The XMC embedded flash on ESP32-S3 (QFN56) has JEDEC ID 164020 which esptool.js
does not recognise — it returns flash size -1 causing 'File doesn't fit in
available flash' before any bytes are written.
firmware/sdkconfig.defaults:
CONFIG_ESPTOOLPY_FLASHSIZE 16MB → 4MB
4MB is the minimum supported flash. The spi_flash check only panics when
physical < header, so 4MB header is safe on 16MB boards as well.
firmware/partitions.csv:
Redesigned to fit within 4MB flash:
factory 0x010000–0x200000 (~1.9MB, fits current 1.7MB binary + 330KB headroom)
ota_0 0x200000–0x3F0000 (~1.9MB, A/B OTA + rollback preserved)
otadata 0x3F0000–0x3F2000 (8KB)
Total flash used: 0x3F2000 (98.6% of 4MB). Drops ota_1 (was at 8MB, unusable
on 4MB devices anyway); rollback still works factory↔ota_0.
dashboard/js/onboard.js:
flashSize: 'detect' → '4MB' (detect returned -1 for this chip's JEDEC ID;
hardcoding '4MB' correctly sets the binary header for all supported boards)
Co-Authored-By: Claude Sonnet 4.6 <noreply@anthropic.com>
Update partition layout to 4MB factory/ota_0/ota_1 partitions for larger
firmware images. Add a 60-second validation timer that starts after the
hello message is sent on boot from an OTA partition. The partition is only
marked valid (via esp_ota_mark_app_valid_cancel_rollback) after receiving
a role message from the mothership. If the timer expires without role
receipt, the partition stays unconfirmed and the bootloader rolls back to
the previous firmware on next reset.
Co-Authored-By: Claude Opus 4.6 <noreply@anthropic.com>
