BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Amanda Hsieh — Wed, 15 Oct 2025 17:00:50 GMT

Since the application with BLE and OpenThread would cause the image to be larger and BLE DFU requires a dual bank to update, you could consider reducing the image size (see Memory footprint optimization) or using an external flash for BLE DFU.

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Shanmugam — Wed, 15 Oct 2025 08:05:16 GMT

Our application requires DFU over FOTA. There is no available option for performing DFU over UART or using external flash.

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Amanda Hsieh — Mon, 13 Oct 2025 15:44:15 GMT

I would suggest considering DFU with an external flash. Check out this Devacademy course https://academy.nordicsemi.com/courses/nrf-connect-sdk-intermediate/lessons/lesson-9-bootloaders-and-dfu-fota/topic/exercise-3-dfu-with-external-flash/

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Lavanya_Manohar — Mon, 13 Oct 2025 14:16:54 GMT

Hi,

we are still facing issue in flash overflow.

devzone.nordicsemi.com/.../Build_5F00_error_5F00_flash_5F00_overflow.txt

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Amanda Hsieh — Mon, 13 Oct 2025 12:46:25 GMT

Try to set the CONFIG_BT_MAX_CONN=10 to 4.

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Lavanya_Manohar — Mon, 13 Oct 2025 05:59:01 GMT

By adding CONFIG_BT_LL_SOFTDEVICE=y. Flash overflow happens. here we attached the log below for your reference.

build_error_log:

FAILED: zephyr/zephyr_pre0.elf zephyr/zephyr_pre0.map D:/joiner_dfu_2_6_1/openthread/build/multiprotocol_rpmsg/zephyr/zephyr_pre0.map
cmd.exe /C "cd . && C:\ncs\toolchains\cf2149caf2\opt\zephyr-sdk\arm-zephyr-eabi\bin\arm-zephyr-eabi-gcc.exe -gdwarf-4 @CMakeFiles\zephyr_pre0.rsp -o zephyr\zephyr_pre0.elf && cmd.exe /C "cd /D D:\jo
iner_dfu_2_6_1\openthread\build\multiprotocol_rpmsg\zephyr && C:\ncs\toolchains\cf2149caf2\opt\bin\cmake.exe -E true""
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: zephyr\zephyr_pre0.elf section `rodata' will not fit in re
gion `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 3436 bytes
collect2.exe: error: ld returned 1 exit status
ninja: build stopped: subcommand failed.

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Amanda Hsieh — Fri, 10 Oct 2025 14:16:34 GMT

Hi,

[quote user="Lavanya_Manohar"]ASSERTION FAIL [err == 0] @ WEST_TOPDIR/zephyr/subsys/bluetooth/host/hci_core.c:331
command opcode 0x0c03 timeout with err -11[/quote]

Try to add CONFIG_BT_LL_SOFTDEVICE=y into multiprotocol_rpmsg.conf.

Comparing the .config file under build/multiprotocol_rpmsg/zephyr before and after you added BLE FOTA configs to would help find the clues.

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Lavanya_Manohar — Fri, 10 Oct 2025 04:38:26 GMT

here is the .config file under build/multiprotocol_rpmsg/zephyr from the openthread + ble project. devzone.nordicsemi.com/.../nrf5340_5F00_config.txt

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Amanda Hsieh — Thu, 09 Oct 2025 16:36:18 GMT

[quote user=""]With that BLE and OpenThread Application are running successfully on the application core.[/quote]

Could you provide the .config file under build/multiprotocol_rpmsg/zephyr from the project before adding BLE FOTA configurations?

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Lavanya_Manohar — Thu, 09 Oct 2025 08:45:19 GMT

We have added this configuration to multiprotocol_rpmsg.conf. However, we are encountering a reset issue.

<inf> ieee802154_nrf5: nRF5 802154 radio initialized
<inf> fs_nvs: 2 Sectors of 4096 bytes
<inf> fs_nvs: alloc wra: 0, d38
<inf> fs_nvs: data wra: 0, 310
<inf> net_l2_openthread: State changed! Flags: 0x00038210 Current role: disabled
*** Booting nRF Connect SDK v3.5.99-ncs1-1 ***
<inf> main: Boot: Initializing...
ASSERTION FAIL [err == 0] @ WEST_TOPDIR/zephyr/subsys/bluetooth/host/hci_core.c:331
command opcode 0x0c03 timeout with err -11
<err> os: r0/a1: 0x00000003 r1/a2: 0x00000000 r2/a3: 0x00000002
<err> os: r3/a4: 0x20004e28 r12/ip: 0x00000010 r14/lr: 0x00032051
<err> os: xpsr: 0x49100000
<err> os: s[ 0]: 0x20003f00 s[ 1]: 0x00000296 s[ 2]: 0x20029ac0 s[ 3]: 0x00066ed9
<err> os: s[ 4]: 0x00000000 s[ 5]: 0x00000000 s[ 6]: 0x0008a2c1 s[ 7]: 0x20023104
<err> os: s[ 8]: 0x20029ac0 s[ 9]: 0x0006612d s[10]: 0x0008a2c1 s[11]: 0x20023104
<err> os: s[12]: 0xfffffff5 s[13]: 0x00032051 s[14]: 0x0008a2c1 s[15]: 0x00000c03
<err> os: fpscr: 0xfffffff5
<err> os: Faulting instruction address (r15/pc): 0x0003205c
<err> os: >>> ZEPHYR FATAL ERROR 3: Kernel oops on CPU 0
<err> os: Current thread: 0x20007ba0 (main)
<err> fatal_error: Resetting system

We kindly request your guidance and suggestions to resolve the problem

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Amanda Hsieh — Wed, 08 Oct 2025 16:29:41 GMT

(updated)

Try to add the following configs to multiprotocol_rpmsg.conf and check the .config file under build/multiprotocol_rpmsg/zephyr if they take effect.

CONFIG_BT_MAX_CONN=10
CONFIG_BT_PERIPHERAL=y
CONFIG_BT_CENTRAL=y
CONFIG_BT_OBSERVER=y
CONFIG_BT_BROADCASTER=y
CONFIG_BT_EXT_ADV=y

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Lavanya_Manohar — Tue, 07 Oct 2025 05:56:33 GMT

Could you provide the .config file under build/multiprotocol_rpmsg/zephyr?

Here is the .config file.

Note: Unable to upload the .config file. Please find the .config content attached below in .txt format.

devzone.nordicsemi.com/.../2630.config.txt

RE: BLE FOTA + OpenThread Integration Issues: Advertising Error, IPC Timeout, and SMP Overflow

Amanda Hsieh — Mon, 06 Oct 2025 19:54:09 GMT

Hi,

[quote user=""][00:00:00.534,973] <err> bt_gatt: Unable to register handle 0x001b[/quote]

Do you call smp_bt_register() manually in your code? If so, please remove it. See this post.

[quote user=""][00:00:00.535,400] <wrn> bt_hci_core: opcode 0x2006 status 0x01
[00:00:00.535,400] <err> BleProvisioner: Advertising failed to start (err -5)[/quote]

The error Advertising failed to start (err -5) and the HCI status opcode 0x2006 status 0x01 indicate a failure in the HCI command to start advertising. Status 0x01 is a generic "Unknown HCI Command" or "Unknown Command Parameter" error from the controller. This can occur if the network core (running the multiprotocol controller) is not configured to support the required number of advertising sets or extended advertising, or if the configuration between the application and the network core is mismatched. Could you provide the .config file under build/multiprotocol_rpmsg/zephyr?

[quote user=""]

When integrating OpenThread on the application core, we encounter IPC timeout errors during initialization.
Is there a recommended sequence or configuration to enable OpenThread alongside BLE FOTA to avoid IPC timeouts?

[/quote]

Please try to apply the Net Core configuration from the CLI sample: https://github.com/nrfconnect/sdk-nrf/blob/main/samples/openthread/cli/sysbuild/ipc_radio/prj.conf

[quote user=""]Could you provide guidance on optimizing memory layout or reducing the BLE stack footprint in this setup?[/quote]

See Memory footprint optimization or consider DFU with added external flash (see this Devacademy course https://academy.nordicsemi.com/courses/nrf-connect-sdk-intermediate/lessons/lesson-9-bootloaders-and-dfu-fota/topic/exercise-3-dfu-with-external-flash/).

Regards,
Amanda H.