Pyro / protocol-subprocess smoke (Flex external 10.0.0-alpha.0)

validated · updated 2026-08-11

Pyro / protocol-subprocess smoke (Flex external 10.0.0-alpha.0)

Validation checklist for Pyro5 IPC on KansasFLEX after installing external v10.0.0-alpha.0 (same product line as former internal ot3@4.0.0-alpha.N; hardware + protocol subprocess flags default on). Prefer full robot reboot for recovery. Nameserver/hardware-api grouped restart later Closed RQA-5789 / RQA-5790 on v10.0.0-alpha.3 (oe-core#373 PartOf=). Narrative: docs/pyro-testing.md. Parent bug epic: RQA-5831.

Jira RQA-5831 10.0.0-alpha.0 Bugs Jira RQA-5484 10.0.0 Bugs Jira RQA-5786 4.0.0-alpha.10 Bugs (historical internal line)Jira RQA-5787 robot-server Application startup / nginx 502 after update while firmware flash in progress Jira RQA-5789 After nameserver restart, OT3API / robot-server-resource never re-register (Closed on v10.0.0-alpha.3)Jira RQA-5790 robot-server does not reattach after hardware-api restart (Closed on v10.0.0-alpha.3)Jira RQA-5791 Uncurrenting a run removes ot-protocol from nameserver but leaves processes running Jira EXEC-2187 Protocol Subprocesses (Current)

Monorepo branch edge

Compared tov10.0.0-alpha.0

Robot OS10.0.0-alpha.0

Hardware flex_1channel_50 (right), opentrons_flex_96_filtertiprack_50ul in A1 (for live tip smoke only)

Harness commands

uv run flex-test inspect
uv run flex-test probe --no-picture
ALLOW_MUTATIONS=true uv run flex-test put 10.0.0-alpha.0 --channel external
ssh -i ~/.ssh/robot_key -o IdentitiesOnly=yes root@$ROBOT_HOST

Tests

ID	Plan
A1 Systemd pyro stack active pass	Nameserver must precede hardware-api and robot-server for IPC. SSH or serial to the robot. Run: systemctl is-active opentrons-pyro-nameserver opentrons-hardware-api opentrons-robot-server Expect all active and enabled. 2026-08-11 all three active; flags enableHardwareSubprocess/enableProtocolSubprocess true.
A2 OT3API registered on nameserver pass	Hardware entrypoint notifies ready only after OT3API is listed. With Pyro5, locate_ns() and confirm OT3API in ns.list() within 60s. Optional: Proxy(resolve('PYRONAME:OT3API')).get_fw_version(). OT3API + robot-server-resource present; get_fw_version → 68.
A3 Health OK with HW proxy path pass	robot-server identify_hardware_process depends on NS + OT3API. GET /health expect 200; GET /instruments and /subsystems/status populate. v10.0.0-alpha.0 healthy; CRS on (OAuth used for mutating calls).
A4 Nameserver restart recovery skipped	Historical; producers should re-register or fail clearly. Optional regression after oe-core#373: restart opentrons-pyro-nameserver and confirm hardware-api + robot-server also bounce and OT3API re-registers. Skipped on alpha.0. Later Closed on KansasFLEX v10.0.0-alpha.3 (grouped PartOf= restart; RQA-5789).
A5 Hardware-api restart reattach skipped	Historical; robot-server must refresh OT3API proxy after HW daemon URI changes. Optional regression after oe-core#373: restart opentrons-hardware-api and confirm robot-server also bounces; GET /health and /instruments recover without a separate robot-server restart. Skipped on alpha.0. Later Closed on KansasFLEX v10.0.0-alpha.3 (grouped PartOf= restart; RQA-5790).
B1 Instruments and subsystems via HTTP pass	Lower-line IPC must serve robot-server instrument inventory. GET /instruments and /subsystems/status. left p50_multi_flex + right p50_single_flex; 6 subsystems ok.
B2 Module nested proxies skipped	Nested module proxies when hardware is attached. Attach a module; GET /modules. No modules attached.
B3 Door open/close via HTTP pass	Door watcher / HW door events must surface through robot-server. Poll GET /robot/door/status while opening and closing the door. Door closed via GET /robot/door/status (no open/close cycle this session).
C1 Create run registers ot-protocol pass	Run lifetime should own a protocol subprocess + NS name. Upload a Python protocol; wait analysis completed; POST /runs. Confirm NS has ot-protocol and ps shows run_process_entry_point. Idle current run 7968ccc8-…; NS now uses UUID-suffixed names (ot-protocol_<uuid>) plus run_process_entry_point processes.
C2 Protocol analysis completes pass	Analysis path uses simulating / subprocess machinery. After upload, poll protocol analysisSummaries until completed. Protocol b96f86d9-… analyses completed.
C3a Idle run actions contract pass	Actions must cross robot-server to ot-protocol Pyro boundary. On idle run: pause expects 409; stop accepted; cancel is not a valid actionType. stop accepted → status stopped.
C3b Live tip smoke play skipped	Play must execute motion commands across the protocol subprocess boundary. Only with explicit operator request. Deck tiprack A1; play; wait succeeded. No live motion requested this session.
C6 Uncurrent tears down process blocked	Protocol process lifetime should match run record create to uncurrent. With current run and ot-protocol in NS, PATCH run current=false. Confirm NS drops ot-protocol and no orphan run_process_entry_point remains. With CRS on, PATCH current=false returned 409 RunSignoffRequired. After stop, ot-protocol_<uuid> and ot-simulating-protocol_<uuid> processes still present (same class as RQA-5791). Needs CRS signoff path or CRS-off retest before filing a new bug.
D1 Door enum via HTTP pass	DoorState must serialize through robot-server product path. GET /robot/door/status; expect open or closed. closed
D7 Subsystems status healthy pass	Regression check for subsystem serialization issues. GET /subsystems/status; expect all subsystems ok. gantry_x/y, head, pipette_left/right, rear_panel all ok.