[Ovmsdev] Firmware size approaching 4 MB limit

[Craig Leres]

I tried 3.3.005-714-gbcf42700. Unfortunately the upgrade step results in 
a crash.



OVMS# ota
Hardware:          OVMS WIFI BLE BT cores=2 rev=ESP32/3; MODEM SIM7600
Firmware:          3.3.005-714-gbcf42700-dirty/factory/main (build idf 
v3.3.4-854-g9063c8662 Feb 25 2026 10:36:43)
Partition type:    v3-f12 (factory, ota1, ota2)
Partition table:   0x8000
Running partition: factory
Boot partition:    factory
Factory image:     3.3.005-714-gbcf42700-dirty
OTA_O image:       3.3.005-714-gbcf42700-dirty
OTA_1 image:       3.3.005-711-g4feca695-dirty
OVMS# ota partitions list
Partition table:
Label            Type Subtype         Address Size
nvs              data nvs          0x00009000 16 KB
otadata          data ota          0x0000d000 8 KB
phy_init         data phy          0x0000f000 4 KB
factory          app  factory      0x00010000 4 MB
ota_0            app  ota_0        0x00410000 4 MB
ota_1            app  ota_1        0x00810000 4 MB
store            data fat          0x00c10000 1 MB
Digest:          cfe36765a6bfe1b802a2abd4ec9f6851 pass
OVMS# ota partitions upgrade
Upgrade partition table to new format (y/n): y
0x00009000 Skipping over data/nvs partition
0x0000d000 Skipping over data/ota partition
0x0000f000 Skipping over data/phy partition
0x00010000 Converted factory partition to 6MB OTA 0
0x00610000 Converted OTA 0 partition to 6MB OTA 1
0x00c10000 Moved data/fat partition up one position
            Recalculated MD5 checksum
            Clearing trailing old MD5 checksum record
Erasing old partition table (4096 bytes at 0x00008000)...




sea 4 % ./backtrace.sh 0x400891b7:0x3ffebbd0 0x40089451:0x3ffebbf0 
0x401c82cc:0x3ffebc10 0x40084cfa:0x3ffebc30 0x4018397d:0x3ffebc60 
0x40180c03:0x3ffebcf0 0x40180c3f:0x3ffebd20 0x40146bdd:0x3ffebd40 
0x40289911:0x3ffebd60 0x400e1091:0x3ffebd80 0x40137f55:0x3ffebe40 
0x400e077d:0x3ffebe70 0x400e0a10:0x3ffebea0 0x400e0a43:0x3ffebf50 
0x401566d1:0x3ffebf70 0x40157ed7:0x3ffebfb0 0x401582e1:0x3ffebfe0 
0x40158593:0x3ffec050 0x40154aa2:0x3ffec0b0 0x4015a2fe:0x3ffec0d0 
0x401442ec:0x3ffec100 0x40144415:0x3ffec160
+ xtensa-esp32-elf-addr2line -e build/ovms3.elf 0x400891b7:0x3ffebbd0 
0x40089451:0x3ffebbf0 0x401c82cc:0x3ffebc10 0x40084cfa:0x3ffebc30 
0x4018397d:0x3ffebc60 0x40180c03:0x3ffebcf0 0x40180c3f:0x3ffebd20 
0x40146bdd:0x3ffebd40 0x40289911:0x3ffebd60 0x400e1091:0x3ffebd80 
0x40137f55:0x3ffebe40 0x400e077d:0x3ffebe70 0x400e0a10:0x3ffebea0 
0x400e0a43:0x3ffebf50 0x401566d1:0x3ffebf70 0x40157ed7:0x3ffebfb0 
0x401582e1:0x3ffebfe0 0x40158593:0x3ffec050 0x40154aa2:0x3ffec0b0 
0x4015a2fe:0x3ffec0d0 0x401442ec:0x3ffec100 0x40144415:0x3ffec160
/home/sea/u0/leres/esp/openvehicles-xtensa-esp32-elf/components/esp32/panic.c:736
/home/sea/u0/leres/esp/openvehicles-xtensa-esp32-elf/components/esp32/panic.c:736
/home/sea/u0/leres/esp/openvehicles-xtensa-esp32-elf/components/spi_flash/flash_ops.c:124
/home/sea/u0/leres/esp/openvehicles-xtensa-esp32-elf/components/spi_flash/flash_ops.c:220 
(discriminator 2)
components/ovms_ota/src/ovms_partitions.cpp:394
components/ovms_ota/src/ovms_ota.cpp:1088
components/ovms_ota/src/ovms_ota.cpp:1088
main/ovms_shell.cpp:67
main/ovms_shell.cpp:80 (discriminator 2)
components/console_ssh/src/console_ssh.cpp:527
main/ovms_console.cpp:184
components/console_ssh/src/console_ssh.cpp:420
components/console_ssh/src/console_ssh.cpp:420
components/console_ssh/src/console_ssh.cpp:420
components/mongoose/mongoose/mongoose.c:1701
components/mongoose/mongoose/mongoose.c:1701
components/mongoose/mongoose/mongoose.c:1701
components/mongoose/mongoose/mongoose.c:1701
components/mongoose/mongoose/mongoose.c:1701
components/mongoose/src/mongoose_client.cpp:52
main/ovms_netmanager.cpp:1000
main/ovms_netmanager.cpp:980