Three real incidents from live-testing the flash feature on archy-x250-dev,
each traced through logs on the node and fixed at the root:
- A failed flash left the mesh listener auto-resuming into a reconnect loop
whose backoff reset to its 5s minimum on any momentary connection, even
mid-boot-loop — every retry's open() toggles DTR/RTS, which resets many
ESP32 boards, so the retries were themselves sustaining the loop. Backoff
now only resets after a session runs stably for 20s+, and the flash job
no longer auto-resumes the listener after a failure (only on success,
after a settle delay).
- The HTTP client's blanket 30s request timeout covered entire downloads
(Meshtastic's zip is ~170MB), killing large transfers mid-stream; fixed
with a per-chunk stall timeout instead of a fixed total-transfer cap. But
the download's initial request had no timeout at all, so a slow-to-start
server hung it forever — wedging the single-flash-job guard permanently
("already in progress" on every subsequent attempt). Fixed with a bounded
wait for the response to start, plus an absolute ceiling around the whole
job as a last-resort safety net.
- archy-rnodeconf's PyInstaller freeze broke its own internal esptool
invocation (sys.executable pointed at the frozen binary itself instead of
a real interpreter) — fixed via a new runtime hook. esptool's own
auto-reset-into-bootloader handshake is separately known to be flaky on
some CP2102/CH340 boards; it now retries once at a conservative baud
rate instead of failing outright, and failure logs show the full error
chain instead of just the outer context message.
Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
