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ESPSomfy-RTS/docs/adr/0003-pioarduino-idf55.md
cjkas d596291677 build: bring back the ESP32-C3 build 
With the old API gone, the C3 image is 1,498,512 bytes at
CORE_DEBUG_LEVEL=2 and leaves 72.6 KB of its 1.5 MB OTA slot. It was
76.5 KB over when ESP-IDF 5.5 dropped it.

- platformio.ini: env esp32c3, single core, esp32_3MB.csv, level 2.
- CI builds and releases it with the other chips.
- ADR 0003: amended.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>
2026-10-28 21:31:10 +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 in 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.

  • 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 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.