Thingy:91 (nRF9160) with nRF SDK 2.6.1 region `FLASH' overflowed error building TFM onomondo softsim_static_profile sample

[Jamesls]

Hi,

When building the Onomondo softsim_static_profile sample using nRF SDK 2.6.1 I get a region `FLASH' overflowed build error for mcuboot_subimage.

c:/ncs/toolchains/cf2149caf2/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.exe: address 0x1a120 of bin\tfm_s.axf section `.TFM_UNPRIV_CODE' is not within region `FLASH'
c:/ncs/toolchains/cf2149caf2/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.exe: bin\tfm_s.axf section `.psa_interface_thread_fn_call' will not fit in region `FLASH'
c:/ncs/toolchains/cf2149caf2/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.exe: address 0x1fc40 of bin\tfm_s.axf section `.gnu.sgstubs' is not within region `FLASH'
c:/ncs/toolchains/cf2149caf2/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.exe: address 0x1a120 of bin\tfm_s.axf section `.TFM_UNPRIV_CODE' is not within region `FLASH'
c:/ncs/toolchains/cf2149caf2/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.exe: address 0x1fc40 of bin\tfm_s.axf section `.gnu.sgstubs' is not within region `FLASH'
c:/ncs/toolchains/cf2149caf2/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.exe: region `FLASH' overflowed by 32100 bytes
Memory region Used Size Region Size %age Used
FLASH: 80740 B 48640 B 166.00%
RAM: 47636 B 88 KB 52.86%
collect2.exe: error: ld returned 1 exit status
ninja: build stopped: subcommand failed.
[21/346] Completed 'mcuboot_subimage'

It's a very simple main.c sample - is there a configuration change possible to build this successfully as I assumed this should just work being a sample app?

Thanks,

James

[Jamesls]

Looks like I might be hitting something similar to this issue:  Partitioning issues on thingy91_nrf9160_ns with nRF connect 1.7.0 

Does anyone have an example or process for updating thingy91_pm_static.yml to support a larger partition for TFM?

[Øyvind]

Hi James, 

This is most likely due to the partition layout for the Thingy:91 not being consistent. Thingy91 builds with a Partition Manager configuration that is static and that doesn't account for the extra partitions that are brought in when enabling SoftSIM.

Due to summer break many of our resources are out of office and thus we are not able to provide answers in a timely manner. I am informed that our SoftSIM expert is back in office next week and I hope to provide you an answer by end of Tuesday. 

Kind regards,
Øyvind

[Øyvind]

Having both SoftSIM and the Asset Tracker v2 can be tricky in regards to available flash. 

You could try to remove the FOTA/DFU support in the Asset Tracker i.e. remove the following/disable:

# FOTA
CONFIG_FOTA_DOWNLOAD=y
CONFIG_DFU_TARGET=y
CONFIG_DOWNLOAD_CLIENT=y
CONFIG_DOWNLOAD_CLIENT_HTTP_FRAG_SIZE_1024=y
CONFIG_DOWNLOAD_CLIENT_STACK_SIZE=4096
CONFIG_DOWNLOAD_CLIENT_BUF_SIZE=2300
CONFIG_DOWNLOAD_CLIENT_MAX_HOSTNAME_SIZE=128

[Jamesls]

Hi,

I disabled FOTA/DFU (which didn't seem to make a difference to the sram_primary size of 262144 logged above) so I also then disabled CONFIG_AT_HOST_LIBRARY and CONFIG_NRF_MODEM_LIB_TRACE which allowed the build to progress beyond above partitioning stage but it now fails at another flash related issue:

[24/485] Performing install step for 'tfm'
-- Install configuration: "MinSizeRel"
----- Installing platform NS -----

<SNIP>

section `text' will not fit in region `FLASH'
c:/ncs/toolchains/cf2149caf2/opt/zephyr-sdk/arm-zephyr-eabi/bin/../lib/gcc/arm-zephyr-eabi/12.2.0/../../../../arm-zephyr-eabi/bin/ld.bfd.exe: region `FLASH' overflowed by 66740 bytes

Thanks,

James

[Maria Gilje]

Hi James,

Are you able to share your prj.conf file and the full build log?

You can add them to a reply by selecting Intert->Code.

Best regards,

Maria

[Jamesls]

Hi Maria,

I get an error when saving a reply with the contents of these files via insert -> code - presumably as they're too large.

However, I've managed to add them as a zip file below instead.

Thanks,

James

0358.build.zip

[Marte Myrvold]

Hi James,

Thank you for providing the log and prj.conf.

MCUboot takes up a large chunk of the flash, effectively halving the available space. For this reason we recommend using external flash for large applications, such as what you are trying to do. Since the Thingy:91 does not have external flash, I recommend using the nRF9160 DK if possible.

You can try to optimize the application by following our Memory footprint optimization guide. Still, it will be difficult to get the flash footprint small enough to fit only by optimizing without removing functionality.

Best regards,
Marte

[Jamesls]

Thanks for the update - sounds like the only viable workaround to use the Thingy:91 is to revert to a physical SIM card for now instead of SoftSIM.