[core] Fix app_state_ status bits clobbered for non-looping components (#15658)

esphome/core/application.cpp

@@ -85,8 +85,12 @@ void Application::setup() {
     if (component->can_proceed())
       continue;
 
+    // Force the status LED to blink WARNING while we wait for a slow
+    // component to come up. Cleared after setup() finishes if no real
+    // component has warning set.
+    this->app_state_ |= STATUS_LED_WARNING;
+
     do {
-      uint8_t new_app_state = STATUS_LED_WARNING;
       uint32_t now = millis();
 
       // Process pending loop enables to handle GPIO interrupts during setup
@@ -96,17 +100,26 @@ void Application::setup() {
         // Update loop_component_start_time_ right before calling each component
         this->loop_component_start_time_ = millis();
         this->components_[j]->call();
-        new_app_state |= this->components_[j]->get_component_state();
-        this->app_state_ |= new_app_state;
         this->feed_wdt();
       }
 
       this->after_loop_tasks_();
-      this->app_state_ = new_app_state;
       yield();
     } while (!component->can_proceed() && !component->is_failed());
   }
 
+  // Setup is complete. Reconcile STATUS_LED_WARNING: the slow-setup path
+  // above may have forced it on, and any status_clear_warning() calls
+  // from components during setup were intentional no-ops (gated by
+  // APP_STATE_SETUP_COMPLETE). Walk components once here to pick up the
+  // real state. STATUS_LED_ERROR is never artificially forced, so its
+  // clear path always works and needs no reconciliation. Finally, set
+  // APP_STATE_SETUP_COMPLETE so subsequent warning clears go through
+  // the normal walk-and-clear path.
+  if (!this->any_component_has_status_flag_(STATUS_LED_WARNING))
+    this->app_state_ &= ~STATUS_LED_WARNING;
+  this->app_state_ |= APP_STATE_SETUP_COMPLETE;
+
   ESP_LOGI(TAG, "setup() finished successfully!");
 
 #ifdef USE_SETUP_PRIORITY_OVERRIDE
@@ -211,6 +224,19 @@ void HOT Application::feed_wdt(uint32_t time) {
 #endif
   }
 }
+bool Application::any_component_has_status_flag_(uint8_t flag) const {
+  // Walk all components (not just looping ones) so non-looping components'
+  // status bits are respected. Only called from the slow-path clear helpers
+  // (status_clear_warning_slow_path_ / status_clear_error_slow_path_) on an
+  // actual set→clear transition, so walking O(N) here is paid once per
+  // transition — not once per loop iteration.
+  for (auto *component : this->components_) {
+    if ((component->get_component_state() & flag) != 0)
+      return true;
+  }
+  return false;
+}
+
 void Application::reboot() {
   ESP_LOGI(TAG, "Forcing a reboot");
   for (auto &component : std::ranges::reverse_view(this->components_)) {

esphome/core/application.h

@@ -401,7 +401,18 @@ class Application {
    */
   void teardown_components(uint32_t timeout_ms);
 
-  uint8_t get_app_state() const { return this->app_state_; }
+  /// Return the public app state status bits (STATUS_LED_* only).
+  /// Internal bookkeeping bits like APP_STATE_SETUP_COMPLETE are masked
+  /// out so external readers (status_led components, etc.) never see them.
+  uint8_t get_app_state() const { return this->app_state_ & ~APP_STATE_SETUP_COMPLETE; }
+
+  /// True once Application::setup() has finished walking all components
+  /// and finalized the initial status flags. Before this point, the
+  /// slow-setup busy-wait may be forcing STATUS_LED_WARNING on, and
+  /// status_clear_* intentionally skips its walk-and-clear step so the
+  /// forced bit doesn't get wiped. Stored as a free bit on app_state_
+  /// (bit 6) to avoid costing additional RAM.
+  bool is_setup_complete() const { return (this->app_state_ & APP_STATE_SETUP_COMPLETE) != 0; }
 
 // Helper macro for entity getter method declarations
 #ifdef USE_DEVICES
@@ -577,6 +588,12 @@ class Application {
   bool is_socket_ready_(int fd) const { return FD_ISSET(fd, &this->read_fds_); }
 #endif
 
+  /// Walk all registered components looking for any whose component_state_
+  /// has the given flag set. Used by Component::status_clear_*_slow_path_()
+  /// (which is a friend) to decide whether to clear the corresponding bit on
+  /// this->app_state_ (the app-wide "any component has this status" indicator).
+  bool any_component_has_status_flag_(uint8_t flag) const;
+
   /// Register a component, detecting loop() override at compile time.
   /// Uses HasLoopOverride<T> which handles ambiguous &T::loop from multiple inheritance.
   template<typename T> void register_component_(T *comp) {
@@ -838,8 +855,6 @@ inline void ESPHOME_ALWAYS_INLINE Application::before_loop_tasks_(uint32_t loop_
 }
 
 inline void ESPHOME_ALWAYS_INLINE Application::loop() {
-  uint8_t new_app_state = 0;
-
   // Get the initial loop time at the start
   uint32_t last_op_end_time = millis();
 
@@ -859,13 +874,10 @@ inline void ESPHOME_ALWAYS_INLINE Application::loop() {
       // Use the finish method to get the current time as the end time
       last_op_end_time = guard.finish();
     }
-    new_app_state |= component->get_component_state();
-    this->app_state_ |= new_app_state;
     this->feed_wdt(last_op_end_time);
   }
 
   this->after_loop_tasks_();
-  this->app_state_ = new_app_state;
 
 #ifdef USE_RUNTIME_STATS
   // Process any pending runtime stats printing after all components have run

esphome/core/component.cpp

@@ -411,10 +411,23 @@ void Component::status_set_error(const LogString *message) {
 }
 void Component::status_clear_warning_slow_path_() {
   this->component_state_ &= ~STATUS_LED_WARNING;
+  // Clear the app-wide STATUS_LED_WARNING bit only if setup has finished
+  // AND no other component still has it set. During setup the forced
+  // STATUS_LED_WARNING (from the slow-setup busy-wait) must not be wiped
+  // by a transient component clear — Application::setup() reconciles
+  // the warning bit once at the end before setting APP_STATE_SETUP_COMPLETE.
+  // The set path is unchanged (set_status_flag_ still writes directly).
+  if (App.is_setup_complete() && !App.any_component_has_status_flag_(STATUS_LED_WARNING))
+    App.app_state_ &= ~STATUS_LED_WARNING;
   ESP_LOGW(TAG, "%s cleared Warning flag", LOG_STR_ARG(this->get_component_log_str()));
 }
 void Component::status_clear_error_slow_path_() {
   this->component_state_ &= ~STATUS_LED_ERROR;
+  // STATUS_LED_ERROR is never artificially forced — it only ever lands
+  // in app_state_ via a real set_status_flag_ call. So the walk-and-clear
+  // path is always safe, including during setup.
+  if (!App.any_component_has_status_flag_(STATUS_LED_ERROR))
+    App.app_state_ &= ~STATUS_LED_ERROR;
   ESP_LOGE(TAG, "%s cleared Error flag", LOG_STR_ARG(this->get_component_log_str()));
 }
 void Component::status_momentary_warning(const char *name, uint32_t length) {

esphome/core/component.h

@@ -89,6 +89,11 @@ inline constexpr uint8_t STATUS_LED_WARNING = 0x08;
 inline constexpr uint8_t STATUS_LED_ERROR = 0x10;
 // Component loop override flag uses bit 5 (set at registration time)
 inline constexpr uint8_t COMPONENT_HAS_LOOP = 0x20;
+// Bit 6 on Application::app_state_ (ONLY) — set at the end of
+// Application::setup(). Component::status_clear_*_slow_path_() uses this to
+// decide whether to propagate clears to App.app_state_. Never set on a
+// Component's component_state_.
+inline constexpr uint8_t APP_STATE_SETUP_COMPLETE = 0x40;
 // Remove before 2026.8.0
 enum class RetryResult { DONE, RETRY };
 

tests/integration/fixtures/status_flags.yaml

@@ -0,0 +1,141 @@
+esphome:
+  name: status-flags-test
+
+host:
+api:
+  actions:
+    # Warning flag services for sensor_a
+    - action: set_warning_a
+      then:
+        - lambda: "id(sensor_a)->status_set_warning();"
+        - component.update: app_warning_bit
+        - component.update: app_error_bit
+    - action: clear_warning_a
+      then:
+        - lambda: "id(sensor_a)->status_clear_warning();"
+        - component.update: app_warning_bit
+        - component.update: app_error_bit
+
+    # Warning flag services for sensor_b
+    - action: set_warning_b
+      then:
+        - lambda: "id(sensor_b)->status_set_warning();"
+        - component.update: app_warning_bit
+        - component.update: app_error_bit
+    - action: clear_warning_b
+      then:
+        - lambda: "id(sensor_b)->status_clear_warning();"
+        - component.update: app_warning_bit
+        - component.update: app_error_bit
+
+    # Error flag services for sensor_a
+    - action: set_error_a
+      then:
+        - lambda: "id(sensor_a)->status_set_error();"
+        - component.update: app_warning_bit
+        - component.update: app_error_bit
+    - action: clear_error_a
+      then:
+        - lambda: "id(sensor_a)->status_clear_error();"
+        - component.update: app_warning_bit
+        - component.update: app_error_bit
+
+    # Error flag services for sensor_b
+    - action: set_error_b
+      then:
+        - lambda: "id(sensor_b)->status_set_error();"
+        - component.update: app_warning_bit
+        - component.update: app_error_bit
+    - action: clear_error_b
+      then:
+        - lambda: "id(sensor_b)->status_clear_error();"
+        - component.update: app_warning_bit
+        - component.update: app_error_bit
+
+    # Snapshot of the status_led_light's output state for observation.
+    - action: snapshot_led
+      then:
+        - component.update: status_led_writes
+        - component.update: status_led_last_state
+
+logger:
+
+# Tracks each write to the fake status_led output.
+globals:
+  - id: status_led_write_count
+    type: uint32_t
+    restore_value: no
+    initial_value: "0"
+  - id: status_led_last_write
+    type: bool
+    restore_value: no
+    initial_value: "false"
+
+# Fake binary output — status_led_light writes to this instead of a pin.
+# Every write bumps a counter and records the last value, both of which
+# are exposed below so the test can verify status_led_light's loop is
+# actually reading App.get_app_state() and responding.
+output:
+  - platform: template
+    id: fake_status_led
+    type: binary
+    write_action:
+      - globals.set:
+          id: status_led_write_count
+          value: !lambda "return id(status_led_write_count) + 1;"
+      - globals.set:
+          id: status_led_last_write
+          value: !lambda "return state;"
+
+# Actual status_led_light component under test.
+light:
+  - platform: status_led
+    name: Status LED
+    id: status_led_light_id
+    output: fake_status_led
+
+sensor:
+  # Two components that the test will toggle warning/error flags on.
+  - platform: template
+    name: Sensor A
+    id: sensor_a
+    update_interval: 24h
+    lambda: return 1.0;
+  - platform: template
+    name: Sensor B
+    id: sensor_b
+    update_interval: 24h
+    lambda: return 2.0;
+
+  # Expose App.app_state_'s STATUS_LED_WARNING / STATUS_LED_ERROR bits
+  # as 0.0 / 1.0. force_update ensures every manual component.update
+  # publishes even if the value is unchanged.
+  - platform: template
+    name: App Warning Bit
+    id: app_warning_bit
+    update_interval: 24h
+    force_update: true
+    lambda: |-
+      return (App.get_app_state() & STATUS_LED_WARNING) != 0 ? 1.0 : 0.0;
+  - platform: template
+    name: App Error Bit
+    id: app_error_bit
+    update_interval: 24h
+    force_update: true
+    lambda: |-
+      return (App.get_app_state() & STATUS_LED_ERROR) != 0 ? 1.0 : 0.0;
+
+  # Observables for the fake status_led output.
+  - platform: template
+    name: Status LED Writes
+    id: status_led_writes
+    update_interval: 24h
+    force_update: true
+    lambda: return id(status_led_write_count);
+  - platform: template
+    name: Status LED Last State
+    id: status_led_last_state
+    update_interval: 24h
+    force_update: true
+    lambda: |-
+      return id(status_led_last_write) ? 1.0 : 0.0;

tests/integration/test_status_flags.py

@@ -0,0 +1,209 @@
+"""Integration tests for Component::status_set/clear_warning/error propagation.
+
+Verifies that toggling STATUS_LED_WARNING / STATUS_LED_ERROR on individual
+components correctly updates the app-wide bits on Application::app_state_,
+AND that the status_led_light component actually responds to those bits
+by writing to its output (the full chain from component.status_set_warning
+→ App.app_state_ → status_led_light.loop() reading get_app_state()).
+
+Exercises the multi-component OR semantics (the app bit stays set while
+any component still has the flag, and only clears when the last component
+clears its bit), the independence of warning and error, and the actual
+status_led_light read of the bits via a fake template output that counts
+writes.
+"""
+
+from __future__ import annotations
+
+import asyncio
+
+import pytest
+
+from .state_utils import InitialStateHelper, SensorTracker, build_key_to_entity_mapping
+from .types import APIClientConnectedFactory, RunCompiledFunction
+
+# Time to let the host-mode main loop run so status_led_light.loop() can
+# execute enough iterations to produce measurable write-count changes on
+# the fake template output. 300 ms is well above the minimum needed.
+STATUS_LED_SETTLE_S = 0.3
+
+
+@pytest.mark.asyncio
+async def test_status_flags(
+    yaml_config: str,
+    run_compiled: RunCompiledFunction,
+    api_client_connected: APIClientConnectedFactory,
+) -> None:
+    async with run_compiled(yaml_config), api_client_connected() as client:
+        entities, services = await client.list_entities_services()
+
+        # Map every custom API service by name for the test to execute.
+        svc = {s.name: s for s in services}
+        for name in (
+            "set_warning_a",
+            "clear_warning_a",
+            "set_warning_b",
+            "clear_warning_b",
+            "set_error_a",
+            "clear_error_a",
+            "set_error_b",
+            "clear_error_b",
+            "snapshot_led",
+        ):
+            assert name in svc, f"service {name} not registered"
+
+        # Track every sensor we care about. SensorTracker gives us
+        # expect(value) / expect_any() futures that resolve when a
+        # matching state arrives; much simpler than manual bookkeeping.
+        tracker = SensorTracker(
+            [
+                "app_warning_bit",
+                "app_error_bit",
+                "status_led_writes",
+                "status_led_last_state",
+            ]
+        )
+        tracker.key_to_sensor.update(
+            build_key_to_entity_mapping(entities, list(tracker.sensor_states.keys()))
+        )
+
+        # Swallow initial state broadcasts so the test only reacts to
+        # state changes triggered by our service calls.
+        initial_state_helper = InitialStateHelper(entities)
+        client.subscribe_states(initial_state_helper.on_state_wrapper(tracker.on_state))
+        try:
+            await initial_state_helper.wait_for_initial_states()
+        except TimeoutError:
+            pytest.fail("Timeout waiting for initial states")
+
+        async def call(name: str) -> None:
+            await client.execute_service(svc[name], {})
+
+        async def call_and_expect_bits(
+            service_name: str, *, warning: float, error: float
+        ) -> None:
+            """Execute a service and wait for both app bit sensors to match.
+
+            Each bit-toggling service calls component.update on both
+            app_warning_bit and app_error_bit, so both sensors publish.
+            """
+            futures = tracker.expect_all(
+                {"app_warning_bit": warning, "app_error_bit": error}
+            )
+            await call(service_name)
+            await tracker.await_all(futures)
+
+        async def snapshot_led_writes() -> int:
+            """Trigger a publish of the fake status_led output counter and return it."""
+            future = tracker.expect_any("status_led_writes")
+            await call("snapshot_led")
+            await tracker.await_change(future, "status_led_writes")
+            return int(tracker.sensor_states["status_led_writes"][-1])
+
+        # ---- Baseline: everything clean ----
+        await call_and_expect_bits("clear_warning_a", warning=0.0, error=0.0)
+
+        # ================================================================
+        # Part 1 — STATUS_LED_WARNING propagation to App.app_state_
+        # ================================================================
+
+        # Single component set/clear
+        await call_and_expect_bits("set_warning_a", warning=1.0, error=0.0)
+        await call_and_expect_bits("clear_warning_a", warning=0.0, error=0.0)
+
+        # Multi-component OR: both set, clear A, bit stays (B still has it), clear B, gone
+        await call_and_expect_bits("set_warning_a", warning=1.0, error=0.0)
+        await call_and_expect_bits("set_warning_b", warning=1.0, error=0.0)
+        await call_and_expect_bits("clear_warning_a", warning=1.0, error=0.0)
+        await call_and_expect_bits("clear_warning_b", warning=0.0, error=0.0)
+
+        # Opposite clear order
+        await call_and_expect_bits("set_warning_a", warning=1.0, error=0.0)
+        await call_and_expect_bits("set_warning_b", warning=1.0, error=0.0)
+        await call_and_expect_bits("clear_warning_b", warning=1.0, error=0.0)
+        await call_and_expect_bits("clear_warning_a", warning=0.0, error=0.0)
+
+        # ================================================================
+        # Part 2 — STATUS_LED_ERROR propagation (same scenarios)
+        # ================================================================
+
+        await call_and_expect_bits("set_error_a", warning=0.0, error=1.0)
+        await call_and_expect_bits("clear_error_a", warning=0.0, error=0.0)
+
+        await call_and_expect_bits("set_error_a", warning=0.0, error=1.0)
+        await call_and_expect_bits("set_error_b", warning=0.0, error=1.0)
+        await call_and_expect_bits("clear_error_a", warning=0.0, error=1.0)
+        await call_and_expect_bits("clear_error_b", warning=0.0, error=0.0)
+
+        # ================================================================
+        # Part 3 — warning and error are independent
+        # ================================================================
+
+        await call_and_expect_bits("set_warning_a", warning=1.0, error=0.0)
+        await call_and_expect_bits("set_error_b", warning=1.0, error=1.0)
+        await call_and_expect_bits("clear_warning_a", warning=0.0, error=1.0)
+        await call_and_expect_bits("clear_error_b", warning=0.0, error=0.0)
+
+        # ================================================================
+        # Part 4 — status_led_light actually reads App.app_state_
+        # ================================================================
+        # The fake status_led_light output increments status_led_write_count
+        # on every write. status_led_light::loop() writes its output on every
+        # iteration while an error/warning bit is set, so after holding a
+        # warning for ~300 ms we should see the counter move significantly.
+        # This is the end-to-end proof that the bits we set above actually
+        # reach status_led_light and drive its behavior.
+
+        count_before_warning = await snapshot_led_writes()
+        await call_and_expect_bits("set_warning_a", warning=1.0, error=0.0)
+        # Let status_led_light's loop run long enough to toggle the pin
+        # several times (it reads get_app_state() every main loop iteration).
+        await asyncio.sleep(STATUS_LED_SETTLE_S)
+        count_after_warning = await snapshot_led_writes()
+        assert count_after_warning > count_before_warning, (
+            "status_led_light did not respond to STATUS_LED_WARNING being set: "
+            f"write count stayed at {count_before_warning} → {count_after_warning}. "
+            "The full chain Component::status_set_warning → App.app_state_ → "
+            "status_led_light::loop reading get_app_state() is broken."
+        )
+        await call_and_expect_bits("clear_warning_a", warning=0.0, error=0.0)
+
+        # Same check for ERROR
+        count_before_error = await snapshot_led_writes()
+        await call_and_expect_bits("set_error_a", warning=0.0, error=1.0)
+        await asyncio.sleep(STATUS_LED_SETTLE_S)
+        count_after_error = await snapshot_led_writes()
+        assert count_after_error > count_before_error, (
+            "status_led_light did not respond to STATUS_LED_ERROR being set: "
+            f"write count stayed at {count_before_error} → {count_after_error}. "
+        )
+        await call_and_expect_bits("clear_error_a", warning=0.0, error=0.0)
+
+        # ---- Set → clear → re-set round-trip ----
+        # After clearing, status_led_light stops writing (steady state).
+        # Re-setting the flag must make it resume. This guards against a
+        # future idle optimization (e.g. #15642) where status_led disables
+        # its own loop when idle: if the re-enable path were broken, the
+        # second set would not produce writes.
+        #
+        # Snapshot AFTER the clear to avoid counting writes that were still
+        # in-flight from the error-set phase.
+        count_after_clear = await snapshot_led_writes()
+        await asyncio.sleep(STATUS_LED_SETTLE_S)
+        count_after_idle = await snapshot_led_writes()
+        assert count_after_idle - count_after_clear <= 5, (
+            "status_led_light kept writing after warning/error was cleared: "
+            f"count grew from {count_after_clear} to {count_after_idle}. "
+            "Expected it to stop writing once all status bits were clear."
+        )
+        # Re-set warning — writes must resume.
+        await call_and_expect_bits("set_warning_a", warning=1.0, error=0.0)
+        await asyncio.sleep(STATUS_LED_SETTLE_S)
+        count_after_reset = await snapshot_led_writes()
+        assert count_after_reset > count_after_idle + 5, (
+            "status_led_light did not resume writing after re-setting "
+            f"STATUS_LED_WARNING: count went from {count_after_idle} to "
+            f"{count_after_reset}. If an idle optimization disabled the "
+            "loop, the re-enable path may be broken."
+        )
+        await call_and_expect_bits("clear_warning_a", warning=0.0, error=0.0)