 @@ class TestParseBinaryData:
         assert result is not None
         assert len(result) == 1
 
-    def test_p_family_single_block_row_has_244_sensors(self):
+    def test_p_family_single_block_row_has_48_sensors(self):
         data = _make_p_block(1)
         result = parse_binary_data(data, "P")
         assert result is not None
-        assert len(result[0]) == 244
+        assert len(result[0]) == 48
 
     def test_p_family_two_blocks_returns_two_rows(self):
         data = _make_p_block(2)
@@ -170,7 +175,7 @@ class TestParseBinaryData:
         data = _make_p_block(1)
         result = parse_binary_data(data, "A")
         assert result is not None
-        assert len(result[0]) == 244
+        assert len(result[0]) == 48
 
     def test_empty_bytes_returns_empty_list(self):
         result = parse_binary_data(b"", "P")

tests/test_device_controller.py

@@ -85,6 +85,10 @@ def test_clear_activity_log(controller):
     controller.clearActivityLog()
     assert len(controller._activity_log) == 0
 
+def test_append_activity_log_appends_to_activity_log(controller):
+    controller.appendActivityLog("Review trial expired")
+    assert "Review trial expired" in controller.activityLog
+
 def test_clear_session(controller):
     controller._connection_status = "Connected"
     controller._selected_port = "COM1"
@@ -236,12 +240,12 @@ def test_parse_and_save_data_and_get_chart_data(controller):
     assert emitted_result is not None
     assert emitted_result.get("success") is True
     assert controller.dataRowCount == 1
-    assert controller.dataColCount == 244
+    assert controller.dataColCount == 48
 
     chart_res = controller.getChartData()
     assert chart_res.get("success") is True
     assert "Sensor1" in chart_res.get("sensor_names")
-    assert len(chart_res.get("series")) == 244
+    assert len(chart_res.get("series")) == 48
 
 def test_logging_handler(controller):
     logger = logging.getLogger("test_logger")

tests/test_family_spec.py

@@ -1,4 +1,8 @@
-"""Tests for the shared wafer family sensor-count lookup."""
+"""Tests for the shared wafer family sensor-count lookup.
+
+Real counts, one per YAML layout file — this is the ground truth every
+caller (streaming decode, NVRAM parsing, CSV column count) must agree on.
+"""
 from pygui.backend.wafer.family_spec import sensor_count_for
 
 
@@ -6,18 +10,27 @@ def test_x_family_returns_80():
     assert sensor_count_for("X") == 80
 
 
-def test_p_family_returns_244():
-    assert sensor_count_for("P") == 244
+def test_aep_family_returns_48():
+    for code in ("A", "E", "P"):
+        assert sensor_count_for(code) == 48
 
 
-def test_other_known_families_return_244():
-    for code in ("A", "B", "C", "D", "E", "F"):
-        assert sensor_count_for(code) == 244
+def test_bcd_family_returns_29():
+    for code in ("B", "C", "D"):
+        assert sensor_count_for(code) == 29
 
 
-def test_unknown_family_returns_244():
-    assert sensor_count_for("Z") == 244
+def test_f_family_returns_22():
+    assert sensor_count_for("F") == 22
 
 
-def test_empty_string_returns_244():
-    assert sensor_count_for("") == 244
+def test_z_family_returns_65():
+    assert sensor_count_for("Z") == 65
+
+
+def test_unknown_family_returns_zero():
+    assert sensor_count_for("Q") == 0
+
+
+def test_empty_string_returns_zero():
+    assert sensor_count_for("") == 0

tests/test_license.py

@@ -267,3 +267,33 @@ def test_replay_trial_expiry(tmp_path, qapp):
 def test_replay_trial_expired_without_marker(tmp_path, qapp):
     model = LicenseModel(str(tmp_path))
     assert model.replayTrialExpired() is True
+
+
+# ===== Review-access gate (ADR-0005 "Deferred" item) =====
+def test_review_access_not_blocked_before_trial_starts(tmp_path, qapp):
+    model = LicenseModel(str(tmp_path))
+    assert model.reviewAccessBlocked() is False
+
+
+def test_review_access_not_blocked_during_fresh_trial(tmp_path, qapp):
+    model = LicenseModel(str(tmp_path))
+    model.startReplayTrial()
+    assert model.reviewAccessBlocked() is False
+
+
+def test_review_access_blocked_once_trial_expired(tmp_path, qapp):
+    model = LicenseModel(str(tmp_path))
+    model.startReplayTrial()
+    old = time.time() - 31 * 86400
+    os.utime(model._trial_marker, (old, old))
+    assert model.reviewAccessBlocked() is True
+
+
+def test_review_access_not_blocked_with_permanent_license_even_if_trial_expired(tmp_path, qapp):
+    (tmp_path / "licenses").mkdir()
+    write_license(tmp_path / "licenses", level="01")
+    model = LicenseModel(str(tmp_path))
+    model.startReplayTrial()
+    old = time.time() - 31 * 86400
+    os.utime(model._trial_marker, (old, old))
+    assert model.reviewAccessBlocked() is False

tests/test_radial_metrics.py

@@ -0,0 +1,89 @@
+import math
+
+import pytest
+
+from pygui.backend.visualization.radial_metrics import bucket_by_ring, ring_boundaries
+from pygui.backend.wafer.zwafer_models import Sensor
+
+
+def test_ring_boundaries_empty_sensors_returns_default_quartiles():
+    assert ring_boundaries([]) == [37.5, 75.0, 112.5, 150.0]
+
+
+def test_ring_boundaries_single_ring_plus_outer_boundary():
+    sensors = [
+        Sensor(label="1", x=100.0, y=0.0),
+        Sensor(label="2", x=0.0, y=100.0),
+        Sensor(label="3", x=-100.0, y=0.0),
+        Sensor(label="4", x=0.0, y=-100.0),
+    ]
+    assert ring_boundaries(sensors) == [100.0, 105.0]
+
+
+def test_ring_boundaries_excludes_center_point():
+    sensors = [
+        Sensor(label="center", x=0.0, y=0.0),
+        Sensor(label="1", x=50.0, y=0.0),
+        Sensor(label="2", x=0.0, y=50.0),
+        Sensor(label="3", x=-50.0, y=0.0),
+        Sensor(label="4", x=0.0, y=-50.0),
+    ]
+    assert ring_boundaries(sensors) == [50.0, 52.5]
+
+
+def test_ring_boundaries_merges_radii_within_2mm_and_averages():
+    sensors = [
+        Sensor(label="1", x=30.0, y=0.0),
+        Sensor(label="2", x=0.0, y=31.5),
+        Sensor(label="3", x=80.0, y=0.0),
+    ]
+    assert ring_boundaries(sensors) == [30.75, 80.0, 84.0]
+
+
+def test_ring_boundaries_square_family_grid_buckets_by_distance_not_axis():
+    # A square-family sensor grid (per wafer_layouts.py, e.g. the 80-sensor
+    # square layout): axis points and corner points sit at different radial
+    # distances from center despite forming a visually square pattern, so
+    # ring clustering must key on hypot() distance, not grid position.
+    sensors = [
+        Sensor(label="axis1", x=40.0, y=0.0),
+        Sensor(label="axis2", x=-40.0, y=0.0),
+        Sensor(label="axis3", x=0.0, y=40.0),
+        Sensor(label="axis4", x=0.0, y=-40.0),
+        Sensor(label="corner1", x=40.0, y=40.0),
+        Sensor(label="corner2", x=-40.0, y=-40.0),
+    ]
+    axis_r = 40.0
+    corner_r = math.hypot(40.0, 40.0)
+    outer = corner_r * 1.05
+    assert ring_boundaries(sensors) == pytest.approx([axis_r, corner_r, outer])
+
+
+def test_bucket_by_ring_groups_single_ring_sensors_together():
+    sensors = [
+        Sensor(label="1", x=100.0, y=0.0),
+        Sensor(label="2", x=0.0, y=100.0),
+        Sensor(label="3", x=-100.0, y=0.0),
+        Sensor(label="4", x=0.0, y=-100.0),
+    ]
+    values = [10.0, 20.0, 30.0, 40.0]
+    assert bucket_by_ring(sensors, values) == {0: [10.0, 20.0, 30.0, 40.0], 1: []}
+
+
+def test_bucket_by_ring_assigns_each_sensor_to_its_nearest_boundary():
+    sensors = [
+        Sensor(label="1", x=30.0, y=0.0),
+        Sensor(label="2", x=0.0, y=31.5),
+        Sensor(label="3", x=80.0, y=0.0),
+    ]
+    values = [1.0, 2.0, 3.0]
+    assert bucket_by_ring(sensors, values) == {0: [1.0, 2.0], 1: [3.0], 2: []}
+
+
+def test_bucket_by_ring_ignores_sensors_beyond_a_short_values_list():
+    sensors = [
+        Sensor(label="1", x=100.0, y=0.0),
+        Sensor(label="2", x=0.0, y=100.0),
+    ]
+    values = [10.0]  # frame shorter than sensor count
+    assert bucket_by_ring(sensors, values) == {0: [10.0], 1: []}

tests/test_session_controller.py

@@ -96,6 +96,102 @@ def test_leaving_live_mode_stops_stream(controller):
     assert not controller._repaint_timer.isActive()
 
 
+def test_binary_frame_decode_bounded_to_loaded_layout(controller, monkeypatch):
+    """Regression for phantom sensor #239 polluting MIN/MAX/AVG: the wire
+    payload carries a fixed-width channel array (up to 244 slots) wider than
+    any single wafer family's real sensor count. Family "X" (xwafer.yaml,
+    the only family live streaming is supported on) has 80 real sensors —
+    everything past that in the payload is an unpopulated hardware slot and
+    must never reach Frame.values."""
+    fake_transport = MagicMock()
+    fake_transport.read.return_value = b""
+    monkeypatch.setattr(
+        "pygui.serialcomm.serial_port.SerialPort.open_port",
+        lambda *a, **k: fake_transport,
+    )
+
+    controller.startStream("COM_FAKE", "X")
+    try:
+        assert len(controller._sensors) == 80  # sanity: xwafer.yaml loaded
+        parse = controller._reader._parse
+        payload = bytes(244 * 2)  # full-width wire payload, well beyond the real 80
+        frame = parse(payload, seq=1)
+        assert len(frame.values) == 80
+    finally:
+        controller.stopStream()
+
+
+def test_live_error_surfaces_message_and_stops_stream(controller):
+    """A fatal StreamReader error must reach QML with its message (for the
+    Activity Log) and must tear the stream down cleanly."""
+    controller.setMode("live")
+    controller._reader = MagicMock()
+
+    error_seen = MagicMock()
+    controller.liveError.connect(error_seen)
+
+    controller._on_live_error("Binary stream resync failed: no sync marker")
+
+    error_seen.assert_called_once_with("Binary stream resync failed: no sync marker")
+    assert controller._reader is None
+
+
+def test_start_stream_refuses_non_x_family(controller, monkeypatch):
+    """C# parity: only X-family wafer firmware supports live streaming.
+    Family A produced ~10s of unrelated ASCII output, not real telemetry —
+    startStream must refuse before ever opening the port."""
+    open_port = MagicMock()
+    monkeypatch.setattr(
+        "pygui.serialcomm.serial_port.SerialPort.open_port", open_port
+    )
+    error_seen = MagicMock()
+    controller.liveError.connect(error_seen)
+
+    controller.startStream("COM_FAKE", "A")
+
+    open_port.assert_not_called()
+    error_seen.assert_called_once()
+    assert "X-family" in error_seen.call_args[0][0]
+    assert controller._reader is None
+
+
+def test_start_stream_allows_x_family(controller, monkeypatch):
+    fake_transport = MagicMock()
+    fake_transport.read.return_value = b""
+    monkeypatch.setattr(
+        "pygui.serialcomm.serial_port.SerialPort.open_port",
+        lambda *a, **k: fake_transport,
+    )
+    error_seen = MagicMock()
+    controller.liveError.connect(error_seen)
+
+    controller.startStream("COM_FAKE", "X")
+    try:
+        error_seen.assert_not_called()
+        assert controller._reader is not None
+    finally:
+        controller.stopStream()
+
+
+def test_stop_stream_skips_d2s_write_when_reader_already_exited(controller):
+    """Reader's own worker thread can exit and close the transport (e.g.
+    after a resync give-up) before stopStream() runs on the main thread.
+    Writing D2S to that already-closed transport is a guaranteed EBADF —
+    skip it instead of racing the close."""
+    controller.setMode("live")
+    fake_reader = MagicMock()
+    fake_reader._thread = MagicMock()
+    fake_reader._thread.is_alive.return_value = False
+    fake_transport = MagicMock()
+    fake_transport.is_open = True
+    fake_reader._transport = fake_transport
+    controller._reader = fake_reader
+
+    controller.stopStream()
+
+    fake_transport.write.assert_not_called()
+
+
 def test_compare_files_integration(controller):
     # Mock the comparisonResult signal
     mock_slot = MagicMock()

tests/test_stream_reader.py

@@ -1,7 +1,7 @@
 import time
 
 from pygui.backend.models.frame import Frame
-from pygui.serialcomm.stream_reader import StreamReader
+from pygui.serialcomm.stream_reader import StreamReader, _crc16
 
 
 class FakeTransport:
@@ -17,33 +17,187 @@ class FakeTransport:
         res = self._data[self._pos:self._pos+n]
         self._pos += n
         return res
-    def readline(self):
-        time.sleep(0.001)
-        if self._pos >= len(self._data):
-            return b""
-        idx = self._data.find(b"\n", self._pos)
-        if idx == -1:
-            res = self._data[self._pos:]
-            self._pos = len(self._data)
-            return res
-        res = self._data[self._pos:idx+1]
-        self._pos = idx + 1
-        return res
     def close(self): self.closed = True
 
-def parse_line(raw: str, seq: int) -> Frame:
-    parts = [float(x) for x in raw.split(",")]
-    return Frame(seq = seq, time = parts[0], values = parts[1:])
 
-def test_reads_frames_and_counts_errors():
-    got, errors = [], []
-    transport = FakeTransport([b"0.0,149,148\n", b"garbage\n", b"0.5,150,149\n"])
-    r = StreamReader(transport, parse_line,
-                    on_frame = got.append, on_error = lambda e: errors.append(e))
+def make_packet(payload: bytes, seq: int = 1) -> bytes:
+    """Build a wire packet exactly as the device does: AA 88, msg type,
+    seq (LE), payload len (LE), payload, CRC16/MODBUS (LE) over the rest."""
+    body = (b"\xaa\x88\x01" + seq.to_bytes(2, "little")
+            + len(payload).to_bytes(2, "little") + payload)
+    return body + _crc16(body).to_bytes(2, "little")
 
+
+def parse_payload(payload: bytes, seq: int) -> Frame:
+    return Frame(seq=seq, time=0.0, values=[float(b) for b in payload])
+
+
+def test_crc16_known_vector():
+    # CRC16/MODBUS check value for "123456789" is 0x4B37.
+    assert _crc16(b"123456789") == 0x4B37
+
+
+def test_binary_stream_parses_crc_valid_packets():
+    got = []
+    data = make_packet(b"\x01\x02", seq=1) + make_packet(b"\x03\x04", seq=2)
+    transport = FakeTransport([data])
+    r = StreamReader(transport, parse_payload,
+                    on_frame=got.append, on_error=lambda e: None)
     r.start()
-    time.sleep(0.1)
+    time.sleep(0.2)
     r.stop()
-    assert [f.values for f in got] == [[149.0, 148.0], [150.0, 149.0]]
-    assert r.error_count == 1
+    assert [f.seq for f in got] == [1, 2]
+    assert r.error_count == 0
     assert transport.closed
+
+
+def test_corrupt_crc_packet_dropped_and_stream_continues():
+    got, errors = [], []
+    bad = bytearray(make_packet(b"\x09\x09", seq=1))
+    bad[-1] ^= 0xFF  # break the CRC
+    data = bytes(bad) + make_packet(b"\x01\x02", seq=2)
+    r = StreamReader(FakeTransport([data]), parse_payload,
+                    on_frame=got.append, on_error=errors.append)
+    r.start()
+    time.sleep(0.2)
+    r.stop()
+    assert [f.seq for f in got] == [2]
+    assert r.error_count == 1
+
+
+def test_bogus_giant_payload_len_does_not_stall_the_stream():
+    """A false 0xAA 0x88 inside data yields a garbage payload_len (up to
+    64KB). Without a sanity cap the reader waits forever accumulating a
+    packet that doesn't exist — the 'frames stop, no error' symptom."""
+    got = []
+    # False sync + header claiming a 0xFFFF-byte payload, then a real packet.
+    bogus = b"\xaa\x88\x01\x00\x00\xff\xff"
+    data = bogus + make_packet(b"\x01\x02", seq=7)
+    r = StreamReader(FakeTransport([data]), parse_payload,
+                    on_frame=got.append, on_error=lambda e: None)
+    r.start()
+    time.sleep(0.2)
+    r.stop()
+    assert [f.seq for f in got] == [7]
+
+
+def test_quiet_port_between_scans_is_not_a_resync_failure():
+    """Device pauses between measurement scans. Empty reads must not count
+    toward the resync give-up cap (C#'s findMessageStart waits forever) —
+    the old code died with TimeoutError after ~50 empty reads."""
+    errors = []
+    got = []
+    r = StreamReader(FakeTransport([make_packet(b"\x01\x02", seq=1)]),
+                    parse_payload, on_frame=got.append, on_error=errors.append)
+    r.start()
+    time.sleep(0.5)  # long idle stretch after the single packet drains
+    r.stop()
+    assert [f.seq for f in got] == [1]
+    assert errors == []
+
+
+def test_resync_giveup_debug_log_has_bytes_error_log_does_not(caplog):
+    """Regression: the give-up log used to dump `buf` after it had already
+    been cleared for the new read, so the hex-diagnostic came back empty —
+    useless for diagnosing what was actually on the wire. Fix: real bytes
+    go to DEBUG only; the ERROR line the terminal/Activity Log show stays
+    free of raw internal buffer content."""
+    import logging
+    errors = []
+    # 0xAA/0x88 excluded so this exercises _run_binary's resync path even
+    # though it's called directly (bypassing the ASCII/binary dispatch,
+    # which is exercised separately — see test_ascii_hex_dump_stream_*).
+    garbage = b"\x42" * 20000
+    r = StreamReader(FakeTransport([garbage]), parse_payload,
+                    on_frame=lambda f: None, on_error=errors.append)
+    with caplog.at_level(logging.DEBUG, logger="pygui.serialcomm.stream_reader"):
+        r._run_binary(bytearray())
+    assert len(errors) == 1
+    error_lines = [r.message for r in caplog.records if r.levelname == "ERROR"]
+    debug_lines = [r.message for r in caplog.records if r.levelname == "DEBUG"]
+    assert any("giving up" in m for m in error_lines)
+    assert not any("42424242" in m for m in error_lines), (
+        "raw wire bytes must not appear in the ERROR line users see"
+    )
+    assert any("42424242" in m for m in debug_lines)
+
+
+def test_resync_gives_up_after_16kb_of_garbage():
+    """Give-up cap counts discarded BYTES, not read attempts, so it fires
+    at a fixed data volume regardless of transfer rate."""
+    errors = []
+    got = []
+    garbage = b"\x01" * 20000  # never contains 0xAA 0x88; well past the cap
+    r = StreamReader(FakeTransport([garbage]), parse_payload,
+                    on_frame=got.append, on_error=errors.append)
+    r._run_binary(bytearray())  # deterministic give-up — no thread needed
+    assert got == []
+    assert len(errors) == 1
+    assert "resync" in str(errors[0]).lower()
+
+
+def test_ascii_hex_dump_stream_decodes_real_wafer_capture():
+    """Regression using an exact byte capture from real hardware (family A):
+    the wire is plain ASCII hex text, 4 chars/word, no 0xAA 0x88 framing at
+    all — see docs/adr/0007. _run() must route to the ASCII path and the
+    words must decode to plausible room-temperature values, not stall."""
+    got = []
+    words = ["280B", "1C0B", "220B", "1B0B", "200B", "1F0B", "190B", "1D0B",
+            "1B0B", "240B", "180B", "210B", "2B0B", "260B", "290B", "2B0B"]
+    # aepwafer.yaml's family "A" has 48 real sensors; pad to one full block
+    # (256 words) the way the real device does — extra slots are unpopulated.
+    block = "".join(words) + "0000" * (256 - len(words))
+    r = StreamReader(FakeTransport([block.encode()]), parse_payload,
+                    on_frame=got.append, on_error=lambda e: None,
+                    family_code="A")
+    r.start()
+    time.sleep(0.2)
+    r.stop()
+    assert len(got) == 1
+    assert len(got[0].values) == 48  # sensor_count_for("A")
+    # First word "280B" byte-swaps to "0B28" -> ~22.31C via the AEP formula.
+    assert 22.0 < got[0].values[0] < 22.5
+
+
+class WedgedTransport:
+    """Simulates a worker thread stuck in a blocking read() that ignores
+    the stop event — read() never returns on its own. stop() must close
+    the port to unblock it rather than relying on the read loop to notice."""
+    def __init__(self):
+        self.closed = False
+
+    def read(self, n=1):
+        while not self.closed:
+            time.sleep(0.001)
+        raise OSError("port closed")
+
+    def close(self):
+        self.closed = True
+
+
+def test_stop_closes_transport_even_if_worker_thread_is_wedged():
+    r = StreamReader(WedgedTransport(), parse_payload,
+                    on_frame=lambda f: None, on_error=lambda e: None)
+    r.start()
+    time.sleep(0.05)  # let the thread enter the blocking read
+    r.stop()
+    assert r._transport.closed, (
+        "stop() must close the transport itself — otherwise a wedged "
+        "worker thread keeps the port open and a subsequent startStream() "
+        "opens a second competing handle to the same port"
+    )
+
+
+def test_stop_does_not_report_the_close_it_caused_as_an_error():
+    """stop()'s own transport.close() unblocks the worker thread's read()
+    by making it raise — that's expected teardown, not a stream fault, and
+    must not reach on_error (Activity Log would otherwise show a fake
+    "Live stream error" on every ordinary Stop)."""
+    errors = []
+    r = StreamReader(WedgedTransport(), parse_payload,
+                    on_frame=lambda f: None, on_error=errors.append)
+    r.start()
+    time.sleep(0.05)
+    r.stop()
+    time.sleep(0.05)  # let the worker thread's except-handler run
+    assert errors == []

uv.lock

@@ -18,6 +18,15 @@ supported-markers = [
     "sys_platform == 'linux'",
 ]
 
+[[package]]
+name = "altgraph"
+version = "0.17.5"
+source = { registry = "https://pypi.org/simple" }
+sdist = { url = "https://files.pythonhosted.org/packages/7e/f8/97fdf103f38fed6792a1601dbc16cc8aac56e7459a9fff08c812d8ae177a/altgraph-0.17.5.tar.gz", hash = "sha256:c87b395dd12fabde9c99573a9749d67da8d29ef9de0125c7f536699b4a9bc9e7", size = 48428, upload-time = "2025-11-21T20:35:50.583Z" }
+wheels = [
+    { url = "https://files.pythonhosted.org/packages/a9/ba/000a1996d4308bc65120167c21241a3b205464a2e0b58deda26ae8ac21d1/altgraph-0.17.5-py2.py3-none-any.whl", hash = "sha256:f3a22400bce1b0c701683820ac4f3b159cd301acab067c51c653e06961600597", size = 21228, upload-time = "2025-11-21T20:35:49.444Z" },
+]
+
 [[package]]
 name = "ast-serialize"
 version = "0.5.0"
@@ -586,6 +595,18 @@ wheels = [
     { url = "https://files.pythonhosted.org/packages/ce/62/b40b382fa0c66fee1478073eb8db352a4a6beda4a1adccf1df911d8c289c/librt-0.11.0-cp314-cp314t-win_arm64.whl", hash = "sha256:dee008f20b542e3cd162ba338a7f9ec0f6d23d395f66fe8aeeec3c9d067ea253", size = 102572, upload-time = "2026-05-10T18:17:06.809Z" },
 ]
 
+[[package]]
+name = "macholib"
+version = "1.16.4"
+source = { registry = "https://pypi.org/simple" }
+dependencies = [
+    { name = "altgraph" },
+]
+sdist = { url = "https://files.pythonhosted.org/packages/10/2f/97589876ea967487978071c9042518d28b958d87b17dceb7cdc1d881f963/macholib-1.16.4.tar.gz", hash = "sha256:f408c93ab2e995cd2c46e34fe328b130404be143469e41bc366c807448979362", size = 59427, upload-time = "2025-11-22T08:28:38.373Z" }
+wheels = [
+    { url = "https://files.pythonhosted.org/packages/c7/d1/a9f36f8ecdf0fb7c9b1e78c8d7af12b8c8754e74851ac7b94a8305540fc7/macholib-1.16.4-py2.py3-none-any.whl", hash = "sha256:da1a3fa8266e30f0ce7e97c6a54eefaae8edd1e5f86f3eb8b95457cae90265ea", size = 38117, upload-time = "2025-11-22T08:28:36.939Z" },
+]
+
 [[package]]
 name = "matplotlib"
 version = "3.11.0"
@@ -867,6 +888,15 @@ wheels = [
     { url = "https://files.pythonhosted.org/packages/f1/d9/7fb5aa316bc299258e68c73ba3bddbc499654a07f151cba08f6153988714/pathspec-1.1.1-py3-none-any.whl", hash = "sha256:a00ce642f577bf7f473932318056212bc4f8bfdf53128c78bbd5af0b9b20b189", size = 57328, upload-time = "2026-04-27T01:46:07.06Z" },
 ]
 
+[[package]]
+name = "pefile"
+version = "2024.8.26"
+source = { registry = "https://pypi.org/simple" }
+sdist = { url = "https://files.pythonhosted.org/packages/03/4f/2750f7f6f025a1507cd3b7218691671eecfd0bbebebe8b39aa0fe1d360b8/pefile-2024.8.26.tar.gz", hash = "sha256:3ff6c5d8b43e8c37bb6e6dd5085658d658a7a0bdcd20b6a07b1fcfc1c4e9d632", size = 76008, upload-time = "2024-08-26T20:58:38.155Z" }
+wheels = [
+    { url = "https://files.pythonhosted.org/packages/54/16/12b82f791c7f50ddec566873d5bdd245baa1491bac11d15ffb98aecc8f8b/pefile-2024.8.26-py3-none-any.whl", hash = "sha256:76f8b485dcd3b1bb8166f1128d395fa3d87af26360c2358fb75b80019b957c6f", size = 74766, upload-time = "2024-08-26T21:01:02.632Z" },
+]
+
 [[package]]
 name = "pillow"
 version = "12.2.0"
@@ -1006,6 +1036,7 @@ dev = [
 [package.dev-dependencies]
 dev = [
     { name = "mypy" },
+    { name = "pyinstaller" },
     { name = "pytest" },
     { name = "ruff" },
 ]
@@ -1029,10 +1060,51 @@ provides-extras = ["dev"]
 [package.metadata.requires-dev]
 dev = [
     { name = "mypy" },
+    { name = "pyinstaller", specifier = "==6.21.0" },
     { name = "pytest", specifier = ">=9.0.3" },
     { name = "ruff" },
 ]
 
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+name = "pyinstaller"
+version = "6.21.0"
+source = { registry = "https://pypi.org/simple" }
+dependencies = [
+    { name = "altgraph" },
+    { name = "macholib", marker = "sys_platform != 'linux' and sys_platform != 'win32'" },
+    { name = "packaging" },
+    { name = "pefile", marker = "sys_platform == 'win32'" },
+    { name = "pyinstaller-hooks-contrib" },
+    { name = "pywin32-ctypes", marker = "sys_platform == 'win32'" },
+    { name = "setuptools" },
+]
+sdist = { url = "https://files.pythonhosted.org/packages/d5/4d/ec706c3fcf39e26888c35b39615ff4d5865d184069666c47492cff1fbe50/pyinstaller-6.21.0.tar.gz", hash = "sha256:bb9fab705983e393a2d1cac77d6972513057ad800215fd861dc15ff5272e98fd", size = 4061519, upload-time = "2026-06-13T14:15:06.25Z" }
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+
+[[package]]
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+version = "2026.6"
+source = { registry = "https://pypi.org/simple" }
+dependencies = [
+    { name = "packaging" },
+]
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+wheels = [
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 [[package]]
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 version = "3.3.2"
@@ -1139,6 +1211,15 @@ wheels = [
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 ]
 
+[[package]]
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+version = "0.2.3"
+source = { registry = "https://pypi.org/simple" }
+sdist = { url = "https://files.pythonhosted.org/packages/85/9f/01a1a99704853cb63f253eea009390c88e7131c67e66a0a02099a8c917cb/pywin32-ctypes-0.2.3.tar.gz", hash = "sha256:d162dc04946d704503b2edc4d55f3dba5c1d539ead017afa00142c38b9885755", size = 29471, upload-time = "2024-08-14T10:15:34.626Z" }
+wheels = [
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+]
+
 [[package]]
 name = "pyyaml"
 version = "6.0.3"
@@ -1290,6 +1371,15 @@ wheels = [
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 ]
 
+[[package]]
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