Merge pull request 'deploy: bootable slim Sintra image + shared UP Board serial hardware' (#72) from deploy/sintra-boot-hardware into dev

Reviewed-on: #72

deploy/nixos/configuration.nix

@@ -7,6 +7,16 @@
   # System basics
   system.stateVersion = "24.05";
 
+  # ── Image slimming (bitspire#70 sizing) ──────────────────────────────
+  # This is a single-purpose Electron kiosk; strip the desktop/multimedia
+  # baggage NixOS pulls in by default so the disk image stays lean.
+  # - speechd: text-to-speech (speech-dispatcher → espeak-ng → mbrola, ~1GB).
+  #   An ATM does not talk.
+  # - documentation: man/info/NixOS manual — no one reads them on a kiosk.
+  services.speechd.enable = lib.mkForce false;
+  documentation.enable = false;
+  documentation.nixos.enable = false;
+
   # Networking
   networking = {
     hostName = "bitspire";
@@ -121,8 +131,10 @@
     # Node.js for the application
     pkgs-unstable.nodejs_22
 
-    # Camera support
-    v4l-utils
+    # Camera support. v4l-utils' default build drags in the whole Qt6 stack
+    # for its qv4l2 GUI (~0.5GB) — we only ever use the v4l2-ctl CLI, so drop
+    # the GUI.
+    (v4l-utils.override { withGUI = false; })
     fswebcam
 
     # ATM operations

deploy/nixos/hardware/upboard-serial.nix

@@ -0,0 +1,61 @@
+# UP Board serial peripherals — the validator / dispenser / printer wiring
+# shared by the INSTALLED configs (hardware/upboard.nix, used by both
+# tejo-installed and sintra-installed) AND the sintra live ISO (live.nix).
+# Single source of truth so the two artifacts can't drift — the earlier bug
+# was exactly this drift (the sintra live ISO lacked ftdi_sio + the ttyJ7
+# symlink, so the F56 dispenser failed while the installed image worked).
+#
+# Sintra IS a UP Board, so these are the UP Board rules; ttyS1/ttyS5 cover the
+# older UP Board / UP4000 (Tejo) dispenser nodes and ttyS4 covers the Sintra
+# (Apollo Lake) where the F56 is on the SoC MMIO UART. Only the device that
+# actually exists at runtime gets the symlink, so all three coexist safely.
+#
+# Serial port mapping:
+#   ttyJ4 = Printer (Nippon NP-2511D-2)
+#   ttyJ5 = Validator (iVIZION, ID003)
+#   ttyJ7 = Dispenser (Fujitsu F53/F56)
+{ lib, ... }:
+
+{
+  boot.kernelModules = [
+    "usbserial" # USB-to-serial adapters
+    "ftdi_sio" # FTDI USB serial (the iVIZION validator bridge)
+    "cp210x" # CP210x USB serial (alternative adapter)
+  ];
+
+  boot.kernelParams = [
+    # Do NOT route the kernel console through ttyS4 on Sintra. ttyS4 is the
+    # SoC's MMIO 16550A (the only real UART besides the legacy ttyS0 at I/O
+    # 0x3f8) and is wired to the Fujitsu F56 dispenser's RS-232 header. Holding
+    # it as console prevents userspace opening it at 9600 baud and HAL fails
+    # with "Input/output error setting custom baud rate of 9600". For serial
+    # debug, point console at ttyS0 instead.
+    "console=tty0"
+  ];
+
+  services.udev.extraRules = lib.mkAfter ''
+    # Generic serial port permissions (so the non-root HAL user can open them)
+    KERNEL=="ttyS[0-9]*", MODE="0666"
+    KERNEL=="ttyUSB[0-9]*", MODE="0666"
+    KERNEL=="ttyACM[0-9]*", MODE="0666"
+
+    # Printer (ttyJ4)
+    KERNELS=="1-7.2:1.0", SYMLINK+="ttyJ4"
+    KERNEL=="ttyUSB0", SYMLINK+="ttyJ4"
+
+    # Validator (ttyJ5)
+    KERNELS=="1-7.3:1.0", SYMLINK+="ttyJ5"
+    KERNEL=="ttyUSB1", SYMLINK+="ttyJ5"
+
+    # Dispenser (ttyJ7). ttyS1/ttyS5 = older UP Board / UP4000; ttyS4 = Sintra.
+    KERNEL=="ttyS1", SYMLINK+="ttyJ7"
+    KERNEL=="ttyS4", SYMLINK+="ttyJ7"
+    KERNEL=="ttyS5", SYMLINK+="ttyJ7"
+
+    # Legacy ttyAMA0 alias
+    SUBSYSTEM=="tty", KERNEL=="ttyS1", SYMLINK+="ttyAMA0", GROUP="dialout"
+
+    # Disable USB autosuspend (prevents serial adapters from sleeping)
+    ACTION=="add", SUBSYSTEM=="usb", TEST=="power/control", ATTR{power/control}="on"
+  '';
+}

deploy/nixos/hardware/upboard.nix

@@ -11,6 +11,10 @@
 { config, lib, pkgs, ... }:
 
 {
+  # Serial peripherals (validator/dispenser/printer modules + udev symlinks +
+  # console=tty0) are shared with the live ISO via ./upboard-serial.nix.
+  imports = [ ./upboard-serial.nix ];
+
   boot = {
     loader = {
       systemd-boot.enable = true;
@@ -42,21 +46,12 @@
       "kvm-intel"
       "i2c-dev"
       "spi-dev"
-      "usbserial" # USB-to-serial adapters
-      "ftdi_sio" # FTDI USB serial
-      "cp210x" # CP210x USB serial
+      # Serial modules (usbserial/ftdi_sio/cp210x) → ./upboard-serial.nix.
     ];
 
     kernelParams = [
       "i915.enable_psr=0"
-      # NOTE: do NOT route the kernel console through ttyS4 on Sintra.
-      # ttyS4 is the SoC's MMIO 16550A (the only real UART besides the
-      # legacy ttyS0 at I/O 0x3f8) and is wired to the Fujitsu F56
-      # dispenser's RS-232 header on Sintra. Holding it as console
-      # prevents userspace from opening it at 9600 baud and HAL fails
-      # with "Input/output error setting custom baud rate of 9600".
-      # If you want serial debug, point console at ttyS0 instead.
-      "console=tty0"
+      # console=tty0 (keeps ttyS4 free for the F56) → ./upboard-serial.nix.
       "quiet"
       "splash"
     ];
@@ -104,37 +99,9 @@
     hybrid-sleep.enable = false;
   };
 
-  # Serial port permissions + tejo-specific symlinks
+  # Camera + LED/SPI peripherals. The serial rules (validator/dispenser/printer
+  # symlinks + permissions) are shared with the live ISO in ./upboard-serial.nix.
   services.udev.extraRules = lib.mkAfter ''
-    # Generic serial port permissions
-    KERNEL=="ttyS[0-9]*", MODE="0666"
-    KERNEL=="ttyUSB[0-9]*", MODE="0666"
-    KERNEL=="ttyACM[0-9]*", MODE="0666"
-
-    # ── Tejo serial port symlinks ──────────────────────────────────────
-    # Both UP Board and UP4000 rules included (match different kernel paths)
-
-    # Printer (ttyJ4)
-    KERNELS=="1-7.2:1.0", SYMLINK+="ttyJ4"
-    KERNEL=="ttyUSB0", SYMLINK+="ttyJ4"
-
-    # Validator (ttyJ5)
-    KERNELS=="1-7.3:1.0", SYMLINK+="ttyJ5"
-    KERNEL=="ttyUSB1", SYMLINK+="ttyJ5"
-
-    # Dispenser (ttyJ7).
-    # ttyS1 / ttyS5 cover earlier UP Board variants where the dispenser
-    # lands on those kernel-enumerated serial nodes; ttyS4 covers the
-    # Sintra (UP Board Atom/Apollo Lake) where the dispenser is wired
-    # to the SoC's MMIO UART. Whichever device actually exists at
-    # runtime gets the ttyJ7 symlink.
-    KERNEL=="ttyS1", SYMLINK+="ttyJ7"
-    KERNEL=="ttyS4", SYMLINK+="ttyJ7"
-    KERNEL=="ttyS5", SYMLINK+="ttyJ7"
-
-    # Legacy ttyAMA0 alias
-    SUBSYSTEM=="tty", KERNEL=="ttyS1", SYMLINK+="ttyAMA0", GROUP="dialout"
-
     # ── Camera devices ─────────────────────────────────────────────────
     SUBSYSTEM=="video4linux", ATTR{index}=="0", KERNELS=="1-5", ATTRS{idVendor}=="0ac8", ATTRS{idProduct}=="0345", SYMLINK+="video-scan"
     SUBSYSTEM=="video4linux", ATTR{index}=="0", KERNELS=="1-2", ATTRS{idVendor}=="0ac8", ATTRS{idProduct}=="0345", SYMLINK+="video-scan"
@@ -147,8 +114,5 @@
     SUBSYSTEM=="spidev", GROUP="spi", MODE="0660"
     SUBSYSTEM=="i2c-dev", GROUP="i2c", MODE="0660"
     SUBSYSTEM=="leds", KERNEL=="upboard:*", ACTION=="add|change", RUN+="${pkgs.findutils}/bin/find /sys$devpath -type f -exec ${pkgs.coreutils}/bin/chmod g+u {} + -exec ${pkgs.coreutils}/bin/chown :leds {} +"
-
-    # Disable USB autosuspend (prevents serial adapters from sleeping)
-    ACTION=="add", SUBSYSTEM=="usb", TEST=="power/control", ATTR{power/control}="on"
   '';
 }

deploy/nixos/live.nix

@@ -48,7 +48,12 @@ in
 
     # Reuse ATM systemd service module
     ./bitspire-atm.nix
-  ];
+  ]
+  # Sintra: share the UP Board serial hardware (validator/dispenser/printer
+  # modules + udev symlinks + console=tty0) with the installed image so the
+  # live ISO drives the same hardware. Safe to import here — unlike upboard.nix
+  # it declares no fileSystems, so there's no live-boot mount conflict.
+  ++ lib.optionals (machineModel == "sintra") [ ./hardware/upboard-serial.nix ];
 
   # ISO image settings
   image.fileName = "bitspire-${machineModel}-live.iso";

flake.nix

@@ -342,6 +342,25 @@
                   fileSystems."/".device = lib.mkForce "/dev/disk/by-label/nixos-usb";
                   fileSystems."/boot".device = lib.mkForce "/dev/disk/by-label/ESP-USB";
                   system.autoUpgrade.enable = lib.mkForce false;
+
+                  # The Sintra's Aaeon firmware USB-boots in Legacy/BIOS mode — it
+                  # boots the live ISO via its isolinux (BIOS) El Torito image, not
+                  # the UEFI ESP. systemd-boot is UEFI-only, so a dd'd systemd-boot
+                  # image isn't recognised as bootable. Switch THIS USB image to
+                  # GRUB with BOTH BIOS (MBR + bios_grub partition, via the "hybrid"
+                  # table below) and UEFI (removable /EFI/BOOT/BOOTX64.EFI) — mirroring
+                  # the live ISO's dual boot — so it boots on Legacy and UEFI alike.
+                  # Scoped to the USB image; the eMMC install keeps systemd-boot.
+                  boot.loader.systemd-boot.enable = lib.mkForce false;
+                  boot.loader.efi.canTouchEfiVariables = lib.mkForce false;
+                  boot.loader.grub = {
+                    enable = lib.mkForce true;
+                    efiSupport = true;
+                    efiInstallAsRemovable = true;
+                    # make-disk-image's build VM exposes the image as /dev/vda;
+                    # GRUB installs its BIOS stage to that disk's MBR.
+                    devices = lib.mkForce [ "/dev/vda" ];
+                  };
                 })
               ];
             };
@@ -349,7 +368,8 @@
               inherit pkgs lib;
               config = cfg.config;
               format = "raw";
-              partitionTableType = "efi";
+              # hybrid = GPT + bios_grub partition + ESP → BIOS + UEFI bootable.
+              partitionTableType = "hybrid";
               diskSize = "auto";
               label = "nixos-usb"; # ext4 root label (make-disk-image -L)
             };