NaoDec Build — Step 9: Commissioning & Test

Revision: 1.0 Date: 2026-07-14 Status: Drafted from decision 8. This is the first power-up: it references the existing subsystem test procedures rather than restating them. Acceptance thresholds for audio/haptics and the occupant-safety sign-off are still owed (see Open Items).

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Purpose

Bring the fully wired installation to life in a controlled order, verify every subsystem, and run an end-to-end show before it carries an occupant.

Quick Reference — power-up order

9.1 Pre-power checks (de-energized)

Confirm, before any PSU is switched on (cite NaoDec_WS2815_LED_Controller_Rev1.6.html engineering notes):

• The three LED V+ rails isolated from each other; coil rail separate; common GND continuous.
• All inline fuses fitted (F1 vertex branch, FB1 edge block, scent F_MAIN, coil exact-3 A).
• No short on any rail to GND.

9.2 Power-up order

1. Logic 5 V (PSU-A) — the 3 ESP32s boot; check 3V3 rails, no brownout.
2. LED 12 V rails (PSU-B vertex, PSU-C edges) — bring up one at a time; watch inrush (NTC1 on the 50 A rail).
3. GAB8 24 V — muted until audio checks; keep gain down.
4. Coils — last, and only via their gate (§9.8).

9.3 Network

Per NaoDec_Media_Playback_Controller_Build_and_Max_Setup.md §8:

• Router up; DHCP reservations: Mac mini static 192.168.50.2, LED boards .111–.113, media controller .114.
• Confirm the media controller leases .114 within ~15 s of link (its acceptance test NET-01).

9.4 WLED / lighting

• Master WLED outputs CH1–CH4; Slave receives DDP and outputs CH5–CH7.
• Mac mini streams WLED/Art-Net over USB-C→UART to the Master.
• Verify each channel lights its intended strips; bench-verify the CH1 vertex waveform (20 m run, controller Note 14) before trusting it.
• Record the confirmed C1–C6 ↔ CH2–CH7 mapping from Step 8 against what actually lights.

9.5 Media controller

Run the controller's own acceptance suite as-is — NaoDec_Media_Playback_Controller_Build_and_Max_Setup.md §11 (ELEC, NET, FUNC, SYS tests: play/pause/stop one-shot, volume ramp, no-command-on-boot, reconnect, 8 h soak).

9.6 Audio

• GAB8 enumerates as a USB audio device on the Mac mini (macOS, no driver).
• Per-channel check: each of the 6 speakers (A, H, C, F, Y, M) sounds on its own channel and in the right occupant-frame position; fix any swap now.
• Transducer sets (back, seat) drive from their 2 channels — feel, not just level.
• Subwoofer plays from the Mac mini 3.5 mm line.

9.7 Scent

• Per firmware/Scent_controller/README.md: exercise each of the 4 relays/atomizers (web UI / UDP / serial command), confirm mist output and no drip onto electronics.

9.8 Coils (pre-release gate — do this last, cautiously)

• Do not energize until the XL4015 is qualified per XL4015_CC_CV_Mockup_Test_Procedure.md and the assembled-loop resistance is measured against the ~1.85 Ω estimate.
• Set CV 11.0 V, CC 3.0 A on the bench first; exact-3 A fuse in; thermal cutoff bonded.
• Only then bring the loop up through the buck; watch the TCO and connector temperatures.
• This subsystem stays pre-release — commissioning it is a gated experiment, not a routine power-up.

9.9 End-to-end & soak

• Run a full show cue (light + sound + haptics + scent together) from the Mac mini / media controller.
• Soak (8 h target, per the media SYS-02 pattern) with no unintended commands, no thermal creep, no scent drip.
• Complete the commissioning record below.

Commissioning Record

Release Gate

Open Items

1. Acceptance thresholds for audio level/positioning and haptic intensity — none defined.
2. Occupant-safety sign-off — who authorizes a person inside (platform load rating, egress, ventilation, mains-inside, fabric-near-strips — all still open across Steps 1, 2, 6 and the index). Step 9 must not pass until that owner signs.
3. Coil commissioning stays pre-release — decide per build whether it's energized at all in this revision.

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