mcuboot, Image in the primary slot is not valid, Unable to find bootable image

[LongQi]

I followed the course to enable MCUBOOT over BLE it is successful for the project peripheral_lbs but not my application.

uart log;

*** Booting nRF Connect SDK v3.5.99-ncs1-1 ***
I: Starting bootloader
I: Primary image: magic=unset, swap_type=0x1, copy_done=0x3, image_ok=0x3
I: Secondary image: magic=unset, swap_type=0x1, copy_done=0x3, image_ok=0x3
I: Boot source: none
I: Image index: 0, Swap type: none
E: Image in the primary slot is not valid!
E: Unable to find bootable image

build log:

Building peripheral
west build --build-dir /home/longqi/peripheral/build /home/longqi/peripheral --pristine --board nrf52833dk_nrf52833 --no-sysbuild -- -DNCS_TOOLCHAIN_VERSION=NONE -DBOARD_ROOT=/home/longqi/peripheral -Dmcuboot_OVERLAY_CONFIG=/home/longqi/ncs/v2.6.1/nrf/subsys/partition_manager/partition_manager_enabled.conf -Dmcuboot_secondary_app_OVERLAY_CONFIG=/home/longqi/ncs/v2.6.1/nrf/subsys/partition_manager/partition_manager_enabled.conf -DCONFIG_CORTEX_M_DEBUG_MONITOR_HOOK=y -DCONFIG_DEBUG_OPTIMIZATIONS=y -DCONFIG_DEBUG_THREAD_INFO=y -DCONFIG_SEGGER_DEBUGMON=y -DCACHED_CONF_FILE=/home/longqi/peripheral/prj.conf -DDTC_OVERLAY_FILE=/home/longqi/peripheral/nrf52833dk_nrf52833.overlay

-- west build: generating a build system
Loading Zephyr default modules (Zephyr base).
-- Application: /home/longqi/peripheral
-- CMake version: 3.21.0
-- Found Python3: /home/longqi/ncs/toolchains/2be090971e/usr/local/bin/python3.9 (found suitable version "3.9.18", minimum required is "3.8") found components: Interpreter
-- Cache files will be written to: /home/longqi/.cache/zephyr
-- Zephyr version: 3.5.99 (/home/longqi/ncs/v2.6.1/zephyr)
-- Found west (found suitable version "1.2.0", minimum required is "0.14.0")
-- Board: nrf52833dk_nrf52833
-- Found host-tools: zephyr 0.16.5 (/home/longqi/ncs/toolchains/2be090971e/opt/zephyr-sdk)
-- Found toolchain: zephyr 0.16.5 (/home/longqi/ncs/toolchains/2be090971e/opt/zephyr-sdk)
-- Found Dtc: /home/longqi/ncs/toolchains/2be090971e/usr/bin/dtc (found suitable version "1.5.0", minimum required is "1.4.6")
-- Found BOARD.dts: /home/longqi/ncs/v2.6.1/zephyr/boards/arm/nrf52833dk_nrf52833/nrf52833dk_nrf52833.dts
-- Found devicetree overlay: /home/longqi/peripheral/nrf52833dk_nrf52833.overlay
-- Generated zephyr.dts: /home/longqi/peripheral/build/zephyr/zephyr.dts
-- Generated devicetree_generated.h: /home/longqi/peripheral/build/zephyr/include/generated/devicetree_generated.h
-- Including generated dts.cmake file: /home/longqi/peripheral/build/zephyr/dts.cmake
Parsing /home/longqi/ncs/v2.6.1/zephyr/Kconfig
Loaded configuration '/home/longqi/ncs/v2.6.1/zephyr/boards/arm/nrf52833dk_nrf52833/nrf52833dk_nrf52833_defconfig'
Merged configuration '/home/longqi/peripheral/prj.conf'
Merged configuration '/home/longqi/peripheral/build/zephyr/misc/generated/extra_kconfig_options.conf'
Configuration saved to '/home/longqi/peripheral/build/zephyr/.config'
Kconfig header saved to '/home/longqi/peripheral/build/zephyr/include/generated/autoconf.h'
-- Found GnuLd: /home/longqi/ncs/toolchains/2be090971e/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.bfd (found version "2.38")
-- The C compiler identification is GNU 12.2.0
-- The CXX compiler identification is GNU 12.2.0
-- The ASM compiler identification is GNU
-- Found assembler: /home/longqi/ncs/toolchains/2be090971e/opt/zephyr-sdk/arm-zephyr-eabi/bin/arm-zephyr-eabi-gcc
CMake Warning at /home/longqi/ncs/v2.6.1/zephyr/subsys/bluetooth/host/CMakeLists.txt:100 (message):
CONFIG_BT_FIXED_PASSKEY is enabled

A fixed passkey is easy to deduce during the pairing procedure, do not use in
production.


CMake Warning at /home/longqi/ncs/v2.6.1/nrf/samples/common/mcumgr_bt_ota_dfu/CMakeLists.txt:14 (message):
MCUmgr Bluetooth OTA DFU: suboptimal configuration of Bluetooth Controller
buffers. Consider using optimal values defined in the
/home/longqi/ncs/v2.6.1/nrf/samples/common/mcumgr_bt_ota_dfu/Kconfig file
for CONFIG_BT_BUF_ACL_TX_SIZE, CONFIG_BT_BUF_ACL_RX_SIZE and
CONFIG_BT_CTLR_DATA_LENGTH_MAX options


CMake Warning at /home/longqi/ncs/v2.6.1/nrf/samples/common/mcumgr_bt_ota_dfu/CMakeLists.txt:27 (message):
MCUmgr Bluetooth OTA DFU: suboptimal configuration of Bluetooth Host
buffers. Consider using optimal values defined in the
/home/longqi/ncs/v2.6.1/nrf/samples/common/mcumgr_bt_ota_dfu/Kconfig file
for CONFIG_BT_BUF_ACL_TX_SIZE, CONFIG_BT_BUF_ACL_RX_SIZE and
CONFIG_BT_L2CAP_TX_MTU options


-- Found Python3: /home/longqi/ncs/toolchains/2be090971e/usr/local/bin/python3.9 (found version "3.9.18") found components: Interpreter

=== child image mcuboot - begin ===
loading initial cache file /home/longqi/peripheral/build/mcuboot/child_image_preload.cmake
Loading Zephyr default modules (Zephyr base).
-- Application: /home/longqi/ncs/v2.6.1/bootloader/mcuboot/boot/zephyr
-- CMake version: 3.21.0
-- Found Python3: /home/longqi/ncs/toolchains/2be090971e/usr/local/bin/python3.9 (found suitable version "3.9.18", minimum required is "3.8") found components: Interpreter
-- Cache files will be written to: /home/longqi/.cache/zephyr
-- Zephyr version: 3.5.99 (/home/longqi/ncs/v2.6.1/zephyr)
-- Found west (found suitable version "1.2.0", minimum required is "0.14.0")
-- Board: nrf52833dk_nrf52833
-- Found host-tools: zephyr 0.16.5 (/home/longqi/ncs/toolchains/2be090971e/opt/zephyr-sdk)
-- Found toolchain: zephyr 0.16.5 (/home/longqi/ncs/toolchains/2be090971e/opt/zephyr-sdk)
-- Found Dtc: /home/longqi/ncs/toolchains/2be090971e/usr/bin/dtc (found suitable version "1.5.0", minimum required is "1.4.6")
-- Found BOARD.dts: /home/longqi/ncs/v2.6.1/zephyr/boards/arm/nrf52833dk_nrf52833/nrf52833dk_nrf52833.dts
-- Found devicetree overlay: /home/longqi/ncs/v2.6.1/bootloader/mcuboot/boot/zephyr/app.overlay
-- Generated zephyr.dts: /home/longqi/peripheral/build/mcuboot/zephyr/zephyr.dts
-- Generated devicetree_generated.h: /home/longqi/peripheral/build/mcuboot/zephyr/include/generated/devicetree_generated.h
-- Including generated dts.cmake file: /home/longqi/peripheral/build/mcuboot/zephyr/dts.cmake
Parsing /home/longqi/ncs/v2.6.1/bootloader/mcuboot/boot/zephyr/Kconfig
Loaded configuration '/home/longqi/ncs/v2.6.1/zephyr/boards/arm/nrf52833dk_nrf52833/nrf52833dk_nrf52833_defconfig'
Merged configuration '/home/longqi/ncs/v2.6.1/bootloader/mcuboot/boot/zephyr/prj.conf'
Merged configuration '/home/longqi/ncs/v2.6.1/nrf/subsys/partition_manager/partition_manager_enabled.conf'
Merged configuration '/home/longqi/peripheral/build/mcuboot/zephyr/misc/generated/extra_kconfig_options.conf'
Configuration saved to '/home/longqi/peripheral/build/mcuboot/zephyr/.config'
Kconfig header saved to '/home/longqi/peripheral/build/mcuboot/zephyr/include/generated/autoconf.h'
-- Found GnuLd: /home/longqi/ncs/toolchains/2be090971e/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.bfd (found version "2.38")
-- The C compiler identification is GNU 12.2.0
-- The CXX compiler identification is GNU 12.2.0
-- The ASM compiler identification is GNU
-- Found assembler: /home/longqi/ncs/toolchains/2be090971e/opt/zephyr-sdk/arm-zephyr-eabi/bin/arm-zephyr-eabi-gcc
CMake Warning at /home/longqi/ncs/v2.6.1/nrf/lib/flash_patch/CMakeLists.txt:8 (message):

----------------------------------------------------------
--- WARNING: To maintain the integrity of secure boot, ---
--- enable CONFIG_DISABLE_FLASH_PATCH in production. ---
----------------------------------------------------------


-- Using ccache: /home/longqi/ncs/toolchains/2be090971e/usr/bin/ccache
MCUBoot bootloader key file: /home/longqi/ncs/v2.6.1/bootloader/mcuboot/root-rsa-2048.pem
-- Configuring done
-- Generating done
-- Build files have been written to: /home/longqi/peripheral/build/mcuboot
=== child image mcuboot - end ===

CMake Warning at /home/longqi/ncs/v2.6.1/nrf/modules/mcuboot/CMakeLists.txt:382 (message):

---------------------------------------------------------
--- WARNING: Using default MCUBoot key, it should not ---
--- be used for production. ---
---------------------------------------------------------


-- Using ccache: /home/longqi/ncs/toolchains/2be090971e/usr/bin/ccache
CMake Warning at /home/longqi/ncs/v2.6.1/nrf/cmake/partition_manager.cmake:79 (message):

---------------------------------------------------------------------
--- WARNING: Using a bootloader without pm_static.yml. ---
--- There are cases where a deployed product can consist of ---
--- multiple images, and only a subset of these images can be ---
--- upgraded through a firmware update mechanism. In such cases, ---
--- the upgradable images must have partitions that are static ---
--- and are matching the partition map used by the bootloader ---
--- programmed onto the device. ---
---------------------------------------------------------------------

Call Stack (most recent call first):
/home/longqi/ncs/v2.6.1/zephyr/cmake/modules/kernel.cmake:248 (include)
/home/longqi/ncs/v2.6.1/zephyr/cmake/modules/zephyr_default.cmake:138 (include)
/home/longqi/ncs/v2.6.1/zephyr/share/zephyr-package/cmake/ZephyrConfig.cmake:66 (include)
/home/longqi/ncs/v2.6.1/zephyr/share/zephyr-package/cmake/ZephyrConfig.cmake:92 (include_boilerplate)
CMakeLists.txt:4 (find_package)


-- Configuring done
-- Generating done
-- Build files have been written to: /home/longqi/peripheral/build
-- west build: building application
[1/274] Preparing syscall dependency handling

[5/274] Generating include/generated/version.h
-- Zephyr version: 3.5.99 (/home/longqi/ncs/v2.6.1/zephyr), build: v3.5.99-ncs1-1
[1/271] Preparing syscall dependency handling

[4/271] Generating include/generated/version.h
-- Zephyr version: 3.5.99 (/home/longqi/ncs/v2.6.1/zephyr), build: v3.5.99-ncs1-1
[271/271] Linking C executable zephyr/zephyr.elf
Memory region Used Size Region Size %age Used
FLASH: 32670 B 48 KB 66.47%
RAM: 23808 B 128 KB 18.16%
IDT_LIST: 0 GB 32 KB 0.00%
[256/274] Building C object CMakeFiles/app.dir/src/main.c.obj
/home/longqi/peripheral/src/main.c:192:13: warning: 'device_name_set' defined but not used [-Wunused-function]
192 | static void device_name_set(uint8_t *name, uint8_t length)
| ^~~~~~~~~~~~~~~
[266/274] Linking C executable zephyr/zephyr.elf
Memory region Used Size Region Size %age Used
FLASH: 229048 B 232960 B 98.32%
RAM: 60564 B 128 KB 46.21%
IDT_LIST: 0 GB 32 KB 0.00%
[269/274] Generating ../../zephyr/app_update.bin
image.py: sign the payload
[271/274] Generating ../../zephyr/app_signed.hex
image.py: sign the payload
[272/274] Generating ../../zephyr/app_test_update.hex
image.py: sign the payload
[274/274] Generating zephyr/merged.hex
* Terminal will be reused by tasks, press any key to close it.

prj.conf

# Increased stack due to settings API usage
CONFIG_SYSTEM_WORKQUEUE_STACK_SIZE=2048

CONFIG_BT=y

# Enable logging
CONFIG_LOG=y

CONFIG_BT_SMP=y
CONFIG_BT_SIGNING=y
CONFIG_BT_PERIPHERAL=y
CONFIG_BT_DIS=y
CONFIG_BT_ATT_PREPARE_COUNT=5
CONFIG_BT_PRIVACY=n
CONFIG_BT_DEVICE_NAME="p1"
CONFIG_BT_DEVICE_APPEARANCE=833
CONFIG_BT_DEVICE_NAME_DYNAMIC=y
CONFIG_BT_DEVICE_NAME_MAX=65

CONFIG_BT_DIS_MANUF="xnergy"
CONFIG_BT_DIS_MODEL="phoenix"

CONFIG_BT_KEYS_OVERWRITE_OLDEST=y
CONFIG_BT_SETTINGS=y
CONFIG_FLASH=y
CONFIG_FLASH_PAGE_LAYOUT=y
CONFIG_FLASH_MAP=y
CONFIG_NVS=y
CONFIG_SETTINGS=y

CONFIG_BT_PERIPHERAL_PREF_MIN_INT=8
CONFIG_BT_PERIPHERAL_PREF_MAX_INT=8
CONFIG_BT_PERIPHERAL_PREF_TIMEOUT=200
CONFIG_BT_GAP_AUTO_UPDATE_CONN_PARAMS=y

CONFIG_BT_BUF_ACL_RX_SIZE=251
CONFIG_BT_BUF_ACL_TX_SIZE=251
CONFIG_BT_BUF_CMD_TX_SIZE=255
CONFIG_BT_BUF_EVT_DISCARDABLE_SIZE=255

CONFIG_BT_L2CAP_TX_MTU=247

CONFIG_BT_USER_DATA_LEN_UPDATE=y
CONFIG_BT_CTLR_DATA_LENGTH_MAX=251

CONFIG_BT_MAX_CONN=2

CONFIG_BT_FIXED_PASSKEY=y

CONFIG_UART_CONSOLE=n
CONFIG_RTT_CONSOLE=y

CONFIG_SERIAL=y
CONFIG_UART_ASYNC_API=y

CONFIG_MAIN_STACK_SIZE=2048

CONFIG_SENSOR=y

CONFIG_BOOTLOADER_MCUBOOT=y
CONFIG_NCS_SAMPLE_MCUMGR_BT_OTA_DFU=y

[LongQi]

I tried every commit in my repo and it eventually works after I disabled CONFIG_UART_ASYNC_API and removed uart related program.

May I know what the reason is? 

[Sigurd Hellesvik]

Hi,

FLASH: 229048 B 232960 B 98.32%

There is a known issue that application size must be smaller than 95% when using MCUboot.

Try to decrease flash space of your app, or add external flash.

Regards,
Sigurd Hellesvik

[LongQi]

Is there a user guide or whitepaper to optimise NPL? my application only occupies 2%

https://docs.nordicsemi.com/bundle/ncs-2.6.1/page/zephyr/develop/optimizations/index.html

https://docs.nordicsemi.com/bundle/ncs-2.6.1/page/nrf/test_and_optimize/optimizing/memory.html

Are these all available for the optimization?

[Sigurd Hellesvik]

I think the largest part of this will be the SoftDevice Controller.
The size of this will vary based on the features you use.
See Softdevice Controller docs.

[LongQi]

how do I disable the features in the SoftDevice Controller? It seems not mentioned in the document.

[Sigurd Hellesvik]

As you can see here, there looks to be three alternatives:

So it will depend on if your device is Peripheral, Central or Multirole.

CONFIG_BT_PERIPHERAL=y => Peripheral-only SoftDevice Controller
CONFIG_BT_CENTRAL=y => Central-only SoftDevice Controller
CONFIG_BT_CENTRAL=y and CONFIG_BT_PERIPHERAL=y  => Multirole SoftDevice Controller

In addition to this, I think Bluetooth Memory Optimization could reduce the space as well.
I suggest you try these tips and see if they reduce the size of NPL. If it does not help, let me know and we will help you look more into this