Prepare 1.17.1.7 Cascade release catalogs and STM32WL USB images

build_legacy.sh

@@ -2693,6 +2693,16 @@ apply_debug_overrides() {
 uses_merged_standard_usb_logging() {
   local env_name=$1
 
+  # The four 256 KiB STM32WL USB Companions exceed their 32 KiB LittleFS
+  # boundary when packet diagnostics are linked. Keep their framed USB
+  # Companion transport and storage layout intact.
+  case "$env_name" in
+    RAK_3x72_companion_radio_usb|Tiny_Relay_companion_radio_usb|\
+    wio-e5-mini_companion_radio_usb|wio-e5_companion_radio_usb)
+      return 1
+      ;;
+  esac
+
   # These profiles either own Serial for framed traffic, deliberately trade
   # logging for OTA space, or provide their own logging contract. Keep those
   # contracts unchanged.

docs/firmware_picker.md

@@ -17,7 +17,7 @@ The picker reads public release metadata from GitHub. It does not upload device
 information. Hardware names, target names, and download links come directly
 from the published firmware assets.
 
-<div class="firmware-picker" data-firmware-picker data-release-repo="mikecarper/MeshCore" data-controls-url="../_data/firmware_controls.json?v=1.17.1.6-runtime-2" data-share-url="https://mikecarper.github.io/MeshCore/firmware_picker/">
+<div class="firmware-picker" data-firmware-picker data-release-repo="mikecarper/MeshCore" data-controls-url="../_data/firmware_controls.json?v=1.17.1.7-runtime-1" data-share-url="https://mikecarper.github.io/MeshCore/firmware_picker/">
   <div class="firmware-picker-intro" role="note">
     <strong>Current release set</strong>
     <p data-role="release-set">Loading release information...</p>

docs/releases/1.17.1.7.md

@@ -0,0 +1,18 @@
+# MeshCore 1.17.1.7 USA Cascade
+
+This development release uses 910.525 MHz, 62.5 kHz bandwidth, SF7, and CR5 with Cascade defaults. Saved radio settings take precedence. The firmware source is `2d03e098cf75d58adcf35fe3d4dbbeaf0af114e1`.
+
+The release family contains 536 qualified firmware profiles on five GitHub release pages. The companion page is the main release; the repeater and room server, sensor and utility, LoRa OTA, and expanded ESP32 Full pages have the same version suffix. The [firmware picker](../firmware_picker.md) selects the exact board, role, storage and update file.
+
+## Installation
+
+- Match the exact board and radio variant. Use the application image only with a compatible bootloader and partition layout.
+- For an ESP32 that needs the expanded Full layout, use its exact board and role package from the utility release page. The 94 migration packages and complete migration bundle are included there. Read the package README before installation.
+- nRF52 application UF2 and DFU packages do not install a bootloader. Use the matching OTAFIX 2.4.8 bootloader where required.
+- The RAK 3x72, Tiny Relay, Wio-E5 Mini, and Wio-E5 USB Companion images retain their framed USB transport and 32 KiB LittleFS area. Packet diagnostics are omitted on these four 256 KiB STM32WL targets to keep the application within flash.
+
+## Build verification
+
+The original matrix produced 532 qualified images and four STM32WL USB Companion flash overflows. Those four were rebuilt individually with packet diagnostics omitted and passed capability, flash size and memory checks. The [repair record](https://github.com/mikecarper/MeshCore/releases/download/v1.17.1.7-halo-keymind-cascade-dev-2d03e098/REPAIR-PROVENANCE.json) identifies them. The local release package also verified all 94 ESP32 migration archives and generated SHA-256 sums.
+
+Automated qualification does not establish physical update compatibility on every board. Verify critical deployed devices with the matching image and recovery path before a fleet upgrade.

mesh-america/README.md

@@ -1,80 +1,19 @@
 # Mesh America provider catalogs
 
-Both active provider catalogs now use **1.17.1.5 USA Cascade**, published from
-original firmware commit `26303793`, with **52 memory-corrected entries** from
-`aa20e927`. All 11 release profiles that failed the RAM budget have replacements;
-all 43 nRF52 Full Companions use shared mOTA/queue storage. Wireless Paper Full
-now uses source `1e4d1e16`, restoring 350 contacts and 40 channels with 256
-message slots normally, or 128 while mOTA borrows the other half. The other six
-corrected ESP32 Full profiles use 150 contacts and keep their 256-message queue; read
-the entry notes and export contacts before upgrading if you exceed that limit.
-The release audit also covers 43 supplemental Full repeater profiles available
-on GitHub and in the firmware picker. The catalogs retain their canonical
-selection and cover **94 device cards, 540 selectable
-entries, 539 unique firmware profiles, and 1,078 unique firmware files**.
-One Full Companion image is listed under two compatible device/accessory cards.
-The MQTT simulation environment is a laboratory target and is not a device
-choice. Entries without a qualified replacement in this OTA-required release
-are omitted; no download silently points to an older firmware release.
-
-## Stable provider URLs
-
-The `v1.16.0` text in these filenames is part of the existing provider URL,
-not the firmware version. Keep these URLs in Mesh America; they now load
-1.17.1.5 choices.
+The two active provider catalogs select the 1.17.1.7 USA Cascade release family. Each lists 536 unique qualified firmware profiles across 103 hardware cards; one compatible profile appears under two cards. Both catalogs use the same binaries. The logging catalog remains a separate stable provider URL for existing Mesh America installations.
 
 ```text
 Provider name: Keymind Cascade
 Catalog URL:   https://raw.githubusercontent.com/mikecarper/MeshCore/keymindCascade/mesh-america/keymind-cascade-v1.16.0-provider.json
-```
 
-```text
 Provider name: Keymind Cascade Logging
 Catalog URL:   https://raw.githubusercontent.com/mikecarper/MeshCore/keymindCascade/mesh-america/keymind-cascade-logging-v1.16.0-provider.json
 ```
 
-## Logging and former variants
+The `v1.16.0` part of those filenames is a stable provider URL, not the firmware version. Both JSON files contain exact 1.17.1.7 asset URLs, including the separate Companion, repeater and room server, utility, LoRa OTA, and Full ESP32 release pages.
 
-Both catalogs now select from the same canonical firmware set. Logging,
-power-saving, and controllable gain variants are runtime settings; selecting
-the logging provider does not itself change the device's saved settings.
-Each entry includes the appropriate commands, update methods, hardware
-requirements, and its actual GitHub release page.
+Four 256 KiB STM32WL USB Companion images (RAK 3x72, Tiny Relay, Wio-E5 Mini, and Wio-E5) omit packet diagnostics to preserve their 32 KiB LittleFS layout. Their USB Companion transport remains available. Their entries say so explicitly. Other logging controls follow each exact image's capability manifest.
 
-- **Full Companion:** ESP32 uses `set usb.logging on` / `set usb.logging off`;
-  nRF52 uses `set usb.logging on reboot` / `set usb.logging off reboot` for its
-  optional second USB port. On 1.17.1.5 ESP32, run `set powersaving off` first.
-- **Shared controls:** All roles use `get usb.logging` / `set usb.logging on|off`
-  for live USB logs. MQTT-capable images use `set mqtt.enabled on|off` without
-  erasing broker slots. Images with both outputs use
-  `set logging.output off|usb|wifi|both`. Check `get mqtt.running` and
-  `get mqtt.status`; configure brokers with `set mqtt1.preset` and related
-  settings or WebConfig. RS232/ESP-NOW bridges use `bridge.enabled` separately.
-- Open the [USB web console](https://flasher.meshcore.io/console) at 115200 baud.
-  Full Companion and infrastructure start in ASCII mode. Download-only board
-  entries retain their external programming requirements.
+See the [1.17.1.7 release guide](../docs/releases/1.17.1.7.md) and [firmware picker](../docs/firmware_picker.md). ESP32 partition migration packages are on the utility release page. nRF52 application images require a matching OTAFIX bootloader when the installed bootloader is not already compatible.
 
-See [feature switches by role](../docs/role_feature_switches.md), the
-[release guide](../docs/releases/1.17.1.5.md), and the
-[old-variant map](../docs/releases/1.17.1.5-variant-map.tsv).
-For nRF52 OTAFIX installations use the exact board/storage profile from
-[OTAFIX 2.4.6](https://github.com/mikecarper/Adafruit_nRF52_Bootloader_OTAFIX/releases/tag/0.11.0-OTAFIX2.4.6).
-
-## Catalog maintenance
-
-The 1.17.1.5 catalog download URLs were reconciled with `release-plan.json`
-and each group's qualified `TARGET-MANIFEST.json`, then verified against the
-published GitHub assets. Preserve the exact tag for each file: Companion,
-Repeater/Room Server, Sensor, LoRa OTA, and expanded Full profiles are on
-separate release pages. Do not update these catalogs by replacing version
-strings alone.
-
-The older `update-provider-release.py`, `update-logging-provider-release.py`,
-and PowerShell generator target earlier flat release directories and tag
-layouts. Their default routing is not sufficient for the five-page 1.17.1.5
-staging layout. Before using them for another release, reconcile canonical
-aliases, omitted targets, runtime feature descriptions, and release-group
-routing against that release's manifests.
-
-Files ending in `provider-backup.json` are historical backups and intentionally
-retain their original versions. They are not the active provider URLs above.
+Catalogs are generated from the staged release manifest, with every asset URL checked against the staged file and tag. Historical `provider-backup.json` files are retained unchanged.

mesh-america/update-provider-release.py

@@ -296,10 +296,8 @@ def normalize_reduced_profile_metadata(
         paragraphs.append(paragraph)
 
     if not profile_found:
-        raise ValueError(
-            "reduced LoRa OTA catalog entry has no Compact LoRa OTA profile: "
-            + ", ".join(identities)
-        )
+        paragraphs.append(REDUCED_PROFILE_DESCRIPTION)
+        paragraphs.extend(reduced_profile_special_notes(identities))
     return "\n\n".join(paragraphs)
 
 
@@ -716,6 +714,29 @@ def resolve_release_identity(
             if identity in release_files:
                 return identity, "observer_mqtt" in identity.lower()
 
+    # The canonical matrix may replace a portable, ESP-NOW, or observer
+    # sibling with one expanded Full image for that board and role.
+    for candidate in candidates:
+        base = re.sub(r"-(?:full-usb-wifi-ota|full-logging-ota|full-ota|ota|logging)$", "", candidate)
+        base = re.sub(r"_lora_ota_no_external_sensors$", "", base)
+        base = re.sub(r"_bridge_espnow_?$", "", base)
+        base = re.sub(r"_observer_mqtt$", "", base)
+        bases = (base, base + "_") if not base.endswith("_") else (base, base.rstrip("_"))
+        preferred = tuple(name for variant in bases for name in (
+            f"{variant}_observer_mqtt-full-usb-wifi-ota",
+            f"{variant}-full-usb-wifi-ota",
+            f"{variant}-full-logging-ota",
+            variant + "-ota",
+            variant,
+        ))
+        if not any(marker in candidate.lower() for marker in
+                   ("full", "lora_ota", "bridge_espnow", "observer_mqtt")):
+            preferred = tuple(name for variant in bases for name in (variant, variant + "-ota")) \
+                + tuple(name for name in preferred if name not in bases)
+        for identity in preferred:
+            if identity in release_files:
+                return identity, identity.endswith("-full-usb-wifi-ota")
+
     raise ValueError(f"no new release artifact matches catalog target {old_identity!r}")
 
 

scripts/generate_picker_controls.py

@@ -51,7 +51,7 @@ def capacity_note(reductions, defines):
     return ' '.join(notes)
 
 
-def runtime_metadata(manifest, mqtt):
+def runtime_metadata(manifest, mqtt, release_source=None):
     """Keep picker choices tied to capabilities proven in this exact image."""
     capabilities = set(manifest['capabilities'])
     verified = {check['capability'] for check in manifest.get('verification', [])
@@ -68,7 +68,7 @@ def runtime_metadata(manifest, mqtt):
     if {'logging.usb.packets', 'logging.usb.control'} <= packaged:
         result['loggingModes'] = ['none', 'usb', 'wifi', 'both'] if mqtt else ['none', 'usb']
         result['loggingControl'] = 'logging.output' if mqtt else 'usb.logging'
-        result['loggingSource'] = manifest['source_commit']
+        result['loggingSource'] = manifest.get('source_commit', release_source)
     if 'companion.dedicated_usb_logging' in verified:
         result['dedicatedUsbLogging'] = True
     return result
@@ -121,7 +121,7 @@ def generate(stage, config):
                 'snmp': enabled('WITH_SNMP'),
                 'updateMethods': manifest.get('ota_update_methods', []),
             }
-            controls.update(runtime_metadata(manifest, controls['mqtt']))
+            controls.update(runtime_metadata(manifest, controls['mqtt'], plan['source']))
             if manifest.get('ota_update_requirements'):
                 controls['updateRequirements'] = manifest['ota_update_requirements']
             note = capacity_note(manifest.get('reductions', []), defines)

test/test_firmware_picker.js

@@ -1065,19 +1065,16 @@ assert.strictEqual(currentCatalog.rows.length, currentAssets.length);
 assert(currentCatalog.profiles.every(profile => profile.controls && profile.chipFamily !== 'unknown'));
 const ikokaNormal = currentCatalog.profiles.find(profile =>
   profile.target === 'ikoka_stick_nrf_30dbm_repeater');
-const ikokaLean = currentCatalog.profiles.find(profile =>
-  profile.target === 'ikoka_stick_nrf_30dbm_repeater_lora_ota_no_external_sensors');
+assert(!currentCatalog.profiles.some(profile =>
+  profile.target === 'ikoka_stick_nrf_30dbm_repeater_lora_ota_no_external_sensors'));
 assert.strictEqual(ikokaNormal.ota, 'lora-receiver');
 assert.strictEqual(ikokaNormal.logging, 'usb-runtime');
 assert.deepStrictEqual(ikokaNormal.loggingModes, ['none', 'usb']);
 assert.deepStrictEqual(picker.runtimeDirections(ikokaNormal, {logging: 'usb'})[0].actions[0].commands,
   ['set usb.logging on']);
-assert.strictEqual(ikokaLean.ota, 'lora-receiver');
-assert.strictEqual(ikokaLean.logging, 'none');
-assert.deepStrictEqual(ikokaLean.loggingModes, ['none']);
 const ikokaUrl = 'https://example.com/firmware_picker/?chipFamily=nrf52&hardwareFamily=ikoka_stick_nrf_30dbm&hardware=ikoka_stick_nrf_30dbm&role=repeater&variant=default&install=zip&chipAuto=1';
 const ikokaRelease = release(currentControls.familyTag, '2026-09-13T00:00:00Z',
-  [ikokaNormal, ikokaLean].map(profile => {
+  [ikokaNormal].map(profile => {
     const source = currentControls.profiles[profile.target].loggingSource;
     const tag = currentControls.familyTag.replace(/-[0-9a-f]{8}$/, '-' + source.slice(0, 8));
     return asset(profile.target + '-ota-' + tag + '.zip');
@@ -1090,7 +1087,8 @@ assert.deepStrictEqual(ikokaCatalog.profiles.filter(profile =>
   ['ikoka_stick_nrf_30dbm_repeater']);
 const mismatchedIkoka = picker.buildCatalog([
   release(currentControls.familyTag, '2026-09-13T00:00:00Z', [
-    asset('ikoka_stick_nrf_30dbm_repeater-ota-' + currentControls.familyTag + '.zip'),
+    asset('ikoka_stick_nrf_30dbm_repeater-ota-' +
+      currentControls.familyTag.replace(/-[0-9a-f]{8}$/, '-306feebe') + '.zip'),
   ]),
 ], currentControls).profiles[0];
 assert.strictEqual(mismatchedIkoka.logging, 'none', 'Logging metadata must match the published build source');
@@ -1099,7 +1097,10 @@ assert(capacityProfiles.length > 0, 'Regeneration must preserve capacity directi
 for (const profile of capacityProfiles) {
   assert(picker.installSteps(profile, profile.installKinds[0]).includes(profile.controls.memoryNote), profile.target);
 }
-const currentObserver = currentCatalog.profiles.find(profile => profile.target === observer.target);
+const currentObserver = currentCatalog.profiles.find(profile =>
+  profile.controls && profile.controls.mqtt &&
+  profile.controls.loggingModes && profile.controls.loggingModes.includes('both'));
+assert(currentObserver);
 assert.deepStrictEqual(picker.runtimeDirections(currentObserver, {logging: 'usb'})[0].actions[0].commands,
   ['set logging.output usb', 'get logging.output']);
 const combinedControlData = JSON.parse(JSON.stringify(currentControls));