feat(telemetry): surface frzWater and sensHealth in the UI (#873)

src/components/AppShell/tests/footerStatus.test.ts

@@ -26,6 +26,10 @@ describe('footerStatus', () => {
     const s = footerStatus(ok, [{ id: 'pump-stall', title: 'Pump-stall protection is off', detail: '' }])
     expect(s).toEqual({ tone: 'warn', summary: '1 issue', issues: ['Pump-stall protection is off'] })
   })
+  it('counts cover-disconnect attention items', () => {
+    const s = footerStatus(ok, [{ id: 'cover-disconnect', title: 'Left cover sensor disconnected', detail: '' }])
+    expect(s).toEqual({ tone: 'warn', summary: '1 issue', issues: ['Left cover sensor disconnected'] })
+  })
 })
 
 describe('buildLine', () => {

src/components/AppShell/tests/navigation.test.tsx

@@ -9,11 +9,15 @@ const state = vi.hoisted(() => ({
   path: '/en', query: '', active: true, base: undefined as { configured: boolean } | undefined,
   status: undefined as unknown, health: undefined as unknown,
   version: undefined as unknown, water: undefined as unknown,
+  sensHealth: undefined as unknown,
   start: vi.fn(), end: vi.fn(),
 }))
 vi.mock('next/navigation', () => ({ usePathname: () => state.path, useSearchParams: () => new URLSearchParams(state.query) }))
 vi.mock('@/src/hooks/useScheduleActive', () => ({ useScheduleActive: () => ({ isActive: state.active }) }))
 vi.mock('@/src/hooks/useSwipeNavigation', () => ({ useSwipeNavigation: () => ({ onTouchStart: state.start, onTouchEnd: state.end }) }))
+vi.mock('@/src/hooks/useSensorStream', () => ({
+  useSensorFrame: (type: string) => (type === 'sensHealth' ? state.sensHealth : undefined),
+}))
 vi.mock('@/src/components/Schedule/CurveChart', () => ({ useNowMinute: () => 29000000 }))
 vi.mock('@/src/utils/trpc', () => ({ trpc: {
   base: { getAvailability: { useQuery: () => ({ data: state.base }) } },
@@ -24,7 +28,7 @@ vi.mock('@/src/utils/trpc', () => ({ trpc: {
 } }))
 
 beforeEach(() => {
-  Object.assign(state, { path: '/en', query: '', active: true, status: undefined, health: undefined, version: undefined, water: undefined, base: undefined })
+  Object.assign(state, { path: '/en', query: '', active: true, status: undefined, health: undefined, version: undefined, water: undefined, base: undefined, sensHealth: undefined })
   vi.clearAllMocks()
 })
 
@@ -122,6 +126,14 @@ describe('responsive navigation', () => {
     expect(screen.getByTestId('system-health-dot').getAttribute('data-tone')).toBe('warn')
     expect(screen.getByRole('link', { name: /SYSTEM, 1 issue/ })).toBeTruthy()
   })
+  it('surfaces cover sensor disconnect warning in the sidebar footer and tab bar', () => {
+    state.sensHealth = { type: 'sensHealth', version: 1, left: { connected: false }, right: { connected: true } }
+    state.health = { status: 'ok', database: { status: 'ok' }, scheduler: {}, iptables: { ok: true } }
+    render(<Sidebar />)
+    const footer = screen.getByRole('link', { name: /Open System dashboard/ })
+    expect(footer.textContent).toContain('1 issue')
+    expect(within(screen.getByTestId('footer-issues')).getAllByRole('listitem').map(li => li.textContent)).toEqual(['Left cover sensor disconnected'])
+  })
   it('renders page content and forwards swipe gestures', () => {
     render(<AppShell><h1>Temperature</h1></AppShell>)
     fireEvent.touchStart(screen.getByRole('main'))

src/components/AppShell/usePodHealth.ts

@@ -2,6 +2,7 @@
 
 import { attentionItems } from '@/src/components/diagnostics/dashboardLogic'
 import { useNowMinute } from '@/src/components/Schedule/CurveChart'
+import { useSensorFrame } from '@/src/hooks/useSensorStream'
 import { trpc } from '@/src/utils/trpc'
 import { footerStatus } from './footerStatus'
 
@@ -15,9 +16,16 @@ export function usePodHealth() {
   const health = trpc.health.system.useQuery({}, { staleTime: 10_000, refetchInterval: 30_000 })
   const maintenance = trpc.health.maintenance.useQuery({}, { staleTime: 30_000, refetchInterval: 60_000 })
   const water = trpc.waterLevel.getLatest.useQuery({}, { staleTime: 10_000, refetchInterval: 30_000 })
+  const sensHealth = useSensorFrame('sensHealth')
   const nowMinute = useNowMinute()
+  const coverDisconnects = sensHealth
+    ? {
+        left: !sensHealth.left.connected,
+        right: !sensHealth.right.connected,
+      }
+    : undefined
   const attention = nowMinute == null
     ? []
-    : attentionItems(maintenance.data, water.data?.level ?? status.data?.waterLevel, nowMinute * 60_000)
+    : attentionItems(maintenance.data, water.data?.level ?? status.data?.waterLevel, nowMinute * 60_000, [], coverDisconnects)
   return { footer: footerStatus(health.data, attention), podVersion: status.data?.podVersion }
 }

src/components/Sensors/FreezerHealthCard.tsx

@@ -3,11 +3,13 @@
 import { SensorAge } from './SensorAge'
 
 import { useSensorFrame } from '@/src/hooks/useSensorStream'
-import type { FrzHealthFrame } from '@/src/hooks/useSensorStream'
+import type { FrzHealthFrame, FrzWaterFrame } from '@/src/hooks/useSensorStream'
 import { trpc } from '@/src/utils/trpc'
 import { useTemperatureUnit } from '@/src/hooks/useTemperatureUnit'
 import { formatDisplayTemp, sensorCToDisplay } from '@/src/lib/tempUtils'
 import { Card, SectionLabel, Skeleton, StatusDot, type Tone } from '@/src/components/ds'
+import { cn } from '@/lib/utils'
+import { WaterTankGauge } from '@/src/components/status/WaterTankGauge'
 
 /** Overcurrent threshold in Amperes. Eight Sleep TECs pull ~10-11.5A during startup
  * circuit calibration and up to 12A under peak thermal demand. Real overcurrent is >13.5A. */
@@ -24,9 +26,15 @@ export function freezerStatus(
   health: FrzHealthFrame | undefined,
   waterLevel: 'low' | 'ok' | undefined,
   hasData: boolean,
+  frzWater?: FrzWaterFrame | undefined,
 ): { tone: Tone, label: string } {
   if (!hasData) return { tone: 'muted', label: 'No data' }
-  if (waterLevel === 'low') return { tone: 'warn', label: 'Water low' }
+  const isLow = frzWater
+    ? (frzWater.capValid ? frzWater.capLevel <= 1 : !frzWater.hasWater)
+    : waterLevel === 'low'
+  if (isLow) return { tone: 'warn', label: 'Water low' }
+  if (frzWater?.isPriming) return { tone: 'ok', label: 'Priming' }
+  if (frzWater?.needsPriming) return { tone: 'warn', label: 'Needs prime' }
   if (health && (health.left.tecCurrent > TEC_OVERCURRENT_AMPS || health.right.tecCurrent > TEC_OVERCURRENT_AMPS)) {
     return { tone: 'warn', label: 'High TEC' }
   }
@@ -51,6 +59,7 @@ export function FreezerHealthCard() {
   const frzTemp = useSensorFrame('frzTemp')
   const frzHealth = useSensorFrame('frzHealth')
   const frzTherm = useSensorFrame('frzTherm')
+  const frzWater = useSensorFrame('frzWater')
 
   // tRPC: latest freezer temp from DB (fallback when WS hasn't sent data)
   const latestFreezerTemp = trpc.environment.getLatestFreezerTemp.useQuery(
@@ -89,7 +98,7 @@ export function FreezerHealthCard() {
       : null
 
   const waterLevel = waterLevelLatest.data?.level as 'low' | 'ok' | undefined
-  const hasData = !!(temps || frzHealth || frzTherm)
+  const hasData = !!(temps || frzHealth || frzTherm || frzWater)
 
   // First paint with no live frames yet: hold the slot while the stored fallback loads.
   if (!hasData && latestFreezerTemp.isLoading) {
@@ -100,7 +109,7 @@ export function FreezerHealthCard() {
       </>
     )
   }
-  const status = freezerStatus(frzHealth, waterLevel, hasData)
+  const status = freezerStatus(frzHealth, waterLevel, hasData, frzWater)
 
   const t = (v: number | null | undefined, decimals = 1) =>
     formatDisplayTemp(v, unit, { decimals, includeUnit: false, nullDisplay: '--' })
@@ -111,12 +120,22 @@ export function FreezerHealthCard() {
     : '--'
   const rpm = (v: number | undefined) => v === undefined ? '--' : v.toLocaleString()
 
+  const tankText = frzWater
+    ? (frzWater.isPriming
+        ? 'priming…'
+        : frzWater.needsPriming
+          ? 'needs prime'
+          : frzWater.capValid
+            ? `tank ${frzWater.capLevel}/5`
+            : `water ${frzWater.hasWater ? 'ok' : 'low'}`)
+    : (waterLevel && `water ${waterLevel}`)
+
   const secondary = [
     frzHealth && `fan ${frzHealth.fan.rpm.toLocaleString()} rpm`,
     frzHealth && `tec ${frzHealth.left.tecCurrent.toFixed(1)}/${frzHealth.right.tecCurrent.toFixed(1)} A`,
     frzTherm && `therm ${frzTherm.left.toFixed(1)}/${frzTherm.right.toFixed(1)}`,
     temps && `hub ${t(temps.ambient)}`,
-    waterLevel && `water ${waterLevel}`,
+    tankText,
   ].filter(Boolean) as string[]
 
   return (
@@ -125,7 +144,15 @@ export function FreezerHealthCard() {
       <Card className="flex-row items-center gap-2.5 px-4 py-3.5 min-[900px]:hidden">
         <span className="sp-label">Freezer</span>
         <StatusDot tone={status.tone} label={status.label} className="text-[13px]" />
-        <span className="ml-auto truncate font-mono text-xs text-fg-2">
+        <WaterTankGauge
+          capLevel={frzWater?.capLevel}
+          capValid={frzWater?.capValid}
+          isPriming={frzWater?.isPriming}
+          needsPriming={frzWater?.needsPriming}
+          waterLevel={waterLevel}
+          className="ml-auto"
+        />
+        <span className={cn('truncate font-mono text-xs text-fg-2', !frzWater?.capValid && 'ml-auto')}>
           {temps ? `${t(temps.heatsink, 0)} sink · ${t(temps.leftWater ?? temps.rightWater, 0)} water` : '--'}
         </span>
       </Card>
@@ -138,7 +165,19 @@ export function FreezerHealthCard() {
         </SectionLabel>
         <div className="grid grid-cols-2 gap-2.5">
           <BigStat value={temps ? `${t(temps.heatsink)}` : '--'} label="Heatsink" warn={false} />
-          <BigStat value={water} label="Water" warn={false} />
+          <div className="min-w-0">
+            <div className="flex items-center gap-2">
+              <span className="truncate font-mono text-lg font-light">{water}</span>
+              <WaterTankGauge
+                capLevel={frzWater?.capLevel}
+                capValid={frzWater?.capValid}
+                isPriming={frzWater?.isPriming}
+                needsPriming={frzWater?.needsPriming}
+                waterLevel={waterLevel}
+              />
+            </div>
+            <div className="text-[11px] text-fg-2">Water</div>
+          </div>
           <BigStat value={rpm(frzHealth?.left.pumpRpm)} label="Pump L · rpm" warn={frzHealth?.left.pumpRpm === 0} />
           <BigStat value={rpm(frzHealth?.right.pumpRpm)} label="Pump R · rpm" warn={frzHealth?.right.pumpRpm === 0} />
         </div>

src/components/Sensors/PresenceCard.tsx

@@ -54,6 +54,7 @@ export function presenceSub(occ: { available: boolean, classification: 'person'
 export function PresenceCard() {
   const capSense = useSensorFrame('capSense')
   const capSense2 = useSensorFrame('capSense2')
+  const sensHealth = useSensorFrame('sensHealth')
   const frame: CapSenseFrame | CapSense2Frame | undefined = capSense2 ?? capSense
   const { sideName } = useSideNames()
 
@@ -115,6 +116,7 @@ export function PresenceCard() {
             <div className="grid grid-cols-2 gap-3">
               {(['left', 'right'] as const).map((side) => {
                 const occ = occupancyQuery.data?.[side]
+                const disconnected = sensHealth ? !sensHealth[side].connected : false
                 return (
                   <PresenceSide
                     key={side}
@@ -125,6 +127,7 @@ export function PresenceCard() {
                     sub={occ ? presenceSub(occ) : '--'}
                     variance={side === 'left' ? variance.leftVariance : variance.rightVariance}
                     hasFrames={!!frame}
+                    disconnected={disconnected}
                   />
                 )
               })}
@@ -134,14 +137,15 @@ export function PresenceCard() {
   )
 }
 
-function PresenceSide({ name, side, occupied, known, sub, variance, hasFrames }: {
+function PresenceSide({ name, side, occupied, known, sub, variance, hasFrames, disconnected }: {
   name: string
   side: 'left' | 'right'
   occupied: boolean
   known: boolean
   sub: string
   variance: number[]
   hasFrames: boolean
+  disconnected?: boolean
 }) {
   const accent = side === 'left' ? 'var(--accent-cool)' : 'var(--accent-warm)'
   const activity = ZONES.map((_, zone) => zoneActivity(variance, zone))
@@ -150,10 +154,10 @@ function PresenceSide({ name, side, occupied, known, sub, variance, hasFrames }:
   return (
     <div className="flex min-w-0 flex-col gap-1.5" data-testid={`presence-${side}`}>
       <span className="flex min-w-0 items-center gap-1.5 text-[13px]">
-        <StatusDot tone={occupied ? 'ok' : 'muted'} />
-        <span className="truncate">{`${name} · ${known ? (occupied ? 'in bed' : 'empty') : '--'}`}</span>
+        <StatusDot tone={disconnected ? 'warn' : occupied ? 'ok' : 'muted'} />
+        <span className="truncate">{`${name} · ${disconnected ? 'disconnected' : known ? (occupied ? 'in bed' : 'empty') : '--'}`}</span>
       </span>
-      <span className="font-mono text-[11px] text-fg-2">{sub}</span>
+      <span className="font-mono text-[11px] text-fg-2">{disconnected ? 'cover disconnected' : sub}</span>
       <div className="flex h-[34px] items-end gap-1" aria-label={`${name} zone activity`}>
         {ZONES.map((zone, i) => (
           <span

src/components/Sensors/streamGroups.ts

@@ -12,9 +12,9 @@ export interface StreamGroup {
 export const STREAM_GROUPS: readonly StreamGroup[] = [
   { key: 'status', label: 'Device', types: ['deviceStatus'] },
   { key: 'piezo', label: 'Piezo', types: ['piezo-dual', 'lps'] },
-  { key: 'presence', label: 'Presence', types: ['capSense2', 'capSense'] },
+  { key: 'presence', label: 'Presence', types: ['capSense2', 'capSense', 'sensHealth'] },
   { key: 'bedTemp', label: 'Bed temp', types: ['bedTemp2', 'bedTemp'] },
-  { key: 'freezer', label: 'Freezer', types: ['frzHealth', 'frzTemp', 'frzTherm'] },
+  { key: 'freezer', label: 'Freezer', types: ['frzHealth', 'frzTemp', 'frzTherm', 'frzWater'] },
   { key: 'log', label: 'Log', types: ['log', 'gesture'] },
 ]
 

src/components/Sensors/tests/sensorCards.test.tsx

@@ -92,6 +92,37 @@ it('shows stored and live freezer readings, water warnings and pump RPM', () =>
   expect(screen.getAllByText('Normal')).toHaveLength(2)
   expect(screen.getByText('2,400')).toBeTruthy()
   expect(screen.getByText(/therm 1.0\/2.0/)).toBeTruthy()
+
+  // With frzWater frame, displays capacitive tank gauge and secondary text
+  mock.frames.frzWater = { type: 'frzWater', capLevel: 3, capValid: true, hasWater: true, isPriming: false, needsPriming: false }
+  rerender(<FreezerHealthCard />)
+  expect(screen.getAllByTestId('water-tank-gauge')).toHaveLength(2)
+  expect(screen.getAllByText('3/5')).toHaveLength(2)
+  expect(screen.getByText(/tank 3\/5/)).toBeTruthy()
+
+  // When priming in progress
+  mock.frames.frzWater = { type: 'frzWater', capLevel: 3, capValid: true, hasWater: true, isPriming: true, needsPriming: false }
+  rerender(<FreezerHealthCard />)
+  expect(screen.getAllByText('Priming')).toHaveLength(2)
+  expect(screen.getByText(/priming…/)).toBeTruthy()
+
+  // When tank needs priming
+  mock.frames.frzWater = { type: 'frzWater', capLevel: 3, capValid: true, hasWater: true, isPriming: false, needsPriming: true }
+  rerender(<FreezerHealthCard />)
+  expect(screen.getAllByText('Needs prime')).toHaveLength(2)
+  expect(screen.getByText(/fan.*needs prime/)).toBeTruthy()
+
+  // When capValid is false and hasWater is true
+  mock.frames.frzWater = { type: 'frzWater', capLevel: 0, capValid: false, hasWater: true, isPriming: false, needsPriming: false }
+  rerender(<FreezerHealthCard />)
+  expect(screen.getAllByText('Normal')).toHaveLength(2)
+  expect(screen.getByText(/fan.*water ok/)).toBeTruthy()
+
+  // When capValid is false and hasWater is false
+  mock.frames.frzWater = { type: 'frzWater', capLevel: 0, capValid: false, hasWater: false, isPriming: false, needsPriming: false }
+  rerender(<FreezerHealthCard />)
+  expect(screen.getAllByText('Water low')).toHaveLength(2)
+  expect(screen.getByText(/fan.*water low/)).toBeTruthy()
 })
 
 it('uses server occupancy while visualizing frame variance independently', () => {
@@ -112,6 +143,20 @@ it('uses server occupancy while visualizing frame variance independently', () =>
   expect(screen.getByTestId('presence-right').textContent).toContain('in bedstill')
 })
 
+it('warns when a cover sensor is disconnected according to sensHealth', () => {
+  mock.frames.sensHealth = { type: 'sensHealth', left: { connected: false }, right: { connected: true } }
+  mock.data.occupancy = { left: { occupied: false, available: true, classification: 'none', movement: { active: false } }, right: { occupied: false, available: true, classification: 'none', movement: { active: false } } }
+  const { rerender } = render(<PresenceCard />)
+  expect(screen.getByTestId('presence-left').textContent).toContain('disconnected')
+  expect(screen.getByTestId('presence-left').textContent).toContain('cover disconnected')
+  expect(screen.getByTestId('presence-right').textContent).not.toContain('disconnected')
+
+  // When sensHealth is absent (older firmware), it does not show disconnected
+  delete mock.frames.sensHealth
+  rerender(<PresenceCard />)
+  expect(screen.getByTestId('presence-left').textContent).not.toContain('disconnected')
+})
+
 it('switches flow units and ranges with live readings and downsampled history', () => {
   const { rerender } = render(<FlowrateChart />)
   expect(screen.getByText('No flow history')).toBeTruthy()

src/components/Sensors/tests/sensorLogic.test.ts

@@ -15,8 +15,10 @@ describe('streamGroups', () => {
     expect(groupForType('piezo-dual')).toBe('piezo')
     expect(groupForType('capSense')).toBe('presence')
     expect(groupForType('capSense2')).toBe('presence')
+    expect(groupForType('sensHealth')).toBe('presence')
     expect(groupForType('bedTemp2')).toBe('bedTemp')
     expect(groupForType('frzTherm')).toBe('freezer')
+    expect(groupForType('frzWater')).toBe('freezer')
     expect(groupForType('gesture')).toBe('log')
     expect(groupForType('unknown')).toBeUndefined()
   })
@@ -74,6 +76,16 @@ describe('freezerStatus', () => {
     expect(freezerStatus(health({ fan: 0, fanDuty: 0 }), 'ok', true).label).toBe('Normal')
     expect(freezerStatus(health({ fan: 100, fanDuty: 50 }), 'ok', true).label).toBe('Normal')
   })
+
+  it('evaluates water level and priming state when frzWater frame is available', () => {
+    const baseWater = { type: 'frzWater' as const, ts: 1, capLevel: 4, capValid: true, hasWater: true, isPriming: false, needsPriming: false }
+    expect(freezerStatus(health(), 'ok', true, { ...baseWater, capLevel: 1 })).toEqual({ tone: 'warn', label: 'Water low' })
+    expect(freezerStatus(health(), 'ok', true, { ...baseWater, capLevel: 4 })).toEqual({ tone: 'ok', label: 'Normal' })
+    expect(freezerStatus(health(), 'ok', true, { ...baseWater, isPriming: true })).toEqual({ tone: 'ok', label: 'Priming' })
+    expect(freezerStatus(health(), 'ok', true, { ...baseWater, needsPriming: true })).toEqual({ tone: 'warn', label: 'Needs prime' })
+    expect(freezerStatus(health(), 'ok', true, { ...baseWater, capValid: false, hasWater: false })).toEqual({ tone: 'warn', label: 'Water low' })
+    expect(freezerStatus(health(), 'ok', true, { ...baseWater, capValid: false, hasWater: true })).toEqual({ tone: 'ok', label: 'Normal' })
+  })
 })
 
 describe('zoneActivity', () => {