test(cyw43): validate WiFi on the production RP2040Simulator path

Headless test that drives the REAL RP2040Simulator (attachCyw43 +
installCyw43PioHooks + lockstep PIO stepping in runFrameForTime), boots
the Pico W firmware, injects a WiFi-connect snippet over the raw REPL, and
asserts isconnected(). Result:

  PYBOOT
  ACTIVE False            (this fw's active() getter reports link status)
  CONN_OK 192.168.4.2     (DHCP-leased IP, isconnected() == True)
  MAINPY_DONE

Reaches link-up in ~31s wall — the production lockstep PIO stepping is
faster than the harness's setTimeout-cranked PIO.

Also fixes a real production bug: the RP2040 logger was
ConsoleLogger(LogLevel.Error) which THROWS on rp2040js unaligned-read
warnings — lwIP reads the IPv4 header at ethernet offset 14 on every
received packet, so WiFi would have crashed on the first DHCP reply.
Now constructed with throwOnError=false.

Gated behind CYW43_PROD_HARNESS=1 (boots real firmware, ~30s).

frontend/src/__tests__/picow-cyw43-prod-sim.investigate.test.ts

@@ -0,0 +1,103 @@
+/**
+ * picow-cyw43-prod-sim.investigate.test.ts
+ *
+ * PRODUCTION-PATH validation (not CI — run explicitly).
+ *
+ * Unlike picow-cyw43-boot-harness.investigate.test.ts (which wires the cyw43
+ * emulator to a raw rp2040js Simulator with its own FIFO/PIO plumbing), this
+ * drives the REAL `RP2040Simulator` — the exact code that runs in the browser:
+ * attachCyw43() + installCyw43PioHooks() (non-dropping FIFO, firmware fast-path,
+ * host-wake GPIO24) + the lockstep PIO stepping in runFrameForTime(). It boots
+ * the real Pico W firmware, injects a WiFi-connect snippet via the raw REPL, and
+ * asserts the link reaches isconnected()==True.
+ *
+ * Run:
+ *   CYW43_PROD_HARNESS=1 npx vitest run \
+ *     src/__tests__/picow-cyw43-prod-sim.investigate.test.ts
+ */
+
+import { describe, it, expect, vi } from 'vitest';
+import { readFileSync } from 'node:fs';
+
+const FW_PATH =
+  '/home/dave/velxio-prod/velxio/frontend/public/firmware/micropython-rp2040w.uf2';
+
+// getFirmware = IndexedDB/fetch (browser only) -> serve from disk.
+// loadUserFiles = LittleFS WASM fetch (browser only) -> no-op; we inject the
+// WiFi snippet over the raw REPL instead of writing main.py to the filesystem.
+vi.mock('../simulation/MicroPythonLoader', async (orig) => {
+  const actual = (await orig()) as Record<string, unknown>;
+  return {
+    ...actual,
+    getFirmware: async () => new Uint8Array(readFileSync(FW_PATH)),
+    loadUserFiles: async () => { /* skip LittleFS */ },
+  };
+});
+
+const INJECT_CODE = [
+  'import network, time',
+  'print("PYBOOT")',
+  'w = network.WLAN(network.STA_IF)',
+  'w.active(True)',
+  'print("ACTIVE", w.active())',
+  'w.connect("Velxio-GUEST", "")',
+  'ok = False',
+  'for i in range(100):',
+  '    if w.isconnected():',
+  '        ok = True',
+  '        print("CONN_OK", w.ifconfig()[0])',
+  '        break',
+  '    time.sleep_ms(150)',
+  'if not ok:',
+  '    print("CONN_TIMEOUT status", w.status())',
+  'print("MAINPY_DONE")',
+].join('\n');
+
+describe.skipIf(!process.env.CYW43_PROD_HARNESS)('Pico W cyw43 — production RP2040Simulator path', () => {
+  it('boots, connects WiFi, and reaches isconnected()', async () => {
+    const { RP2040Simulator } = await import('../simulation/RP2040Simulator');
+    const { PinManager } = await import('../simulation/PinManager');
+
+    const sim = new RP2040Simulator(new PinManager());
+    let serial = '';
+    let buf = '';
+    sim.attachCyw43(); // selects Pico W firmware + registers host-wake listener
+    await sim.loadMicroPython([]);
+
+    // eslint-disable-next-line @typescript-eslint/no-explicit-any
+    const cdc = (sim as any).usbCDC as { sendSerialByte: (b: number) => void } | null;
+    expect(cdc).toBeTruthy();
+    const send = (s: string) => { for (const c of s) cdc!.sendSerialByte(c.charCodeAt(0)); };
+
+    // Raw-REPL injection state machine, fed by the serial stream.
+    let state: 'idle' | 'prompt' | 'raw' | 'sent' = 'idle';
+    sim.onSerialData = (ch: string) => {
+      serial += ch; buf += ch;
+      if (serial.length > 60000) serial = serial.slice(-20000);
+      if (state === 'idle' && buf.includes('>>>')) {
+        state = 'prompt'; buf = '';
+        cdc!.sendSerialByte(0x01); // Ctrl-A -> raw REPL
+      } else if (state === 'prompt' && buf.includes('raw REPL')) {
+        state = 'raw'; buf = '';
+        send(INJECT_CODE);
+        cdc!.sendSerialByte(0x04); // Ctrl-D -> execute
+        state = 'sent';
+      }
+    };
+
+    const deadline = Date.now() + 175_000;
+    let frames = 0;
+    while (Date.now() < deadline) {
+      for (let i = 0; i < 16; i++) { sim.runFrameForTime(50); frames++; }
+      if (serial.includes('MAINPY_DONE') || serial.includes('CONN_OK')) break;
+      await new Promise((r) => setTimeout(r, 0));
+    }
+    try { sim.stop(); } catch { /* noop */ }
+
+    // eslint-disable-next-line no-console
+    console.log(`\n===== PROD-SIM SERIAL (frames=${frames}, state=${state}) =====\n` + serial.slice(-1500));
+
+    expect(serial).toContain('PYBOOT');
+    expect(serial).toContain('CONN_OK');
+  }, 200_000);
+});

frontend/src/simulation/RP2040Simulator.ts

@@ -291,7 +291,7 @@ export class RP2040Simulator {
 
     // 2. Create fresh RP2040 instance
     this.rp2040 = new RP2040();
-    this.rp2040.logger = new ConsoleLogger(LogLevel.Error);
+    this.rp2040.logger = new ConsoleLogger(LogLevel.Error, false);
     this.rp2040.loadBootrom(bootromB1);
 
     // 3. Load UF2 firmware into flash
@@ -598,7 +598,7 @@ export class RP2040Simulator {
     this.rp2040 = new RP2040();
 
     // Suppress noisy internal logs (only show errors)
-    this.rp2040.logger = new ConsoleLogger(LogLevel.Error);
+    this.rp2040.logger = new ConsoleLogger(LogLevel.Error, false);
 
     // Load RP2040 B1 bootrom — needed for proper boot sequence
     this.rp2040.loadBootrom(bootromB1);
@@ -979,7 +979,7 @@ export class RP2040Simulator {
       if (this.micropythonMode) {
         // In MicroPython mode, restore the full flash snapshot (UF2 + LittleFS)
         this.rp2040 = new RP2040();
-        this.rp2040.logger = new ConsoleLogger(LogLevel.Error);
+        this.rp2040.logger = new ConsoleLogger(LogLevel.Error, false);
         this.rp2040.loadBootrom(bootromB1);
         this.rp2040.flash.set(this.flashCopy);
         this.rp2040.core.PC = 0x10000000;