apps/machine/electron/hal-service.ts

@@ -376,10 +376,12 @@ export async function initializeHal(config: HalConfig): Promise<HalInstance> {
     setCassettes: async (cassettes: CassetteConfig[]): Promise<void> => {
       console.log(
         '[HAL] Hot-reloading cassette layout:',
-        cassettes.map((c) => `bay${c.position}:${c.denomination}×${c.count ?? 0}`).join(', ')
+        cassettes
+          .map((c) => `bay${c.position}:${c.denomination}×${c.count ?? 0}`)
+          .join(', ')
       )
-      const previousBays = bays
-      const previousInitData = dispenserInitData
+      // Rebuild bays first so subsequent dispense calls see the new layout
+      // even if the dispenser re-init is slow / fails.
       bays = cassettes
         .slice()
         .sort((a, b) => a.position - b.position)
@@ -389,40 +391,31 @@ export async function initializeHal(config: HalConfig): Promise<HalInstance> {
           count: c.count ?? 0,
         }))
       dispenserInitData = { fiatCode: valConfig.fiatCode, cassettes }
-      // Close + re-init the dispenser so its internal per-bay state matches the
-      // new layout. close() now resolves only once the port is really closed,
-      // so the re-open below cannot race it (aiolabs/bitspire#118).
-      //
-      // On failure, roll the in-memory layout back. This reverses an earlier
-      // deliberate choice to keep the new bays "even if the dispenser re-init
-      // is slow / fails": with the re-init failing every time on douro, the app
-      // kept a layout the device had never taken and the operator-config
-      // consumer went on to publish a cassettes-state event advertising it. A
-      // subsequent dispense would then pick bays by a layout the hardware does
-      // not share. Better to surface the failure and stay truthful about what
-      // the device is actually running.
+      // Close + re-init the dispenser so its internal per-bay state matches
+      // the new layout. Errors here surface to the caller (operator-config
+      // consumer) — the renderer can decide whether to retry.
       try {
-        await dispenser.close()
-        await dispenser.init(dispenserInitData)
+        dispenser.close()
       } catch (err) {
-        bays = previousBays
-        dispenserInitData = previousInitData
-        console.error('[HAL] Dispenser re-init failed; keeping the previous cassette layout:', err)
-        throw err
+        console.warn('[HAL] Dispenser close during setCassettes raised:', err)
       }
+      await dispenser.init(dispenserInitData)
       console.log('[HAL] Dispenser re-initialized with new cassettes')
     },
 
     cleanup: async () => {
+      return new Promise<void>((resolve) => {
         validator?.disable()
         validator?.lightOff()
-      await dispenser.close()
-      if (!validator) return
-      await new Promise<void>((resolve) => {
-        validator?.close((err?: Error) => {
+        dispenser.close()
+        if (validator) {
+          validator.close((err?: Error) => {
             if (err) console.error('[HAL] Validator close error:', err)
             resolve()
           })
+        } else {
+          resolve()
+        }
       })
     },
   }

packages/hal/src/dispensers/f56/f56-rs232.ts

@@ -240,25 +240,9 @@ fsm.on('send', (data: Buffer) => {
   serial?.write(data)
 })
 
-/**
- * Close the serial port, resolving once the OS handle is really gone.
- *
- * serialport's close() is asynchronous, so returning before its callback fires
- * let a close-then-reopen caller (setCassettes -> init) race the old handle and
- * fail to take the exclusive lock. Narrower window than puloon's, which
- * deferred the close behind a timer, but the same bug. See aiolabs/bitspire#118.
- */
-export async function close(): Promise<void> {
-  const port = serial
-  if (!port) return
-  // Claim the handle up front so a concurrent close() can't double-close it.
+export function close(): void {
+  serial?.close()
   serial = null
-  await new Promise<void>((resolve) => {
-    port.close((err?: Error | null) => {
-      if (err) console.warn('F56 | serial close raised:', err.message)
-      resolve()
-    })
-  })
 }
 
 export default {

packages/hal/src/dispensers/f56/index.ts

@@ -56,14 +56,14 @@ export class F56Dispenser implements BillDispenser {
       const { bills, error } = await f56.billCount(notes)
 
       if (error) {
-        await this.close()
+        this.close()
         ;(error as Error & { name: string; statusCode: number }).name = 'F56DispenseError'
         ;(error as Error & { statusCode: number }).statusCode = 570
       }
 
       return { value: bills, error }
     } catch (err) {
-      await this.close()
+      this.close()
       const error = err as Error
       ;(error as Error & { name: string; statusCode: number }).name = 'F56DispenseError'
       ;(error as Error & { statusCode: number }).statusCode = 570
@@ -71,8 +71,8 @@ export class F56Dispenser implements BillDispenser {
     }
   }
 
-  async close(): Promise<void> {
-    await f56.close()
+  close(): void {
+    f56.close()
     this.initialized = false
   }
 

packages/hal/src/dispensers/puloon/index.ts

@@ -50,7 +50,7 @@ export class PuloonDispenser implements BillDispenser {
     const { bills, error } = await this.device.dispense(notes)
 
     if (error) {
-      await this.close()
+      this.close()
       error.name = 'PuloonDispenseError'
       console.log('PULOON | dispense error', error)
     }
@@ -58,8 +58,8 @@ export class PuloonDispenser implements BillDispenser {
     return { value: bills, error }
   }
 
-  async close(): Promise<void> {
-    await this.device.close()
+  close(): void {
+    this.device.close()
     this.initialized = false
   }
 

packages/hal/src/dispensers/puloon/puloon-rs232.ts

@@ -13,9 +13,6 @@
  */
 
 import { SerialPort } from 'serialport'
-
-/** Grace period for an in-flight write to land before the port is closed. */
-const SERIAL_DRAIN_MS = 100
 import { billLengths, encodeBillLength } from './bills.js'
 import type { CassetteConfig, DispenseResult } from '../../types.js'
 
@@ -241,32 +238,13 @@ export class PuloonRs232 {
   }
 
   /** Close the serial port */
-  /**
-   * Close the serial port, resolving only once the OS handle is really gone.
-   *
-   * This used to defer `serial.close()` behind a 100 ms setTimeout and return
-   * immediately, with no way for a caller to know when the port was free. A
-   * caller that closed and reopened — setCassettes -> init — therefore raced a
-   * handle that was still open and got EAGAIN "Cannot lock port" every time,
-   * since the overlap was the full 100 ms. And if the reopen ever won the
-   * race, the pending timer fired afterwards and closed the *new* handle,
-   * leaving a silently dead dispenser. See aiolabs/bitspire#118.
-   *
-   * The drain delay is kept — it lets an in-flight write land before the port
-   * goes away — but it is now awaited rather than fired and forgotten.
-   */
-  async close(): Promise<void> {
-    const serial = this.serial
-    if (!serial) return
-    // Claim the handle up front so a concurrent close() can't double-close it.
+  close(): void {
+    if (this.serial) {
+      setTimeout(() => {
+        this.serial?.close()
         this.serial = null
-    await new Promise((resolve) => setTimeout(resolve, SERIAL_DRAIN_MS))
-    await new Promise<void>((resolve) => {
-      serial.close((err?: Error | null) => {
-        if (err) console.warn('PULOON | serial close raised:', err.message)
-        resolve()
-      })
-    })
+      }, 100)
+    }
   }
 
   /** Send a command and wait for a single response */

packages/hal/src/types.ts

@@ -179,13 +179,8 @@ export interface BillDispenser {
     error?: Error
   }>
 
-  /**
-   * Close the connection.
-   *
-   * Resolves only once the underlying port is actually closed, so a caller may
-   * safely reopen it straight after awaiting this (aiolabs/bitspire#118).
-   */
-  close(): Promise<void>
+  /** Close the connection */
+  close(): void
 
   /**
    * Check if bills are present at the dispense outlet