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nRF5340 BT robustness issue with xxx-QKAAD0 silicon?

Hi there,

I have spent the last week trying to understand why my board, which is largely identical to the DK had various BT robustness issue; it was basically impossible to perform a DFU without a premature GATT_TIMEOUT; the exact same firmware on the DK worked fine though?  Using the smp_svr sample, my debug process was as follows:

  1. My first thought was the antenna tune may be out, (despite exhibiting superior RSSI to the DK), however I double checked it with the VNA, and it was resonating nicely at 2.4GHz.
  2. I checked the power rails and DCDCs to to confirm no brown-out situations during the message-flow - all good.
  3. I set up an nRF52840 dongle as a BT packet sniffer, and compared the successful (DK) and unsuccessful (custom) scenarios - nothing looked untoward in the Wireshark captures, excepting that immediately prior to the DFU failing, there were a number of sequential packet submissions originating from the phone that timed-out (unsurprisingly).
  4. I rebuilt the hci_rpmsg to enable detailed logging - again, nothing seemed untoward as far as the BT stack went, although occasionally I did see an <err> hci_rpmsg: ACL payload length is not correct message.
  5. I then turned on  detailed BT debugging on the app core, and lo-and-behold, it worked FLAWLESSLY!

My feeling is that there is some timing issue in BT stack / RPMsg.  I could however be entirely wrong!

Other salient info relating to my setup:

  • NCS 1.5
  • HV DCDC disabled
  • Silicon markings: N5340 QKAAD0 2044AB
  • Battery powered: ~3.0V
  • HFXT: Same Golledge crystal as DK 
    • internal caps
  • LFXT: Golledge MP03952 (C0: 1.1pF, C1: 3.7fF. Circuit condition: 9pF) as no MP07668 in stock
    • all internal cap values tested with no difference in behaviour

Quite urgently need to sort this one out, so any guidance is VERY appreciated.  Many thanks!

BR,
Z

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