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ESPSomfy-RTS/docs/adr/0003-pioarduino-idf55.md
cjkas 527215d21a fix: review fixes for the C3 build 
- The C3's default radio pins were GPIO 12-17, which hold its SPI flash.
  They are now the framework's SPI pins (SCK 4, MISO 5, MOSI 6, CSN 7)
  with TX 10 and RX 3. A board with pins saved keeps them.
- ADR 0003: the amendment links ADR 0006, says the C3 needs chip
  revision v0.3 or later (CONFIG_ESP32C3_REV_MIN_3), and the Ethernet
  bullet names the C3.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
2026-10-28 22:32:37 +01:00

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Firmware builds on pioarduino (Arduino 3.x, ESP-IDF 5.5), pinned to one release

We moved every firmware env from espressif32 @ 6.13.0 (Arduino 2.0.17 on ESP-IDF 4.4.7) to pioarduino's 55.03.312 (Arduino 3.3.12 on ESP-IDF 5.5). IDF 4.4 no longer gets security fixes for Wi-Fi, lwIP and mbedTLS, and the planned RMT radio needs IDF 5's RMT driver. The official PlatformIO platform never shipped Arduino 3.x, so pioarduino, a community fork, is the only way to get it in PlatformIO. We pin one release URL rather than stable, so a framework upgrade is always its own PR with its own size check and hardware test.

Considered Options

  • Stay on IDF 4.4. Rejected: no more security fixes, and no new RMT driver.
  • Rebuild the IDF libraries with custom_sdkconfig to leave out PPP, NAT and provisioning (about 20 KB the firmware never uses). Deferred: it makes builds much slower, and log level 2 already makes the ESP32 build fit.
  • Grow the app slots in the partition table. Rejected: an OTA update can't change the partition table, so every existing device would need a USB flash.

Consequences

  • Firmware size. The ESP32 image grows from 1,382,640 bytes (v3.0.14) to 1,555,472 at CORE_DEBUG_LEVEL=2, leaving 17 KB of the 1.5 MB OTA slot. At level 3 it doesn't fit, so release envs build at level 2 (warnings and errors) and debug envs stay at 3. PlatformIO's "Flash:" figure counts ELF sections, not the image, and reads about 45 KB low, so CI checks firmware.bin against the app partition and fails under 8 KB free (.github/size_check.py).

  • No more C3 builds. Its image grows by 214 KB to 1,651,216 bytes, 76.5 KB over the OTA slot even at level 2. C3 boards stay on the 3.0.x releases.

    Amended by ADR 0006 (4.0.0). The C3 builds again. Without the old API (ports 8080 and 8081), its image is 1,498,512 bytes at level 2 and leaves 72.6 KB of the OTA slot. It runs on chip revision v0.3 or later only: the framework's C3 libraries are built with CONFIG_ESP32C3_REV_MIN_3. Its default radio pins moved off GPIO 12-17, which hold the SPI flash.

  • Ethernet PHY ids are ours. Arduino 3.x renumbered eth_phy_type_t (ETH_PHY_GENERIC is 0). NVS, backups and the web UI keep the Arduino 2.x numbers as eth_phy_id_t (src/EthPhy.h), translated by name when Ethernet starts. Never cast a stored id to the framework enum.

  • Ethernet only on the original ESP32. Arduino 3.x has the RMII MAC API only where CONFIG_ETH_USE_ESP32_EMAC is set. S3, C3 and C6 build without Ethernet.

  • Updates roll back until proven. We override the core's verifyRollbackLater() hook to return true, and loop() marks the new firmware valid once it has run 60 s and the network is up. A reset before then boots the previous firmware. The LittleFS image an update wrote stays, so the old firmware runs with the new web UI.

  • Tooling. pioarduino needs its own Core fork (pip install pioarduino, the pioarduino IDE extension in VS Code), which it installs into ~/.platformio/penv in place of PlatformIO Core.