ErsatzTV.Tests/Controllers/TroubleshootControllerTests.cs

@@ -448,6 +448,94 @@ public class TroubleshootControllerTests
         }
     }
 
+    [Test]
+    public async Task TroubleshootPlayback_Should_Return_404_And_Not_Spin_When_Ffmpeg_Fails_Before_Segments()
+    {
+        // ersatztv#320: if ffmpeg dies after writing the playlist but before any segments appear, the
+        // segment-readiness poll must break on notifier.IsFailed instead of spinning until the client
+        // cancels (which would tie up the request thread + hold the troubleshooting lock).
+        //
+        // The segment scan uses the real Directory.GetFiles on the shared troubleshooting folder, so
+        // ensure the folder EXISTS — otherwise Directory.GetFiles throws DirectoryNotFoundException,
+        // which the pre-fix loop would surface as a fast 404 (a false pass that hides the regression).
+        // We deliberately do NOT delete stray *.ts here: this folder is machine-global and may hold a
+        // live troubleshooting session's segments (don't reap files this test didn't create). It isn't
+        // needed for determinism — NUnit runs serially and the sibling Should_Return_200 test cleans up
+        // its own seg-test-*.ts in a finally, so no test leaves >= initialSegmentCount(2) files behind;
+        // and the fixed code breaks on IsFailed before the scan runs regardless of folder contents.
+        Directory.CreateDirectory(FileSystemLayout.TranscodeTroubleshootingFolder);
+
+        _entityLocker.IsTroubleshootingPlaybackLocked().Returns(false);
+
+        var playoutItemResult = new PlayoutItemResult(
+            new CliWrap.Command("ffmpeg"),
+            Option<ErsatzTV.Core.Interfaces.Streaming.GraphicsEngineContext>.None,
+            Option<int>.Some(1));
+
+        _mediator.Send(Arg.Any<PrepareTroubleshootingPlayback>(), Arg.Any<CancellationToken>())
+            .Returns(Either<BaseError, PlayoutItemResult>.Right(playoutItemResult));
+        _mediator.Send(Arg.Any<GetMediaItemInfo>(), Arg.Any<CancellationToken>())
+            .Returns(Either<BaseError, MediaItemInfo>.Right(FakeMediaItemInfo()));
+        _mediator.Send(Arg.Any<GetTroubleshootingInfo>(), Arg.Any<CancellationToken>())
+            .Returns(new TroubleshootingInfo(
+                "1.2.3",
+                new Dictionary<string, string>(),
+                [],
+                [],
+                [],
+                new ErsatzTV.Application.FFmpegProfiles.FFmpegSettingsViewModel(),
+                [],
+                [],
+                [],
+                false,
+                false,
+                null,
+                null,
+                null,
+                null));
+
+        var fileSystem = Substitute.For<IFileSystem>();
+        // playlist "exists" so the first wait loop exits immediately and we reach the segment poll
+        fileSystem.File.Exists(Arg.Any<string>()).Returns(true);
+
+        var configElementRepository = Substitute.For<IConfigElementRepository>();
+        configElementRepository
+            .GetValue<int>(ConfigElementKey.FFmpegInitialSegmentCount, Arg.Any<CancellationToken>())
+            .Returns(Option<int>.Some(2));
+
+        var notifier = Substitute.For<ITroubleshootingNotifier>();
+        notifier.IsFailed(Arg.Any<Guid>()).Returns(true);
+
+        var controller = new TroubleshootController(
+            System.Threading.Channels.Channel.CreateUnbounded<IFFmpegWorkerRequest>().Writer,
+            fileSystem,
+            configElementRepository,
+            notifier,
+            _entityLocker,
+            _statusStore,
+            _mediator)
+        {
+            ControllerContext = new ControllerContext
+            {
+                HttpContext = new DefaultHttpContext { Request = { PathBase = "/etv" } }
+            }
+        };
+
+        // safety deadline so a regression (the loop spinning) fails the test in bounded time instead
+        // of hanging CI; the fixed code exits via IsFailed long before this fires
+        using var cts = new CancellationTokenSource(TimeSpan.FromSeconds(10));
+
+        IActionResult result = await controller.TroubleshootPlayback(DefaultPlaybackRequest(), cts.Token);
+
+        var notFound = result.ShouldBeOfType<NotFoundObjectResult>();
+        notFound.Value.ShouldBeOfType<ProblemDetails>().Status.ShouldBe(404);
+
+        // the loop must have exited via IsFailed, NOT by hitting the cancellation deadline — this is
+        // what makes the test non-vacuous (it fails on the pre-fix spinning loop)
+        cts.IsCancellationRequested.ShouldBeFalse();
+        notifier.Received().RemoveSession(Arg.Any<Guid>());
+    }
+
     [Test]
     public async Task GetPlaybackStatus_Should_Report_Idle_When_No_Result_And_Unlocked()
     {

ErsatzTV/Controllers/Api/TroubleshootController.cs

@@ -238,6 +238,17 @@ public class TroubleshootController(
                     {
                         await Task.Delay(TimeSpan.FromMilliseconds(100), cancellationToken);
 
+                        // if ffmpeg died before segments appeared, stop waiting instead of spinning
+                        // until client-cancel; the !IsFailed guard below then falls through to the
+                        // terminal NotFoundProblem, releasing the request thread + lock. (Client
+                        // cancellation is already handled by the Task.Delay above throwing; checking
+                        // it here too would let a cancel exit into the Ok gate and return a spurious
+                        // 200 for a request with no segments.)
+                        if (notifier.IsFailed(sessionId))
+                        {
+                            break;
+                        }
+
                         string[] segmentFiles = streamingMode switch
                         {
                             // StreamingMode.HttpLiveStreamingSegmenter => Directory.GetFiles(