I cannot flash my zephyr app to feather nrf52480 sence board "Input/output error"

[fouadaladhami]

Issue Summary:
When running west flash to program my board using the UF2 runner, the process fails with an OSError related to copying the .uf2 file to the UF2 bootloader drive. The error message is:

OSError: [Errno 5] Input/output error: '/Users/fuad/Documents/coding/nrf_sdk/blinky/build/blinky/zephyr/zephyr.uf2' -> '/Volumes/FTHRSNSBOOT/zephyr.uf2'

Steps to Reproduce:

1. Build the application (e.g., Blinky) for a UF2-compatible board.
2. Run west flash from the build directory.
3. The process starts, finds the UF2 bootloader drive (/Volumes/FTHRSNSBOOT), and attempts to copy the .uf2 file.
4. The process fails with the above OSError.

What I’ve Observed:

• The UF2 runner in Zephyr/NCS is designed to copy the generated .uf2 file to the mounted bootloader volume, which should appear as a USB mass storage device when the board is in bootloader mode. This is the expected workflow for UF2 flashing (Zephyr UF2 Uploader documentation).
• The error occurs during the file copy operation, which suggests a problem with either the source .uf2 file, the destination volume, or the connection between the host and the device.

Relevant Documentation:

• The UF2 runner expects the board to be in bootloader mode and the UF2 volume to be mounted. If the volume is not detected, the --device option can be used to specify the mount point (Zephyr UF2 Uploader).
• The process is described in the official Zephyr and NCS documentation for UF2-compatible boards (Adafruit Feather nRF52840). and also described in nordic documentation.

Questions/Request for Help:

• What could cause an OSError: Input/output error when copying the .uf2 file to the UF2 bootloader drive?
• Are there known issues with UF2 flashing on macOS or with certain versions of the NCS toolchain?
• Are there recommended troubleshooting steps for verifying the integrity of the .uf2 file or the mounted volume?
  

The west flash log is as following : 

➜  build git:(master) ✗ west flash
-- west flash: rebuilding
[0/5] Performing build step for 'blinky'
ninja: no work to do.
[4/5] cd /Users/fuad/Documents/coding/nrf_...722e/Cellar/cmake/3.21.0/bin/cmake -E true
-- west flash: using runner uf2
-- runners.uf2: Copying UF2 file to '/Volumes/FTHRSNSBOOT'
Traceback (most recent call last):
  File "/opt/nordic/ncs/toolchains/ef4fc6722e/bin/west", line 8, in <module>
    sys.exit(main())
             ^^^^^^
  File "/opt/nordic/ncs/toolchains/ef4fc6722e/lib/python3.12/site-packages/west/app/main.py", line 1085, in main
    app.run(argv or sys.argv[1:])
  File "/opt/nordic/ncs/toolchains/ef4fc6722e/lib/python3.12/site-packages/west/app/main.py", line 244, in run
    self.run_command(argv, early_args)
  File "/opt/nordic/ncs/toolchains/ef4fc6722e/lib/python3.12/site-packages/west/app/main.py", line 505, in run_command
    self.run_extension(args.command, argv)
  File "/opt/nordic/ncs/toolchains/ef4fc6722e/lib/python3.12/site-packages/west/app/main.py", line 654, in run_extension
    self.cmd.run(args, unknown, self.topdir, manifest=self.manifest,
  File "/opt/nordic/ncs/toolchains/ef4fc6722e/lib/python3.12/site-packages/west/commands.py", line 194, in run
    self.do_run(args, unknown)
  File "/opt/nordic/ncs/v3.0.2/zephyr/scripts/west_commands/flash.py", line 33, in do_run
    do_run_common(self, my_args, runner_args, domain_file=domains_file)
  File "/opt/nordic/ncs/v3.0.2/zephyr/scripts/west_commands/run_common.py", line 331, in do_run_common
    prev_runner = do_run_common_image(command, user_args, user_runner_args, used_cmds,
                  ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^
  File "/opt/nordic/ncs/v3.0.2/zephyr/scripts/west_commands/run_common.py", line 506, in do_run_common_image
    runner.run(command_name)
  File "/opt/nordic/ncs/v3.0.2/zephyr/scripts/west_commands/runners/core.py", line 720, in run
    self.do_run(command, **kwargs)
  File "/opt/nordic/ncs/v3.0.2/zephyr/scripts/west_commands/runners/uf2.py", line 105, in do_run
    self.copy_uf2_to_partition(part)
  File "/opt/nordic/ncs/v3.0.2/zephyr/scripts/west_commands/runners/uf2.py", line 88, in copy_uf2_to_partition
    copy(self.cfg.uf2_file, part.mountpoint)
  File "/opt/nordic/ncs/toolchains/ef4fc6722e/Cellar/[email protected]/3.12.4/Frameworks/Python.framework/Versions/3.12/lib/python3.12/shutil.py", line 435, in copy
    copyfile(src, dst, follow_symlinks=follow_symlinks)
  File "/opt/nordic/ncs/toolchains/ef4fc6722e/Cellar/[email protected]/3.12.4/Frameworks/Python.framework/Versions/3.12/lib/python3.12/shutil.py", line 266, in copyfile
    _fastcopy_fcopyfile(fsrc, fdst, posix._COPYFILE_DATA)
  File "/opt/nordic/ncs/toolchains/ef4fc6722e/Cellar/[email protected]/3.12.4/Frameworks/Python.framework/Versions/3.12/lib/python3.12/shutil.py", line 110, in _fastcopy_fcopyfile
    raise err from None
  File "/opt/nordic/ncs/toolchains/ef4fc6722e/Cellar/[email protected]/3.12.4/Frameworks/Python.framework/Versions/3.12/lib/python3.12/shutil.py", line 103, in _fastcopy_fcopyfile
    posix._fcopyfile(infd, outfd, flags)
OSError: [Errno 5] Input/output error: '/Users/fuad/Documents/coding/nrf_sdk/blinky/build/blinky/zephyr/zephyr.uf2' -> '/Volumes/FTHRSNSBOOT/zephyr.uf2'

I also try to drag and drop the file to the disk but I get the same error.

The build configuration is as following.

Please help me fixing this error, I try a lot of things but I am not able to fix it.

[Menon]

Hello,

While looking into the issue, I believe this is more of an Adafruit forum question than something directly related to Nordic. I recommend reaching out to the Adafruit or Zephyr community.

I found a similar issue reported at the following link , it looks related. Please see if the solution explained there resolves your issue as well.

Kind regards,
Abhijith

[fouadaladhami]

Thank you, Abhijith, for your response. I tried this solution, but it does not work for me, and I also opened a question in the Adafruit forum, but it has not been solved yet. They recommend updating the bootloader, but this causes more issues, and I am currently unable to use the development board. Please read this: https://forums.adafruit.com/viewtopic.php?t=219527&e=1&view=unread#unread. I will be very happy if you have any information you can share with me. I also upload a video of the issue after trying the solution of Adafruit, and you can watch it here: www.youtube.com/watch