SPIFFS not flashed when using merged binary with ESP Web Tools #624
Description
When creating a merged_firmware.bin from bootloader.bin, partitions.bin, boot_app0.bin, app.bin, and spiffs.bin and flashing it through ESP Web Tools, the SPIFFS partition is not correctly flashed or mounted.
Steps to reproduce:
Build firmware in Arduino IDE with "No OTA (2MB APP / 2MB SPIFFS)" partition scheme.
Generate spiffs.bin with mkspiffs.
Merge binaries:
esptool --chip esp32 merge-bin -o merged_firmware.bin \ --flash-mode dio --flash-freq 80m --flash-size 4MB \ 0x1000 app.bootloader.bin \ 0x8000 app.partitions.bin \ 0xe000 boot_app0.bin \ 0x10000 app.bin \ 0x210000 spiffs.bin
Flash merged_firmware.bin via ESP Web Tools.
SPIFFS mount fails with:
E (1455) SPIFFS: mount failed, -10025
Expected behavior:
SPIFFS should be flashed correctly and mount without errors.
Actual behavior:
SPIFFS partition remains empty or corrupted.
Merging works for app.bin but not for spiffs.bin.
Flashing via esptool.py with separate offsets works as expected.
Additional info:
Board: ESP-WROVER-B (4MB flash)
ESP32 Arduino Core: 2.0.11
ESP Web Tools: latest
spiffs.bin size matches partition table.
Issue occurs regardless of partition scheme.