Service flow & 7-year parts

SERVICE-FLOW.md — Ambassador-side service flow

Inbound Diagnostic

Test Sequence Summary

Upon receiving a new WanderPlug unit, the following diagnostic tests are co conducted:

• Visual Inspection: Check for physical damage or manufacturing defects

defects.

• Power-On Test:
• Connect the device to power and observe LED behavior according to mode

(see _MANIFEST.md).

• Ensure proper functionality of USB PD ports if applicable.
• Confirm firmware version matches expected build ID.
• Current Load Test: Apply a controlled current load and verify sensor

accuracy.

Detailed Steps

1. Unpack Unit

• Verify packaging integrity, check for any signs of rough handling.

2. Visual Inspection

• Inspect the exterior casing for scratches or dents.
• Confirm that all components (USB PD ports if applicable) are present a

and undamaged.

3. Power-On Test

• Connect WanderPlug to a 120V AC outlet.
• Observe LED status: Green indicates power-on, blinking blue for firmwa

firmware update in progress, red for error state.

• If USB PD ports are present (WV-PLUG-PRO), ensure they function correc

correctly by connecting compatible devices and verifying power delivery.

4. Current Load Test

• Apply a 5A current load using an adjustable power supply.
• Monitor the ACS37800 sensor readings via serial interface on ESP32-S3-

ESP32-S3-WROOM-1 (BOM-modules.csv).

• Verify that the measured current aligns within ±5% tolerance of applie

applied value.

Field-Replaceable Units

Part Numbers and Vendors

| FRU Name | Description | Part Number

Vendor

| Relay Module | Controls power to connected load | WPLUG-RELAY-1

Molex Inc.

| Current Sensor | Monitors electrical current | ACS37800

Allegro Microsystems

| USB PD Hub | Dual USB-C Power Delivery Port | WPLUG-PD-HUB-2

C&K Components

| Enclosure Shell | Plastic housing for all parts | WPLUG-SHELL-1

Zhejiang Juheng

Replacement Procedure

1. Preparation

• Gather necessary tools: insulated screwdriver, anti-static wrist strap

strap.

2. Disassembly

• Power down WanderPlug and unplug from outlet.
• Remove screws securing the enclosure shell (BOM-platform.csv).
• Disconnect FRU’s wiring harnesses.

3. Replacement

• Insert new relay module into designated socket on main PCB.
• Solder in the replacement current sensor, verifying pinout matches ACS

ACS37800 datasheet.

• For WV-PLUG-PRO models, install new USB PD hub by reattaching wiring h

harness to matching connector.

4. Assembly

• Reconnect all cable harnesses and secure enclosure shell back into pla

place with original screws.

• Power up WanderPlug and verify proper operation through diagnostic tes

tests.

Battery Service

Test Sequence Summary

Battery service involves inspecting battery health, replacing if necessary, necessary, and ensuring the device operates correctly post-replacement.

Detailed Steps

1. Disassemble Unit

• Remove enclosure shell to access internal components.
• Disconnect any existing batteries from main PCB.

2. Health Check

• Use a multimeter set to 20V DC range to measure voltage across battery

battery terminals.

• Compare reading against expected values (BOM-modules.csv).
• Replace if readings indicate degradation or failure.

3. Battery Replacement

• Install new CR123A lithium batteries from Panasonic brand.
• Reconnect wires to main PCB, ensuring correct polarity and secure conn

connection points.

4. Reassembly & Testing

• Close enclosure shell and power up unit.
• Conduct current load test (see "Current Load Test" in Inbound Diagnost

Diagnostic section) to confirm sensor functionality post-replacement.

Firmware Roll-Back

Procedure Summary

To roll back firmware, a specific backup file must be loaded onto the devic device via USB interface. This action is used when encountering issues with with newer builds and requires precise steps due to dependency on exact bui build IDs.

Detailed Steps

1. Download Backup File

• Access secure server housing previous version backups.
• Ensure downloaded .bin matches known-good checksum for rollback proced

procedure (BOM-normalized.csv).

2. Connect via USB

• Use a mini-USB cable compatible with ESP32-S3-WROOM-1 to connect Wande

WanderPlug to development machine.

3. Load Backup Firmware

• Execute esptool.py command from Espressif SDK environment:

     esptool.py --port /dev/ttyUSB0 write_flash 0x00000 <path/to/backup.bin
<path/to/backup.bin>

4. Verification and Testing

• Reboot device after upload is complete.
• Verify firmware version via serial console output (BOM-modules.csv).
• Conduct standard diagnostic tests to ensure system stability.

Decommission + Secure-Wipe

Procedure Summary

Decommissioning involves securely erasing all data from a retired unit befo before disposal. This ensures compliance with data protection regulations a and prevents unauthorized access to any residual information stored on the device.

Detailed Steps

1. Panic-Wipe Activation

• Press and hold panic button for 5 seconds until red LED blinks rapidly

rapidly.

• Monitor serial output for confirmation of wipe process (CONFIGURATOR.m

(CONFIGURATOR.md).

2. Secure Erase Command

• Initiate secure erase command via serial interface:

     esptool.py --port /dev/ttyUSB0 write_flash 0x10000 <path/to/secure_era
<path/to/secure_erase_script.bin>

3. Physical Destruction

• Once data wipe is confirmed complete, physically destroy unit by crush

crushing enclosure shell with hammer.

• Ensure PCB components are unrecognizable to prevent data recovery atte

attempts.

Ambassador Signature Provenance

Verification Process

Each WanderPlug unit features a unique signature engraved inside the enclos enclosure body as part of quality assurance. This signature serves both as a mark of authenticity and a traceability measure for assembly oversight.

Detailed Steps

1. Signature Location

• Engraving is placed on inner surface of rear housing, visible upon dis

disassembly.

2. Verification Steps

• Compare engraved name/initials against records maintained in productio

production database.

• Confirm signature matches authorized list provided by quality control

department.

3. Record Keeping

• Document verification results and timestamp each check for audit trail

trail compliance.

Cost + 10% Parts Table

Pricing Breakdown (USD)

| Component | Description | Unit Price Price ($) | Quantity | Total ($) | 10% Margin ($)

| WPLUG-RELAY-1 | Relay Module | 2.50

2	5	.5

| ACS37800 | Current Sensor | 4.00

1	4	.4

| WPLUG-PD-HUB-2 | USB PD Hub (WV-PLUG-PRO only) | 6.50

1	6.5	.65

| CR123A Battery x2 | Lithium Batteries | 1.00

2	2	.2

| WPLUG-SHELL-1 | Enclosure Shell | 3.75

1	3.75	.38

Total Cost Before Margin: $21.25

Cost with 10% Margin: $23.375

Notes

• All unit prices are per single component.
• Quantity reflects usage per WanderPlug unit (except for batteries, which

are paired).

• Total cost and margin calculations assume no bulk discounts or volume pur

purchases apply.

Open STL files

WanderPlug — Open Mechanical Files

Per the WanderVerse 7-year repair commitment, every mechanical file required to fabricate replacement parts is published here under CC-BY-SA 4.0.

Files

• enclosure-front.stl, enclosure-back.stl — outer case
• pcb-mount-bracket.stl, battery-tray.stl — internal mounts
• pcb-3d-step.step — full mechanical PCB outline
• drawings.pdf — assembly drawings + tolerance sheet

Engraved signature stays inside; do not place wordmarks on the exterior.