Helios Verification Tests

These tests verify Helios behavior using Stan’s simulated thermistor signals before connecting to real heater hardware.

Prerequisites

• Stan firmware with verification support (stan#6)

• Helios connected to test stand

• Heliostat in controller mode

Test Cases

Test 1: Normal Burn Cycle

Requirement: Helios MUST complete a normal burn cycle from start to shutdown without errors when temperature is simulated accurately.

Procedure:

1. Start Helios in IDLE state

2. Send STATE_COMMAND to enter FAN mode

3. Simulate temperature progression through preheat → ignition → heating

4. Send STATE_COMMAND to initiate shutdown

5. Verify Helios completes cooldown and returns to IDLE

Pass Criteria: No errors, all state transitions complete successfully.

Notes: No minimum time requirement for heating state.

Test 2: Emergency Stop

Requirement: Helios MUST pass a controller-initiated emergency stop test after reaching the heating state.

Procedure:

1. Start simulated burn cycle

2. Wait for Helios to enter HEATING state

3. Send EMERGENCY_STOP command

4. Verify Helios immediately transitions to emergency shutdown

Pass Criteria: Helios stops fuel delivery and enters cooldown immediately.

Test 3: Ping Timeout

Requirement: Helios MUST begin cooldown after entering heating state, then idle after ping request timeout.

Procedure:

1. Start simulated burn cycle

2. Wait for Helios to enter HEATING state

3. Stop sending PING_REQUEST packets

4. Wait for ping timeout (30 seconds)

5. Verify Helios begins cooldown

6. Simulate appropriate temperature decrease

7. Verify Helios returns to IDLE

Pass Criteria: Helios autonomously initiates cooldown after ping timeout.

Test 4: Flame-Out

Requirement: Helios MUST pass a simulated flame-out test.

Procedure:

1. Start simulated burn cycle

2. Wait for Helios to enter HEATING state

3. Simulate rapid temperature drop (flame-out condition)

4. Verify Helios detects flame-out and responds appropriately

Pass Criteria: Helios detects flame-out and initiates appropriate response.

Test 5: Overheat Recovery

Requirement: Helios MUST pass a simulated overheat condition where the temperature returns to normal.

Procedure:

1. Start simulated burn cycle

2. Wait for Helios to enter HEATING state

3. Simulate temperature exceeding overheat threshold

4. Verify Helios responds to overheat condition

5. Simulate temperature returning to normal range

6. Verify Helios recovers and continues operation

Pass Criteria: Helios detects overheat, responds appropriately, and recovers when temperature normalizes.

Test 6: Overheat Emergency Stop

Requirement: Helios MUST pass a simulated overheat emergency stop.

Procedure:

1. Start simulated burn cycle

2. Wait for Helios to enter HEATING state

3. Simulate temperature exceeding emergency stop threshold

4. Verify Helios initiates emergency shutdown

Pass Criteria: Helios triggers emergency stop when temperature exceeds critical threshold.

Results Template

Test	Result	Notes
Test 1: Normal Burn Cycle	☐ Pass / ☐ Fail
Test 2: Emergency Stop	☐ Pass / ☐ Fail
Test 3: Ping Timeout	☐ Pass / ☐ Fail
Test 4: Flame-Out	☐ Pass / ☐ Fail
Test 5: Overheat Recovery	☐ Pass / ☐ Fail
Test 6: Overheat Emergency Stop	☐ Pass / ☐ Fail