Ben Meadors 8abae90838 Give the 4MB T3-S3 boards an app partition that fits (#10978) ...

* fix(device-install): flash littlefs at the offset from firmware metadata

device-install.sh read the spiffs offset out of the .mt.json metadata into
SPIFFS_OFFSET, but flashed the littlefs image at $OFFSET -- a separate
variable still holding the hardcoded 0x300000 default. The metadata value
was never used, so any board with a non-default partition table had its
filesystem written to the wrong place.

Unify on SPIFFS_OFFSET, and guard both metadata overrides so a table that
omits ota_1 or spiffs falls back to the built-in default instead of handing
esptool an empty offset. Quote both offsets at the call site: the spiffs one
is newly consumed from jq, and a multi-line result would otherwise word-split
into esptool's argv and silently mis-pair address with file.

device-install.bat already does all of this correctly; this brings the shell
script to parity.

* fix(tlora-t3s3): give the 4MB T3-S3 boards an app partition that fits

tlora-t3s3-v1 and tlora-t3s3-epaper have overflowed the shared 4MB
partition-table.csv app slot (ota_0 = 0x250000 = 2,424,832 bytes) on every
develop build since 22072c5f4 (2026-06-20). The last green build,
ca7d82629, cleared it by 881 bytes; develop is now ~38.7KB over. These envs
have no board_level, so they only build in the full matrix on push to
develop -- which is why no PR ever caught it.

Add partition-table-t3s3.csv, dedicated to the 4MB ESP32-S3FH4R2 T3-S3
boards, and point all three t3s3 envs at it:

  app      ota_0  0x010000  0x290000   (was 0x250000, +256KB)
  flashApp ota_1  0x2A0000  0x0A0000   (unchanged size)
  spiffs          0x340000  0x0C0000   (was 0x100000, -256KB)

The headroom comes out of spiffs, not flashApp: the unified BLE OTA image is
636,544 bytes against a 655,360 byte slot, so ota_1 has nothing to give. The
table is contiguous, ends exactly on the 4MB boundary, keeps both app
partitions 64KB-aligned, and leaves the littlefs image these boards ship well
inside the remaining 768KB.

Verified with a Docker build of all three envs:

  tlora-t3s3-v1             2,463,504  91.7%
  tlora-t3s3-epaper         2,458,487  91.5%
  tlora-t3s3-epaper-inkhud  2,400,851  89.4%

Trimming was considered and rejected. The entire emoji set is 6,304 bytes
(measured A/B build), and cutting traffic management plus the paxcounter,
storeforward, rangetest and atak modules recovers 46,636 -- enough to land at
99.7% full, i.e. weeks of headroom at develop's observed growth rate, in
exchange for shipping a feature-reduced board. The slot was simply mis-sized
for a board this full.

Note this changes flash layout: existing T3-S3 units must be erased and
factory-flashed once to pick up the new offsets. They already cannot run a
current develop build, so no working configuration regresses.

2026-07-10 10:18:09 -05:00

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