Unified firmware: runtime Bluetooth Proxy switch + Stable/Beta channel OTA

.github/workflows/build-beta.yml

@@ -0,0 +1,114 @@
+name: Build and Publish Beta
+
+# Builds PLT-1 firmware from the beta branch and publishes it as assets on a
+# rolling "beta-fw" pre-release. The on-device "Firmware Channel" select points
+# OTA updates at these assets. Stable firmware is built/published separately
+# by build.yml (push to main -> GitHub Pages).
+
+on:
+  push:
+    branches: [beta]
+    paths:
+      - 'Integrations/ESPHome/**'
+  workflow_dispatch:
+
+# Least privilege: read-only by default; only publish-beta is elevated to write.
+permissions:
+  contents: read
+
+jobs:
+  version:
+    name: Read version
+    runs-on: ubuntu-latest
+    outputs:
+      v: ${{ steps.read.outputs.v }}
+    steps:
+      - uses: actions/checkout@9c091bb21b7c1c1d1991bb908d89e4e9dddfe3e0 # v7.0.0
+        with:
+          persist-credentials: false
+      - id: read
+        run: |
+          v=$(awk '/substitutions:/ {f=1} f && /version:/ {print $2; exit}' \
+            Integrations/ESPHome/Core.yaml | tr -d '"')
+          echo "v=$v" >> "$GITHUB_OUTPUT"
+          echo "Beta version: $v"
+
+  build:
+    name: Build ${{ matrix.name }}
+    needs: version
+    strategy:
+      matrix:
+        include:
+          # Beta serves OTA updates only, so it builds the end-user Minimal
+          # images, not the first-flash improv images.
+          - { yaml: Integrations/ESPHome/beta-channel/PLT-1_Minimal.yaml,  name: firmware-beta }
+          - { yaml: Integrations/ESPHome/beta-channel/PLT-1B_Minimal.yaml, name: firmware-b-beta }
+    uses: esphome/workflows/.github/workflows/build.yml@025a1e6255610c498ed590403b7e510b69e474df # 2026.4.1
+    with:
+      files: ${{ matrix.yaml }}
+      esphome-version: stable
+      combined-name: ${{ matrix.name }}
+      release-version: ${{ needs.version.outputs.v }}
+
+  publish-beta:
+    name: Publish beta release assets
+    needs: [version, build]
+    runs-on: ubuntu-latest
+    permissions:
+      contents: write
+    steps:
+      - name: Download firmware artifacts
+        uses: actions/download-artifact@3e5f45b2cfb9172054b4087a40e8e0b5a5461e7c # v8.0.1
+        with:
+          path: fw
+          pattern: firmware*
+
+      - name: Ensure rolling 'beta-fw' pre-release exists
+        env:
+          GH_TOKEN: ${{ secrets.GITHUB_TOKEN }}
+        run: |
+          gh release view beta-fw -R "${{ github.repository }}" >/dev/null 2>&1 \
+            || gh release create beta-fw -R "${{ github.repository }}" \
+                 --prerelease --title "Beta (rolling)" \
+                 --notes "Latest PLT-1 beta firmware. Auto-updated on every push to the beta branch."
+
+      - name: Rewrite manifests to absolute URLs and upload assets
+        env:
+          GH_TOKEN: ${{ secrets.GITHUB_TOKEN }}
+        run: |
+          BASE="https://github.com/${{ github.repository }}/releases/download/beta-fw"
+          # Manifest names match the on-device variant_slug: "" and "-b".
+          declare -A DIRS=( [""]=firmware-beta ["-b"]=firmware-b-beta )
+          for v in "" "-b"; do
+            src="fw/${DIRS[$v]}"
+            man=$(find "$src" -name manifest.json | head -1)
+            if [ -z "$man" ]; then
+              echo "::error::manifest.json not found for ${DIRS[$v]}"
+              exit 1
+            fi
+            echo "Rewriting $man"
+            # Make ota.path and parts[].path absolute release-asset URLs so the
+            # device never has to resolve a relative path against a redirect.
+            # The two variants have distinct device names, so bin filenames
+            # don't collide in the flat release-asset namespace.
+            jq --arg base "$BASE" '
+              .builds[0].ota.path = ($base + "/" + (.builds[0].ota.path | sub(".*/"; "")))
+              | .builds[0].parts |= map(.path = ($base + "/" + (.path | sub(".*/"; ""))))
+            ' "$man" > "manifest$v.json"
+            cat "manifest$v.json"
+            gh release upload beta-fw "manifest$v.json" -R "${{ github.repository }}" --clobber
+            find "$src" -name '*.bin' -print -exec \
+              gh release upload beta-fw {} -R "${{ github.repository }}" --clobber \;
+          done
+          echo "Beta assets published."
+
+      - name: Point beta-fw tag at the built commit
+        env:
+          GH_TOKEN: ${{ secrets.GITHUB_TOKEN }}
+        run: |
+          # gh release create tags default-branch HEAD, and uploads never move
+          # the tag, so without this the release's source commit drifts away
+          # from the assets actually published.
+          gh api -X PATCH "repos/${{ github.repository }}/git/refs/tags/beta-fw" \
+            -f sha="${{ github.sha }}" -F force=true
+          echo "beta-fw -> ${{ github.sha }}"

.github/workflows/build.yml

@@ -16,18 +16,24 @@ on:
 
 jobs:
   build-and-publish:
-    uses: ApolloAutomation/Workflows/.github/workflows/build.yml@main
+    uses: ApolloAutomation/Workflows/.github/workflows/build.yml@430d90dc695c6f7d1075c4e4a0df4b13a6496252 # main 2026-07-23
     permissions:
       contents: write
       pages: write
       id-token: write
       pull-requests: write
     with:
       device-name: plt-1
+      # The Minimal yamls are the end-user images served at firmware/ and
+      # firmware-b/ (OTA updates and dashboard adoption). The improv images
+      # move to *-factory/ and are only used for first flashes via the web
+      # installer.
       yaml-files: |
+        Integrations/ESPHome/PLT-1_Minimal.yaml
+        Integrations/ESPHome/PLT-1B_Minimal.yaml
         Integrations/ESPHome/PLT-1.yaml
         Integrations/ESPHome/PLT-1B.yaml
-      firmware-names: "1:firmware,1B:firmware-b"
+      firmware-names: "1_Minimal:firmware,1B_Minimal:firmware-b,1:firmware-factory,1B:firmware-b-factory"
       core-yaml-path: Integrations/ESPHome/Core.yaml
       esphome-version: stable
       # Bypass check if manually triggered with bypass option

Integrations/ESPHome/.gitignore

@@ -3,3 +3,4 @@
 # You can modify this file to suit your needs.
 /.esphome/
 /secrets.yaml
+beta-channel/.esphome/

Integrations/ESPHome/Core.yaml

@@ -1,5 +1,41 @@
 substitutions:
-  version: "26.3.2.1"
+  version: "26.7.14.1"
+  # Firmware variant identity: overridden to "-b" by the PLT-1B images so
+  # each hardware variant tracks its own manifests.
+  variant_slug: ""
+  # Default update channel on first boot (no stored user choice yet, i.e. a
+  # fresh flash). The beta-channel builds override this to "Beta" (see
+  # Integrations/ESPHome/beta-channel/) so firmware obtained from the beta
+  # channel keeps tracking it instead of offering a stable "downgrade".
+  firmware_channel_default: "Stable"
+  # Manifest URL bases. Stable = GitHub Pages (main branch builds).
+  # Beta = rolling "beta-fw" pre-release assets (beta branch builds).
+  stable_manifest_base: "https://apolloautomation.github.io/PLT-1"
+  beta_manifest_base: "https://github.com/ApolloAutomation/PLT-1/releases/download/beta-fw"
+  # Per-variant OTA manifest URLs picked by apply_ota_source.
+  ota_stable_manifest: "${stable_manifest_base}/firmware${variant_slug}/manifest.json"
+  ota_beta_manifest: "${beta_manifest_base}/manifest${variant_slug}.json"
+
+esphome:
+  # List form so package merging concatenates with each variant's own on_boot
+  # entries (mapping form would be replaced by the variant's block instead).
+  on_boot:
+    # Point the update entity at the selected channel's manifest.
+    - priority: -100
+      then:
+        - script.execute: apply_ota_source
+    # Re-apply the Bluetooth Proxy switch after all components set up, so BLE
+    # scanning matches the persisted switch (proxy stays off by default).
+    - priority: -300
+      then:
+        - if:
+            condition:
+              switch.is_on: bluetooth_proxy_switch
+            then:
+              - esp32_ble_tracker.start_scan:
+                  continuous: true
+            else:
+              - esp32_ble_tracker.stop_scan:
 
 esp32:
   variant: esp32c3
@@ -10,7 +46,15 @@ esp32:
        assertion_level: SILENT
        enable_lwip_assert: false
 
+esp32_ble_tracker:
+  id: ble_tracker
+  scan_parameters:
+    continuous: true
+
+bluetooth_proxy:
+
 api:
+  encryption:
   actions:
     - action: play_buzzer
       variables:
@@ -76,6 +120,17 @@ globals:
 
 captive_portal:
 
+http_request:
+  verify_ssl: true
+  # GitHub release-asset downloads answer with a redirect carrying a
+  # ~3.6 KB Content-Security-Policy header; each header line must fit
+  # this buffer or the request fails with "HTTP_CLIENT: Out of buffer".
+  buffer_size_rx: 5120
+  # The redirect target is a signed URL with a ~850-char query string; the
+  # follow-up request line must fit the TX buffer or esp_http_client_open
+  # fails with "Out of buffer" before sending anything.
+  buffer_size_tx: 2048
+
 
 i2c:
   sda: GPIO1
@@ -339,6 +394,34 @@ button:
     icon: mdi:power-cycle
     name: "ESP Reboot"
 
+  - platform: template
+    name: "Firmware Update"
+    id: update_firmware
+    icon: mdi:cloud-download
+    entity_category: "config"
+    on_press:
+      - logger.log: "Applying firmware update for the selected channel"
+      # OTA download needs the device awake for its whole duration.
+      - lambda: |-
+          id(deep_sleep_1).prevent_deep_sleep();
+      - delay: 3s
+      - script.execute: apply_ota_source
+      - script.wait: apply_ota_source
+      # The manifest fetch runs in its own task; give it a fixed window to land
+      # (update.is_available stays false for same-version switches).
+      - delay: 5s
+      - lambda: id(update_http_request).perform(true);
+      # Only reached if the update did not start (e.g. manifest unreachable).
+      # Re-arm deep sleep unless something else is holding the device awake.
+      - if:
+          condition:
+            and:
+              - switch.is_off: prevent_sleep
+              - binary_sensor.is_off: ota_mode
+          then:
+            - lambda: |-
+                id(deep_sleep_1).allow_deep_sleep();
+
   - platform: factory_reset
     disabled_by_default: True
     name: "Factory Reset ESP"
@@ -365,9 +448,24 @@ switch:
             condition:
               binary_sensor.is_off: ota_mode
             then:
-              - lambda: |- 
+              - lambda: |-
                   id(deep_sleep_1).allow_deep_sleep();
 
+  # Note: on this deep-sleep device the proxy only forwards while the device
+  # is awake - pair it with "Prevent Sleep" to use it continuously.
+  - platform: template
+    name: "Bluetooth Proxy"
+    id: bluetooth_proxy_switch
+    icon: mdi:bluetooth
+    entity_category: "config"
+    restore_mode: RESTORE_DEFAULT_OFF
+    optimistic: true
+    on_turn_on:
+      - esp32_ble_tracker.start_scan:
+          continuous: true
+    on_turn_off:
+      - esp32_ble_tracker.stop_scan:
+
 
 text_sensor:
   - platform: wifi_info
@@ -385,7 +483,35 @@ text_sensor:
     update_interval: never
     entity_category: "diagnostic"
 
+select:
+  - platform: template
+    name: "Firmware Channel"
+    id: firmware_channel
+    icon: mdi:source-branch
+    entity_category: "config"
+    optimistic: true
+    restore_value: true
+    options:
+      - "Stable"
+      - "Beta"
+    initial_option: "${firmware_channel_default}"
+    on_value:
+      then:
+        - script.execute: apply_ota_source
+
 script:
+  - id: apply_ota_source
+    # Sets the OTA manifest URL from the Firmware Channel select (Stable/Beta).
+    # The manifest URLs are per-variant (ota_*_manifest substitutions via
+    # ${variant_slug}) so each hardware variant tracks its own manifests.
+    then:
+      - lambda: |-
+          const bool beta = id(firmware_channel).current_option() == "Beta";
+          std::string url = beta ? "${ota_beta_manifest}" : "${ota_stable_manifest}";
+          ESP_LOGI("firmware", "OTA manifest set to: %s", url.c_str());
+          id(update_http_request).set_source_url(url);
+      - component.update: update_http_request
+
   - id: statusCheck
     then:
       - if:

Integrations/ESPHome/PLT-1.yaml

@@ -7,7 +7,7 @@ esphome:
     name: "ApolloAutomation.PLT-1"
     version: "${version}"
 
-  min_version: 2025.6.0
+  min_version: 2025.11.0
   on_boot:
     - priority: 800.0
       then:
@@ -58,20 +58,17 @@ ota:
   - platform: http_request
     id: ota_managed
 
-http_request:
-  verify_ssl: true
-
 safe_mode:
 
 update:
   - platform: http_request
-    id: firmware_update
+    id: update_http_request
     name: Firmware Update
     source: https://apolloautomation.github.io/PLT-1/firmware/manifest.json
 
 wifi:
   on_connect:
-    - component.update: firmware_update
+    - component.update: update_http_request
   ap:
     ssid: "Apollo PLT1 Hotspot"
 

Integrations/ESPHome/PLT-1B.yaml

@@ -1,3 +1,6 @@
+substitutions:
+  variant_slug: "-b"
+
 esphome:
   name: "apollo-plt-1b"
   friendly_name: Apollo PLT-1B
@@ -7,7 +10,7 @@ esphome:
     name: "ApolloAutomation.PLT-1B"
     version: "${version}"
 
-  min_version: 2025.6.0
+  min_version: 2025.11.0
   on_boot:
     - priority: 999.0
       then:
@@ -55,9 +58,6 @@ ota:
   - platform: http_request
     id: ota_managed
 
-http_request:
-  verify_ssl: true
-
 safe_mode:
 
 web_server:
@@ -66,13 +66,13 @@ web_server:
 
 update:
   - platform: http_request
-    id: firmware_update
+    id: update_http_request
     name: Firmware Update
     source: https://apolloautomation.github.io/PLT-1/firmware-b/manifest.json
 
 wifi:
   on_connect:
-    - component.update: firmware_update
+    - component.update: update_http_request
   ap:
     ssid: "Apollo PLT1B Hotspot"