From 9b62b439956d30fd797c3c8bd73db1fb549f56da Mon Sep 17 00:00:00 2001 From: mikecarper Date: Thu, 22 Oct 2026 23:21:14 -0700 Subject: [PATCH] Record targeted RAK build, radio and CPU sleep passes [skip ci] --- docs/test-results/index.md | 1 + .../rak3401_all_roles_cpu_sleep_2026-10-21.md | 5 + .../rak_release_fixes_2026-10-22.md | 127 +++++++ .../rak_release_fixes_2026-10-22.safe.json | 349 ++++++++++++++++++ .../rs232_bridge_diagnostics_2026-10-22.md | 4 + 5 files changed, 486 insertions(+) create mode 100644 docs/test-results/rak_release_fixes_2026-10-22.md create mode 100644 docs/test-results/rak_release_fixes_2026-10-22.safe.json diff --git a/docs/test-results/index.md b/docs/test-results/index.md index b35697919..94ef47464 100644 --- a/docs/test-results/index.md +++ b/docs/test-results/index.md @@ -75,6 +75,7 @@ Completed validation reports, experiments, and test guides are collected here. O ## Build, storage, memory, and checklists +- [RAK4631 Full/Reduced RAM repair and RAK3401 Room Server radio/sleep qualification, 2026-10-22](rak_release_fixes_2026-10-22.md) - [Shared battery ADC calibration validation, 2026-10-22](battery_calibration_2026-10-22.md) - [Heltec V2 BLE RAM reserve repair, 2026-10-22](heltec_v2_ble_memory_2026-10-22.md) - [ESP32 Bluetooth shutdown and radio2 CPU idle, 2026-10-21](esp32_ble_radio2_sleep_2026-10-21.md) diff --git a/docs/test-results/rak3401_all_roles_cpu_sleep_2026-10-21.md b/docs/test-results/rak3401_all_roles_cpu_sleep_2026-10-21.md index 4775043ec..4b0b14028 100644 --- a/docs/test-results/rak3401_all_roles_cpu_sleep_2026-10-21.md +++ b/docs/test-results/rak3401_all_roles_cpu_sleep_2026-10-21.md @@ -4,6 +4,11 @@ # RAK3401 all firmware CPU sleep checks, 21 October 2026 +Follow-up: the [targeted RAK release checks](rak_release_fixes_2026-10-22.md) +record a new Full Room Server PASS at `adb11e7b4`: three physical LoRa round +trips, 79.31% sampled CPU sleep and zero post-check errors. The original failed +capture below remains unchanged; its RF cause was not established. + All 15 applicable images were installed and measured sequentially on the same RAK3401. **All 13 profiles that support power saving passed the CPU sleep capture with PS on.** Twelve also passed every runtime check. Full Room Server diff --git a/docs/test-results/rak_release_fixes_2026-10-22.md b/docs/test-results/rak_release_fixes_2026-10-22.md new file mode 100644 index 000000000..2ef57c27f --- /dev/null +++ b/docs/test-results/rak_release_fixes_2026-10-22.md @@ -0,0 +1,127 @@ + +

View this page on MeshCore Docs.

+ + +# RAK release fixes and targeted hardware checks, 22 October 2026 + +Status: **RAK4631 Full/Reduced Repeater builds and physical radio checks PASS; +RAK3401 Full Room Server radio, CPU sleep and health checks PASS.** +All six selected RAK release packages passed their existing capacity, +capability, Bluetooth DFU and packaging gates. + +Firmware and hardware results are bound to +[`adb11e7b4`](https://github.com/mikecarper/MeshCore/commit/adb11e7b41f2d3c561bc6aba4ebf6c92a45623bd). +The later `302e441e2` changes only Mini-selected CLI messages; selecting the +non-Mini branches reproduces the prior RAK source byte for byte. Unchanged RAK +checks were retained. The [machine-readable receipt](rak_release_fixes_2026-10-22.safe.json) +includes package hashes, RAM requirements, radio counters and CPU observations. + +## RAM repair + +The fresh starting source, `e34e83e6b`, failed both RAK4631 Repeater profiles: +Full had 81,668 internal bytes available against 85,152 required; Reduced had +84,680 against 85,152. These are separate from the earlier Full Companion +flash repair. + +Repeater rule targets cannot contain both a scope and a region. One tagged +32-byte name replaces their two separate names, reducing each actual rule +from 332 to 300 bytes. All 63 slots remain, saving 2,016 allocated heap bytes. +FPF6/7/8 file formats retain their existing field widths and validation. + +Ordinary nRF52 SSD1306 builds now use the existing source-enforced 2 KiB +allocation bound for this same concrete driver, correcting its previous +4 KiB estimate. This is a 2,048-byte accounting correction, distinct from +the rule-table saving. Stacks, packet pools, allocator/transient reserves, +sensor features and admission boundaries remain unchanged. + +| Target/profile | Available internal bytes | Required heap bytes | Margin | Result | +| --- | ---: | ---: | ---: | --- | +| RAK4631 Repeater Full | 81,676 | 81,088 | 588 | PASS | +| RAK4631 Repeater Reduced | 84,680 | 81,088 | 3,592 | PASS | +| RAK3401 Room Server Full | 153,940 | 58,416 | 95,524 | PASS | +| RAK3401 Room Server Reduced | 156,928 | 58,416 | 98,512 | PASS | +| RAK3401 unified Repeater Full | 78,364 | 74,176 | 4,188 | PASS | +| RAK3401 unified Repeater Reduced | 81,368 | 74,176 | 7,192 | PASS | + +These are canonical `build.sh build-firmware` Full/Reduced pairs with Cascade +settings, `--radio-preset usa-cascade-fixed` and `--require-ota`. The canonical +RAK4631 Repeater and Room Server packages retain their normalized internal-OTA +target identities. PlatformIO commands ran sequentially. + +## Channel-busy repair + +A proven dispatcher defect retained a profile's channel-busy timestamp after +its last waiting packet was cancelled or retired. A later unrelated packet +could inherit the old age and immediately force a transmit with error `0x02`. + +New work now retires an unused wait before joining that profile. Queued work, +retained driver retries and foreign/direct-OTA owners preserve their live +backoff. `begin()` resets previous CAD state. No RAM fields or idle-loop scans +were added. Genuine sustained contention still raises the original timeout. + +The original failed Room Server capture lacked enough RF data to prove this +was its cause. Both old installed repeaters also had latched `0x02` flags. +The new software regressions and finite new-image hardware results are the +evidence for this repair; historical failures remain recorded. + +## Physical results + +Application-only DFU installed the source-bound images on the Mercerwood Pi. +USB reopen checks confirmed role, version, EndF body identity and continuous +uptime. No chip/data erase, filesystem backup, bootloader or SoftDevice update occurred. + +The RAK Tag was the independent LoRa witness. Each case used three fresh +eight-byte nonces, exact routed trace replies and advancing target RX/TX +counters. USB carried commands and observations; the request and reply crossed +the physical radio link. Settings were 917 MHz, SF7, BW62.5, CR5, preamble32, +with two-minute temporary radio leases. The RAK targets retained 2 dBm TX +power; the Tag used its saved 22 dBm. The excluded 910.525 MHz channel was +not used. + +| Installed image | Exact-nonce round trips | Core errors before/after | Result | +| --- | ---: | --- | --- | +| RAK4631 Reduced Repeater | 3/3 | 0 / 0 | PASS | +| RAK4631 Full Repeater | 3/3 | 0 / 0 | PASS | +| RAK3401 Full Room Server | 3/3 | 0 / 0 | PASS | + +After radio cleanup, the Room Server completed one 90.009-second nonhalting +SWD capture with power saving on: 6,374 sleeping observations among 8,035 +samples, or **79.31% weighted sampled sleep**. There were no sampled resets, +halts, steps, interrupt masking or lockups; debug controls stayed unchanged. +Maximum read time was 3 ms and maximum sample gap 16 ms. Uptime advanced +continuously; the post-check had zero errors and an empty queue. This measures +sampled CPU states, not electrical current or exact sleep residency. + +The first Room preparation stopped on an unsupported `ota bootloader status` +getter before any RF or CPU capture. Its failure and repeater restoration are +retained. The corrected room-only follow-up treats that optional status page +as unavailable while retaining mandatory bootloader-version and application +identity checks. It did not repeat the already-passing RAK4631 tests. + +Final handback leaves both RAKs on patched Full Repeater images, saved 917 MHz +settings and power saving on. The RAK3401 gateway service is active again with +its original configuration and exact USB owner; final core errors were zero. + +## Regression checks and CI + +- 62 packet-manager cases, including four stale-wait reproductions that failed + before their fixes; genuine timeout and live-owner backoff still pass. +- Three Meshtext and nine direct-OTA sanitizer cases; five receive-contract + cases; startup-watchdog and radio-idle regressions. +- 55 RAM tests, 21 flood test methods and two OLED checks, including native + sanitizers, ARM layout, all 63 rules, FPF6/7/8 compatibility, full-length + names, room imports, fault recovery and malformed-file rejection. +- Actual CI now builds both RAK4631 Repeater profiles and both RAK3401 Room + Server profiles, rather than relying on a Full Companion build alone. + +The shared CAD fix initially exposed a 44-byte Mini Repeater flash overflow. +Mini-only CLI text was shortened without removing commands, values or checks. +Its exact release-wrapper build now passes at 245,696 of 245,760 application +bytes; RAM passes at 43,920 available against 32,288 required. Four replay +integration and eight Mini-profile tests passed. Other platforms select their +unchanged messages. + +The updated [CI run](https://github.com/mikecarper/MeshCore/actions/runs/39909897061) +was still running when this report was prepared. These targeted checks do not +claim a new all-board campaign, RS232 cable traffic, physical OTA installation, +maximum-load operation or a long RF soak. diff --git a/docs/test-results/rak_release_fixes_2026-10-22.safe.json b/docs/test-results/rak_release_fixes_2026-10-22.safe.json new file mode 100644 index 000000000..bcdef6dac --- /dev/null +++ b/docs/test-results/rak_release_fixes_2026-10-22.safe.json @@ -0,0 +1,349 @@ +{ + "schema": 1, + "status": "targeted_checks_passed", + "firmware_source": "adb11e7b41f2d3c561bc6aba4ebf6c92a45623bd", + "mini_only_followup": "302e441e2b0baae4d87bf6c1c87785c762944c7a", + "builds": [ + { + "artifact": "RAK_4631_repeater_lora_ota_no_external_sensors-full-ota-v1.18.0.1-halo-keymind-cascade-dev-adb11e7b.zip", + "zip_sha256": "06c8e8df88f35deed3785dde37674ee5973a91cdba95e6f32c108f2df2a579a7", + "available_internal_bytes": 81676, + "required_heap_bytes": 81088, + "margin_bytes": 588, + "required_contiguous_bytes": 19168, + "capabilities": [ + "profile.auto", + "sensor.profile.full", + "bridge.rs232", + "ota.update.bluetooth", + "ota.update.lora", + "cli.retry_preset", + "telemetry.history", + "ota.cli", + "sensor.gps", + "sensor.ina219", + "sensor.ina226", + "sensor.ina260", + "sensor.ina3221", + "logging.usb.packets", + "logging.usb.control", + "bridge.rs232.merged" + ], + "passed": true + }, + { + "artifact": "RAK_4631_repeater_lora_ota_no_external_sensors-reduced-ota-v1.18.0.1-halo-keymind-cascade-dev-adb11e7b.zip", + "zip_sha256": "84221bbb430e47028ea47dc11e9ac7ac2f62568d2ea134e7325b7ff54943bc03", + "available_internal_bytes": 84680, + "required_heap_bytes": 81088, + "margin_bytes": 3592, + "required_contiguous_bytes": 19168, + "capabilities": [ + "profile.auto", + "sensor.profile.reduced", + "bridge.rs232", + "ota.update.bluetooth", + "ota.update.lora", + "cli.retry_preset", + "telemetry.history", + "ota.cli", + "sensor.gps", + "sensor.ina219", + "sensor.ina226", + "sensor.ina260", + "sensor.ina3221", + "logging.usb.packets", + "logging.usb.control", + "bridge.rs232.merged" + ], + "passed": true + }, + { + "artifact": "RAK_3401_room_server_lora_ota_no_external_sensors-full-ota-v1.18.0.1-halo-keymind-cascade-dev-adb11e7b.zip", + "zip_sha256": "0f5cb79b19f2e9bebb05e6c7ce68cce7cad0e8093b45c3ec910e476c6f102908", + "available_internal_bytes": 153940, + "required_heap_bytes": 58416, + "margin_bytes": 95524, + "required_contiguous_bytes": 10256, + "capabilities": [ + "profile.auto", + "sensor.profile.full", + "ota.update.bluetooth", + "ota.update.lora", + "cli.retry_preset", + "telemetry.history", + "ota.cli", + "sensor.gps", + "sensor.ina219", + "sensor.ina226", + "sensor.ina260", + "sensor.ina3221", + "logging.usb.packets", + "logging.usb.control" + ], + "passed": true + }, + { + "artifact": "RAK_3401_room_server_lora_ota_no_external_sensors-reduced-ota-v1.18.0.1-halo-keymind-cascade-dev-adb11e7b.zip", + "zip_sha256": "00fb2075cd4ac74d5b5a121dcf63c7fdcd91743405ab14727daa67fe95e4942a", + "available_internal_bytes": 156928, + "required_heap_bytes": 58416, + "margin_bytes": 98512, + "required_contiguous_bytes": 10256, + "capabilities": [ + "profile.auto", + "sensor.profile.reduced", + "ota.update.bluetooth", + "ota.update.lora", + "cli.retry_preset", + "telemetry.history", + "ota.cli", + "sensor.gps", + "sensor.ina219", + "sensor.ina226", + "sensor.ina260", + "sensor.ina3221", + "logging.usb.packets", + "logging.usb.control" + ], + "passed": true + }, + { + "artifact": "RAK_3401_repeater_unified_lora_ota-full-ota-v1.18.0.1-halo-keymind-cascade-dev-adb11e7b.zip", + "zip_sha256": "de9e8a316a6d5806698892622521dba8430c874d4507391c62ccc90e0fc29914", + "available_internal_bytes": 78364, + "required_heap_bytes": 74176, + "margin_bytes": 4188, + "required_contiguous_bytes": 14304, + "capabilities": [ + "profile.auto", + "sensor.profile.full", + "ota.update.bluetooth", + "ota.update.lora", + "cli.retry_preset", + "telemetry.history", + "ota.cli", + "sensor.gps", + "sensor.ina219", + "sensor.ina226", + "sensor.ina260", + "sensor.ina3221", + "logging.usb.packets", + "logging.usb.control" + ], + "passed": true + }, + { + "artifact": "RAK_3401_repeater_unified_lora_ota-reduced-ota-v1.18.0.1-halo-keymind-cascade-dev-adb11e7b.zip", + "zip_sha256": "7d5cbe203e9115d7d3a82289b16730d67f39531a5c9d12630cea5890c464d71c", + "available_internal_bytes": 81368, + "required_heap_bytes": 74176, + "margin_bytes": 7192, + "required_contiguous_bytes": 14304, + "capabilities": [ + "profile.auto", + "sensor.profile.reduced", + "ota.update.bluetooth", + "ota.update.lora", + "cli.retry_preset", + "telemetry.history", + "ota.cli", + "sensor.gps", + "sensor.ina219", + "sensor.ina226", + "sensor.ina260", + "sensor.ina3221", + "logging.usb.packets", + "logging.usb.control" + ], + "passed": true + } + ], + "rf": { + "rak4631_reduced": { + "passed": true, + "rounds_passed": 3, + "expected_rounds": 3, + "radio": { + "frequency_mhz": 917, + "bw_khz": 62.5, + "sf": 7, + "cr": 5, + "preamble": 32, + "temporary_lease_minutes": 2, + "target_tx_dbm": 2, + "witness_tx_dbm": 22 + }, + "core_before": { + "battery_mv": 4239, + "uptime_secs": 8, + "errors": 0, + "queue_len": 1 + }, + "core_after": { + "battery_mv": 4266, + "uptime_secs": 16, + "errors": 0, + "queue_len": 0 + }, + "receipt_sha256": "f15a342bdc1897a74f5c5106027d45f1436ddfe4a767e34cb4d5dcb6fa3937bd", + "application": { + "target": "RAK_4631_repeater_lora_ota_no_external_sensors", + "version": "v1.18.0.1-halo-keymind-cascade-dev-adb11e7b", + "application_sha256": "489d3bae98d7bda2c3f2b600d5bd79116685bc0a2ceb41c0d25fc7d0d3f0233d", + "body_hash": "427AFAF40AF4904C", + "zip_sha256": "84221bbb430e47028ea47dc11e9ac7ac2f62568d2ea134e7325b7ff54943bc03", + "runtime_role": "repeater", + "powersaving": "on" + } + }, + "rak4631_full": { + "passed": true, + "rounds_passed": 3, + "expected_rounds": 3, + "radio": { + "frequency_mhz": 917, + "bw_khz": 62.5, + "sf": 7, + "cr": 5, + "preamble": 32, + "temporary_lease_minutes": 2, + "target_tx_dbm": 2, + "witness_tx_dbm": 22 + }, + "core_before": { + "battery_mv": 4283, + "uptime_secs": 8, + "errors": 0, + "queue_len": 1 + }, + "core_after": { + "battery_mv": 4236, + "uptime_secs": 16, + "errors": 0, + "queue_len": 0 + }, + "receipt_sha256": "f38a76152bacb4a267b916383912806f4055908ba763d0dc747b6c9398e3a739", + "application": { + "target": "RAK_4631_repeater_lora_ota_no_external_sensors", + "version": "v1.18.0.1-halo-keymind-cascade-dev-adb11e7b", + "application_sha256": "518fb91c1c053183e20e2927e278ba287718f355fd4de34a8488e84b338d6f31", + "body_hash": "D511EA44AFEACBA4", + "zip_sha256": "06c8e8df88f35deed3785dde37674ee5973a91cdba95e6f32c108f2df2a579a7", + "runtime_role": "repeater", + "powersaving": "on" + } + }, + "rak3401_room_full": { + "passed": true, + "rounds_passed": 3, + "expected_rounds": 3, + "radio": { + "frequency_mhz": 917, + "bw_khz": 62.5, + "sf": 7, + "cr": 5, + "preamble": 32, + "temporary_lease_minutes": 2, + "target_tx_dbm": 2, + "witness_tx_dbm": 22 + }, + "core_before": { + "battery_mv": 4247, + "uptime_secs": 8, + "errors": 0, + "queue_len": 1 + }, + "core_after": { + "battery_mv": 4215, + "uptime_secs": 13, + "errors": 0, + "queue_len": 0 + }, + "receipt_sha256": "39edf68662db0080eec1013b31d2e17c8db0f701809d7899c05ba162267f0dd5", + "application": { + "target": "RAK_3401_room_server_lora_ota_no_external_sensors", + "version": "v1.18.0.1-halo-keymind-cascade-dev-adb11e7b", + "application_sha256": "31418a1a7d76bab0ee9b21b81dbdeaa8eb2123be1defeb0a4a3b95f6e664fac7", + "body_hash": "99642F2A9CB51F73", + "zip_sha256": "0f5cb79b19f2e9bebb05e6c7ce68cce7cad0e8093b45c3ec910e476c6f102908", + "runtime_role": "room_server", + "powersaving": "on" + } + } + }, + "room_sleep": { + "passed": true, + "cpu_sleep_passed": true, + "weighted_sleep_fraction": 0.7930892728181768, + "sampling": { + "passed": true, + "failures": [], + "sample_count": 8035, + "counts": { + "C_DEBUGEN": 0, + "C_HALT": 0, + "C_STEP": 0, + "C_MASKINTS": 0, + "S_HALT": 0, + "S_SLEEP": 6374, + "S_LOCKUP": 0, + "S_RESET_ST": 0 + }, + "elapsed_ms": 90009, + "observed_ms": 90005.0, + "weighted_sleep_ms": 71382.0, + "weighted_sleep_fraction": 0.7930892728181768, + "unweighted_sleep_fraction": 0.7932794026135657, + "max_gap_ms": 16.0, + "max_read_ms": 3, + "baseline_debug_ctrl_hex": "0000", + "baseline_C_DEBUGEN": false, + "initial_sticky_reset": true, + "final_DHCSR": "01050000", + "openocd_version": [ + "Open On-Chip Debugger 0.12.0+dev-snapshot (2025-07-16-14:15)" + ], + "qualification": "sampled CPU sleep observations, not exact residency or electrical current", + "firmware_identity_must_be_bound_separately": true + }, + "core_before": { + "battery_mv": 4184, + "uptime_secs": 14, + "errors": 0, + "queue_len": 0 + }, + "core_after": { + "battery_mv": 4190, + "uptime_secs": 110, + "errors": 0, + "queue_len": 0 + }, + "ps_after": "on", + "capture_sha256": "0bd8925efa1115c6df88347c9a75b0570dd7e9ec1772a16c36b0e9f1896d476a", + "diagnostic_boolean_restored": true + }, + "first_room_preparation": { + "stopped_before_cpu_capture": true, + "failure": "USB getter rejected: ota bootloader status", + "gateway_restored": true + }, + "final_handback": { + "service_restored": true, + "core": { + "battery_mv": 4250, + "uptime_secs": 9, + "errors": 0, + "queue_len": 1 + }, + "version": "v1.18.0.1-halo-keymind-cascade-dev-adb11e7b (Build: 23-Oct-2026)", + "role": "repeater", + "radio": "917.0,62.5,7,5", + "powersaving": "on" + }, + "mini": { + "application_bytes": 245696, + "application_limit_bytes": 245760, + "passed": true + } +} diff --git a/docs/test-results/rs232_bridge_diagnostics_2026-10-22.md b/docs/test-results/rs232_bridge_diagnostics_2026-10-22.md index 108d77ca3..abdc03003 100644 --- a/docs/test-results/rs232_bridge_diagnostics_2026-10-22.md +++ b/docs/test-results/rs232_bridge_diagnostics_2026-10-22.md @@ -4,6 +4,10 @@ # RS-232 bridge diagnostics, 22 October 2026 +Follow-up: the [RAK RAM repair and hardware checks](rak_release_fixes_2026-10-22.md) +close the Full/Reduced build failure below at `adb11e7b4`. Physical RS232 cable +and line-driver testing remain outside that follow-up's scope. + Status: **host tests and ESP32 Full build PASS**. The RAK4631 Reduced sensor/LoRa OTA build passes, but its Full sensor build fails the RAM gate. The same Full failure occurs on the previous source, before these diagnostics.