problems migrating nrf5340 project from SDK 1.9.1 to 2.3.0

[GerardB]

Dear Nordic Support

We are having problems migrating our nrf5340 project from SDK v1.9.1 to v2.3.0.
We have now spent more than 1 week on the migration & although the project builds with no (obvious) errors, the code will crash after flashing. So it won;'t run.
With SDK v1.9.1 everything works great and we can't isolate the problem with v2.3.0 & have no way of debugging it as it seems to be in a permanent reset loop after flashing/installing the version built with SDK v2.3.0.

So need your help to figure out how to fix this. Here are some details;

We are using vscode with nrfExtension on MacOS for development and latest nrfConnect version.

We have read the migration guide for v1.x to v2.x and can't see anything there that points to our problem.

We use mcuboot and OTA DFU. It all works well with v1.9.1

We do NOT have a sample.yaml file in the project.

Our west.yml file looks like this:

manifest:
  remotes:
    - name: ncs
      url-base: https://github.com/nrfconnect
  projects:
    - name: sdk-nrf
      remote: ncs
      path: nrf
      revision: v2.3.0
      import: true
      clone-depth: 1
  self:
    path: WS_firmware_sdk2

Our cMakeList.tx file looks like this:

#
#
cmake_minimum_required(VERSION 3.20.0)

#set(PM_STATIC_YML_FILE
#  ${CMAKE_CURRENT_SOURCE_DIR}/boards/pm_static_${BOARD}.yml
#  )

find_package(Zephyr REQUIRED HINTS $ENV{ZEPHYR_BASE})
project(WS_firmware_sdk2)

# NORDIC SDK APP START
target_sources(app PRIVATE
  src/main.c
  src/analog.c
  src/usb_serial.c
  src/sensor_settings.c
  src/i2c_accel.c
  src/i2c_pressure.c
)

# NORDIC SDK APP END

zephyr_library_include_directories(.)

Our nrf5340dk_nrf5340_cpuapp.overlay is very simple and is the same for v1.9.1. and v2.3.0:

&adc {
	status = "okay";
};

&button0 {
	status = "disabled";
};
&button1 {
	status = "disabled";
};
&button2 {
	status = "disabled";
};
&button3 {
	status = "disabled";
};

&uart0 {
	status = "okay";
};

&uart1 {
	status = "disabled";
};

&uart2 {
	status = "disabled";
};

&uart3 {
	status = "disabled";
};
&zephyr_udc0 {
    status = "okay";
	cdc_acm_uart0: cdc_acm_uart0 {
		compatible = "zephyr,cdc-acm-uart";
		label = "CDC_ACM_0";
	};
};

/ {
	chosen {
			zephyr,console = &cdc_acm_uart0;
	};
};

Our prf.config file looks like this:

#
# Copyright (c) 2021 WearSense LLC
#

CONFIG_PM=y
CONFIG_PM_DEVICE=y

# DC/DC JB
CONFIG_BOARD_ENABLE_DCDC_APP=y
CONFIG_BOARD_ENABLE_DCDC_NET=y
CONFIG_BOARD_ENABLE_DCDC_HV=y

# set next 4 lines to "y" for USB log/debug... (has significant power draw impact)
CONFIG_CONSOLE=y
CONFIG_UART_CONSOLE=y
CONFIG_SERIAL=y
CONFIG_STDOUT_CONSOLE=y

CONFIG_ASSERT=n

# set next 3 lines to "y" for USB logging and uncomment 4th line (CONFIG_USB_DEVICE_PRODUCT=....)
CONFIG_USB_DEVICE_STACK=y
# CONFIG_USB_CDC_ACM_LOG_LEVEL_WRN=n
CONFIG_USB_DEVICE_PRODUCT="WearSensee USB Debug Port"

CONFIG_ENTROPY_GENERATOR=y
CONFIG_ENTROPY_DEVICE_RANDOM_GENERATOR=y

# We need heap!
CONFIG_HEAP_MEM_POOL_SIZE=16386

CONFIG_FLASH=y
CONFIG_FLASH_PAGE_LAYOUT=y
CONFIG_FLASH_MAP=y
CONFIG_NVS=y
CONFIG_SETTINGS=y
CONFIG_SETTINGS_NVS=y
CONFIG_SETTINGS_RUNTIME=y

# BLE Settings
CONFIG_BT=y
CONFIG_BT_SETTINGS=y
CONFIG_BT_PERIPHERAL=y
CONFIG_BT_DEVICE_NAME="WearSense Sensor"    # Name is re-defind & replaced at runtime
CONFIG_BT_DEVICE_NAME_DYNAMIC=y
# CONFIG_BT_MAX_CONN=1
CONFIG_BT_MAX_PAIRED=1

# appearance 1344 = "Generic Sensor" 
# (see: https://specificationrefs.bluetooth.com/assigned-values/Appearance%20Values.pdf )
CONFIG_BT_DEVICE_APPEARANCE=1344

# configure BLE "Device Information Service" (BT_DIS) characteristics.
CONFIG_BT_DIS=y
CONFIG_BT_DIS_MODEL="WearSense LS2"
CONFIG_BT_DIS_MANUF="wear-sense.com"
CONFIG_BT_DIS_FW_REV=y
CONFIG_BT_DIS_FW_REV_STR="08.51"    # FIRMWARE REVISION TO BE UPDATED HERE!!!
CONFIG_BT_DIS_SETTINGS=y            # allows following values to be assigned at runtime
CONFIG_BT_DIS_SERIAL_NUMBER=y       # assigned at runtime in code
CONFIG_BT_DIS_HW_REV=y              # assigned at runtime in code
CONFIG_BT_DIS_SW_REV=n              # not required for WearSense app. 
CONFIG_BT_DIS_PNP=n                 # not required for WearSense app.

# Enable the NUS service
CONFIG_BT_NUS=y
CONFIG_BT_BAS=y

# Don't Enable DK (nordic dev Boards) LED and Buttons library for WearSense boards
CONFIG_DK_LIBRARY=n

# This example requires more workqueue stack
CONFIG_SYSTEM_WORKQUEUE_STACK_SIZE=4096

# Config logger

# for USB logging set next 4 lines to 'y" (has significant power draw impact)
CONFIG_LOG=y
CONFIG_LOG_BACKEND_UART=y
CONFIG_UART_INTERRUPT_DRIVEN=y
CONFIG_UART_LINE_CTRL=y

# CONFIG_UART_ASYNC_API=n
CONFIG_USE_SEGGER_RTT=n
# CONFIG_LOG_BACKEND_RTT=n
# CONFIG_LOG_DEFAULT_LEVEL=3


CONFIG_NEWLIB_LIBC=y
CONFIG_NEWLIB_LIBC_FLOAT_PRINTF=y
CONFIG_NEWLIB_LIBC_FLOAT_SCANF=y

# Enable mcumgr (used for reset over BLE and OTA firmware updates).
CONFIG_MCUMGR=y

# Enable most core commands.
CONFIG_MCUMGR_CMD_IMG_MGMT=y
CONFIG_MCUMGR_CMD_OS_MGMT=y

# Ensure an MCUboot-compatible binary is generated.
CONFIG_BOOTLOADER_MCUBOOT=y

# Allow for large Bluetooth data packets.
CONFIG_BT_L2CAP_TX_MTU=252
CONFIG_BT_BUF_ACL_RX_SIZE=256
CONFIG_MCUMGR_BUF_COUNT=10

# Enable the Bluetooth (unauthenticated) and shell mcumgr transports.
CONFIG_MCUMGR_SMP_BT=y
CONFIG_MCUMGR_SMP_BT_AUTHEN=n

# Enable the SAADC ADC support
CONFIG_ADC=y
CONFIG_ADC_ASYNC=y
CONFIG_ADC_NRFX_SAADC=y
CONFIG_MAIN_STACK_SIZE=8192

CONFIG_FPU=y

# Use I2C for sensors for now
CONFIG_I2C=y

We have a "child_image" folder which contains the file "hci_rpmsg.conf", which looks like this:

CONFIG_LOG=n #changed
CONFIG_SERIAL=n #added

CONFIG_RPMSG_SERVICE=y
CONFIG_RPMSG_SERVICE_MODE_REMOTE=y

# CONFIG_HEAP_MEM_POOL_SIZE=8192

CONFIG_MAIN_STACK_SIZE=2048
# CONFIG_SYSTEM_WORKQUEUE_STACK_SIZE=2048
# CONFIG_BT=y
# CONFIG_BT_HCI_RAW=y
# CONFIG_BT_MAX_CONN=2
# CONFIG_BT_CTLR_ASSERT_HANDLER=y
# CONFIG_BT_HCI_RAW_RESERVE=1
# CONFIG_BT_BUF_CMD_TX_COUNT=8

# Workaround: Unable to allocate command buffer when using K_NO_WAIT since
# Host number of completed commands does not follow normal flow control.
CONFIG_BT_BUF_CMD_TX_COUNT=10

The terminal log from a pristine build looks like this:

-- Found BOARD.dts: /opt/nordic/ncs/v2.3.0/zephyr/boards/arm/nrf5340dk_nrf5340/nrf5340dk_nrf5340_cpunet.dts
-- Generated zephyr.dts: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/zephyr/zephyr.dts
-- Generated devicetree_generated.h: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/zephyr/include/generated/devicetree_generated.h
-- Including generated dts.cmake file: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/zephyr/dts.cmake

warning: UART_CONSOLE (defined at drivers/console/Kconfig:43) was assigned the value 'y' but got the
value 'n'. Check these unsatisfied dependencies: SERIAL (=n), SERIAL_HAS_DRIVER (=n). See
http://docs.zephyrproject.org/latest/kconfig.html#CONFIG_UART_CONSOLE and/or look up UART_CONSOLE in
the menuconfig/guiconfig interface. The Application Development Primer, Setting Configuration
Values, and Kconfig - Tips and Best Practices sections of the manual might be helpful too.

Parsing /opt/nordic/ncs/v2.3.0/zephyr/Kconfig
Loaded configuration '/opt/nordic/ncs/v2.3.0/zephyr/boards/arm/nrf5340dk_nrf5340/nrf5340dk_nrf5340_cpunet_defconfig'
Merged configuration '/opt/nordic/ncs/v2.3.0/zephyr/samples/bluetooth/hci_rpmsg/prj.conf'
Merged configuration '/opt/nordic/ncs/v2.3.0/nrf/subsys/bootloader/image/secure_boot.conf'
Merged configuration '/opt/nordic/ncs/v2.3.0/nrf/subsys/partition_manager/partition_manager_enabled.conf'
Merged configuration '/Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/child_image/hci_rpmsg.conf'
Merged configuration '/Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/zephyr/misc/generated/extra_kconfig_options.conf'
Configuration saved to '/Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/zephyr/.config'
Kconfig header saved to '/Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/zephyr/include/generated/autoconf.h'
-- The C compiler identification is GNU 12.1.0
-- The CXX compiler identification is GNU 12.1.0
-- The ASM compiler identification is GNU
-- Found assembler: /opt/nordic/ncs/toolchains/v2.3.0/opt/zephyr-sdk/arm-zephyr-eabi/bin/arm-zephyr-eabi-gcc

=== child image b0n - CPUNET (inherited) begin ===
loading initial cache file /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/b0n/child_image_preload.cmake
Loading Zephyr default modules (Zephyr base).
-- Application: /opt/nordic/ncs/v2.3.0/nrf/samples/nrf5340/netboot
-- Found Python3: /opt/nordic/ncs/toolchains/v2.3.0/bin/python3.9 (found suitable exact version "3.9.6") found components: Interpreter 
-- Cache files will be written to: /Users/gerardbucas/Library/Caches/zephyr
-- Zephyr version: 3.2.99 (/opt/nordic/ncs/v2.3.0/zephyr)
-- Found west (found suitable version "0.14.0", minimum required is "0.7.1")
-- Board: nrf5340dk_nrf5340_cpunet
-- Found host-tools: zephyr 0.15.2 (/opt/nordic/ncs/toolchains/v2.3.0/opt/zephyr-sdk)
-- Found toolchain: zephyr 0.15.2 (/opt/nordic/ncs/toolchains/v2.3.0/opt/zephyr-sdk)
-- Found Dtc: /opt/nordic/ncs/toolchains/v2.3.0/bin/dtc (found suitable version "1.6.1", minimum required is "1.4.6") 
-- Found BOARD.dts: /opt/nordic/ncs/v2.3.0/zephyr/boards/arm/nrf5340dk_nrf5340/nrf5340dk_nrf5340_cpunet.dts
-- Generated zephyr.dts: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/b0n/zephyr/zephyr.dts
-- Generated devicetree_generated.h: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/b0n/zephyr/include/generated/devicetree_generated.h
-- Including generated dts.cmake file: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/b0n/zephyr/dts.cmake
Parsing /opt/nordic/ncs/v2.3.0/nrf/samples/nrf5340/netboot/Kconfig
Loaded configuration '/opt/nordic/ncs/v2.3.0/zephyr/boards/arm/nrf5340dk_nrf5340/nrf5340dk_nrf5340_cpunet_defconfig'
Merged configuration '/opt/nordic/ncs/v2.3.0/nrf/samples/nrf5340/netboot/prj.conf'
Merged configuration '/opt/nordic/ncs/v2.3.0/nrf/subsys/partition_manager/partition_manager_enabled.conf'
Configuration saved to '/Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/b0n/zephyr/.config'
Kconfig header saved to '/Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/b0n/zephyr/include/generated/autoconf.h'
-- The C compiler identification is GNU 12.1.0
-- The CXX compiler identification is GNU 12.1.0
-- The ASM compiler identification is GNU
-- Found assembler: /opt/nordic/ncs/toolchains/v2.3.0/opt/zephyr-sdk/arm-zephyr-eabi/bin/arm-zephyr-eabi-gcc
CMake Warning at /opt/nordic/ncs/v2.3.0/zephyr/CMakeLists.txt:1838 (message):
  __ASSERT() statements are globally ENABLED


-- Configuring done
-- Generating done
-- Build files have been written to: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg/b0n
=== child image b0n - CPUNET (inherited) end ===

CMake Warning at /opt/nordic/ncs/v2.3.0/nrf/subsys/bootloader/cmake/debug_keys.cmake:36 (message):
  

      --------------------------------------------------------------
      --- WARNING: Using generated NSIB public/private key-pair. ---
      --- It should not be used for production.                  ---
      --- See CONFIG_SB_SIGNING_KEY_FILE                         ---
      --------------------------------------------------------------
      

Call Stack (most recent call first):
  /opt/nordic/ncs/v2.3.0/nrf/subsys/bootloader/cmake/provision_hex.cmake:23 (include)
  /opt/nordic/ncs/v2.3.0/nrf/subsys/bootloader/image/CMakeLists.txt:42 (include)


-- libmetal version: 1.3.0 (/opt/nordic/ncs/v2.3.0/zephyr/samples/bluetooth/hci_rpmsg)
-- Build type:  
-- Host:    Darwin/x86_64
-- Target:  Generic/arm
-- Machine: arm
-- Looking for include file stdatomic.h
-- Looking for include file stdatomic.h - found
-- open-amp version: 1.3.0 (/opt/nordic/ncs/v2.3.0/modules/lib/open-amp/open-amp)
-- Host:    Darwin/x86_64
-- Target:  Generic/arm
-- Machine: arm
-- C_FLAGS :  -Wall -Wextra
-- Looking for include file fcntl.h
-- Looking for include file fcntl.h - found
CMake Warning at ../../../CMakeLists.txt:824 (message):
  No SOURCES given to Zephyr library: drivers__console

  Excluding target from build.


-- Configuring done
-- Generating done
-- Build files have been written to: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/hci_rpmsg
=== child image hci_rpmsg - CPUNET end ===

-- Found Python3: /opt/nordic/ncs/toolchains/v2.3.0/bin/python3.9 (found version "3.9.6") found components: Interpreter 

=== child image mcuboot -  begin ===
loading initial cache file /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/mcuboot/child_image_preload.cmake
Loading Zephyr default modules (Zephyr base).
-- Application: /opt/nordic/ncs/v2.3.0/bootloader/mcuboot/boot/zephyr
-- Found Python3: /opt/nordic/ncs/toolchains/v2.3.0/bin/python3.9 (found suitable exact version "3.9.6") found components: Interpreter 
-- Cache files will be written to: /Users/gerardbucas/Library/Caches/zephyr
-- Zephyr version: 3.2.99 (/opt/nordic/ncs/v2.3.0/zephyr)
-- Found west (found suitable version "0.14.0", minimum required is "0.7.1")
-- Board: nrf5340dk_nrf5340_cpuapp
-- Found host-tools: zephyr 0.15.2 (/opt/nordic/ncs/toolchains/v2.3.0/opt/zephyr-sdk)
-- Found toolchain: zephyr 0.15.2 (/opt/nordic/ncs/toolchains/v2.3.0/opt/zephyr-sdk)
-- Found Dtc: /opt/nordic/ncs/toolchains/v2.3.0/bin/dtc (found suitable version "1.6.1", minimum required is "1.4.6") 
-- Found BOARD.dts: /opt/nordic/ncs/v2.3.0/zephyr/boards/arm/nrf5340dk_nrf5340/nrf5340dk_nrf5340_cpuapp.dts
-- Found devicetree overlay: /opt/nordic/ncs/v2.3.0/nrf/modules/mcuboot/usb.overlay
-- Found devicetree overlay: /opt/nordic/ncs/v2.3.0/bootloader/mcuboot/boot/zephyr/dts.overlay
-- Generated zephyr.dts: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/mcuboot/zephyr/zephyr.dts
-- Generated devicetree_generated.h: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/mcuboot/zephyr/include/generated/devicetree_generated.h
-- Including generated dts.cmake file: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/mcuboot/zephyr/dts.cmake
Parsing /opt/nordic/ncs/v2.3.0/bootloader/mcuboot/boot/zephyr/Kconfig
Loaded configuration '/opt/nordic/ncs/v2.3.0/zephyr/boards/arm/nrf5340dk_nrf5340/nrf5340dk_nrf5340_cpuapp_defconfig'
Merged configuration '/opt/nordic/ncs/v2.3.0/bootloader/mcuboot/boot/zephyr/prj.conf'
Merged configuration '/opt/nordic/ncs/v2.3.0/nrf/subsys/pcd/pcd.conf'
Merged configuration '/opt/nordic/ncs/v2.3.0/nrf/subsys/partition_manager/partition_manager_enabled.conf'
Merged configuration '/Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/mcuboot/zephyr/misc/generated/extra_kconfig_options.conf'
Configuration saved to '/Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/mcuboot/zephyr/.config'
Kconfig header saved to '/Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/mcuboot/zephyr/include/generated/autoconf.h'
-- The C compiler identification is GNU 12.1.0
-- The CXX compiler identification is GNU 12.1.0
-- The ASM compiler identification is GNU
-- Found assembler: /opt/nordic/ncs/toolchains/v2.3.0/opt/zephyr-sdk/arm-zephyr-eabi/bin/arm-zephyr-eabi-gcc
MCUBoot bootloader key file: /opt/nordic/ncs/v2.3.0/bootloader/mcuboot/root-rsa-2048.pem
-- Configuring done
-- Generating done
-- Build files have been written to: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build/mcuboot
=== child image mcuboot -  end ===

CMake Warning at /opt/nordic/ncs/v2.3.0/nrf/modules/mcuboot/CMakeLists.txt:286 (message):
  

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



-- libmetal version: 1.3.0 (/Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2)
-- Build type:  
-- Host:    Darwin/x86_64
-- Target:  Generic/arm
-- Machine: arm
-- Looking for include file stdatomic.h
-- Looking for include file stdatomic.h - found
-- open-amp version: 1.3.0 (/opt/nordic/ncs/v2.3.0/modules/lib/open-amp/open-amp)
-- Host:    Darwin/x86_64
-- Target:  Generic/arm
-- Machine: arm
-- C_FLAGS :  -Wall -Wextra
-- Looking for include file fcntl.h
-- Looking for include file fcntl.h - found
-- Configuring done
-- Generating done
-- Build files have been written to: /Users/gerardbucas/Documents/GitHub/WS_firmware_sdk2/build
-- west build: building application
[1/337] Preparing syscall dependency handling

[2/337] Generating include/generated/version.h
-- Zephyr version: 3.2.99 (/opt/nordic/ncs/v2.3.0/zephyr), build: v3.2.99-ncs2
[3/337] Generating misc/generated/syscalls_subdirs.trigger
[4/337] Creating directories for 'hci_rpmsg_subimage'
[5/337] Creating directories for 'mcuboot_subimage'
[6/337] No download step for 'mcuboot_subimage'
[7/337] No download step for 'hci_rpmsg_subimage'
[8/337] No update step for 'mcuboot_subimage'
[9/337] No update step for 'hci_rpmsg_subimage'
[10/337] No patch step for 'hci_rpmsg_subimage'
[11/337] No patch step for 'mcuboot_subimage'
[12/337] No configure step for 'hci_rpmsg_subimage'
[12/337] Performing build step for 'hci_rpmsg_subimage'
[0/246] Generating signing key
[1/246] Preparing syscall dependency handling

[2/246] Generating include/generated/version.h
-- Zephyr version: 3.2.99 (/opt/nordic/ncs/v2.3.0/zephyr), build: v3.2.99-ncs2
[3/246] Generating misc/generated/syscalls_subdirs.trigger
[4/246] Creating public key from private key used for signing
[7/246] No update step for 'b0n_subimage'
[8/246] Creating data to be provisioned to the Bootloader, storing to provision.hex
[10/246] No configure step for 'b0n_subimage'
[11/246] Performing build step for 'b0n_subimage'
[1/163] Preparing syscall dependency handling

[2/163] Generating include/generated/version.h
-- Zephyr version: 3.2.99 (/opt/nordic/ncs/v2.3.0/zephyr), build: v3.2.99-ncs2
[3/163] Generating misc/generated/syscalls_subdirs.trigger
[4/163] Generating misc/generated/syscalls.json, misc/generated/struct_tags.json
[5/163] Generating include/generated/kobj-types-enum.h, include/generated/otype-to-str.h, include/generated/otype-to-size.h
[6/163] Generating include/generated/driver-validation.h
[7/163] Generating include/generated/syscall_dispatch.c, include/generated/syscall_list.h
[8/163] Building C object zephyr/CMakeFiles/offsets.dir/arch/arm/core/offsets/offsets.c.obj
[9/163] Generating include/generated/offsets.h
[10/163] Building ASM object zephyr/arch/arch/arm/core/aarch32/CMakeFiles/arch__arm__core__aarch32.dir/cpu_idle.S.obj
[11/163] Building C object zephyr/arch/common/CMakeFiles/isr_tables.dir/isr_tables.c.obj
[12/163] Building C object zephyr/arch/common/CMakeFiles/arch__common.dir/sw_isr_common.c.obj
[13/163] Building ASM object zephyr/arch/arch/arm/core/aarch32/CMakeFiles/arch__arm__core__aarch32.dir/nmi_on_reset.S.obj
[14/163] Building C object zephyr/arch/arch/arm/core/aarch32/CMakeFiles/arch__arm__core__aarch32.dir/irq_manage.c.obj
[15/163] Building C object zephyr/arch/arch/arm/core/aarch32/CMakeFiles/arch__arm__core__aarch32.dir/fatal.c.obj
[16/163] Building C object zephyr/arch/arch/arm/core/aarch32/CMakeFiles/arch__arm__core__aarch32.dir/nmi.c.obj
[17/163] Building C object zephyr/arch/arch/arm/core/aarch32/CMakeFiles/arch__arm__core__aarch32.dir/prep_c.c.obj
[18/163] Building C object zephyr/arch/arch/arm/core/aarch32/CMakeFiles/arch__arm__core__aarch32.dir/swap.c.obj
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[20/163] Building ASM object zephyr/arch/arch/arm/core/aarch32/CMakeFiles/arch__arm__core__aarch32.dir/isr_wrapper.S.obj
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  158 | static void ipm_callback(const struct device *dev,
      |             ^~~~~~~~~~~~
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/opt/nordic/ncs/v2.3.0/zephyr/subsys/ipc/rpmsg_service/rpmsg_backend.c:140:12: warning: 'status' is used uninitialized [-Wuninitialized]
  140 |         if (status != 0) {
      |            ^
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  247 | static void gipm_send(uint32_t id)
      |             ^~~~~~~~~
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  147 | static int vipm_nrf_init(const struct device *dev)
      |            ^~~~~~~~~~~~~
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  140 | static uint32_t vipm_nrf_max_id_val_get(const struct device *dev)
      |                 ^~~~~~~~~~~~~~~~~~~~~~~
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  135 | static int vipm_nrf_max_data_size_get(const struct device *dev)
      |            ^~~~~~~~~~~~~~~~~~~~~~~~~~
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  251 |                 int measurement = get_pF(false, false);
      |                     ^~~~~~~~~~~
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Memory region         Used Size  Region Size  %age Used
           FLASH:       40964 B        48 KB     83.34%
             RAM:       22712 B       440 KB      5.04%
        IDT_LIST:          0 GB         2 KB      0.00%
[321/337] Generating ../../zephyr/net_core_app_update.bin
sign the payload
[322/337] Generating ../../zephyr/net_core_app_signed.hex
sign the payload
[323/337] Generating ../../zephyr/net_core_app_test_update.hex
sign the payload
[325/337] Linking C executable zephyr/zephyr.elf
Memory region         Used Size  Region Size  %age Used
           FLASH:      212300 B     491008 B     43.24%
             RAM:       77272 B       440 KB     17.15%
        IDT_LIST:          0 GB         2 KB      0.00%
[327/337] Generating zephyr/mcuboot_primary_app.hex
[329/337] No install step for 'mcuboot_subimage'
[330/337] Generating ../../zephyr/app_update.bin
sign the payload
[331/337] Completed 'mcuboot_subimage'
[332/337] Generating ../../zephyr/dfu_application.zip
[333/337] Generating ../../zephyr/app_signed.hex
sign the payload
[334/337] Generating ../../zephyr/app_test_update.hex
sign the payload
[335/337] Generating ../../zephyr/app_moved_test_update.hex
[336/337] Generating zephyr/merged.hex
[337/337] Generating zephyr/merged_domains.hex
 *  Terminal will be reused by tasks, press any key to close it. 

The project folder looks like this:

As per this devzone suggestion: https://devzone.nordicsemi.com/f/nordic-q-a/97081/ncs-v2-3-0-rc1-ota-dfu-does-not-compile, we removed the 5 lines of code recommended there.

I would REALLY appreciate it if you could look at the above and let me know if there are any obvious issues with any of the above.

As I mentioned, the project seems to build OK but after flashing, the code seems to go into an endless "reset loop" (seems to crash immediately after it starts up). Yet the same code seems rot work (with minor changes to add zephyr/ prefix to #include paths) perfectly when built with v1.9.1.

Thanking you in anticipation.

Gerard.

[Naeem Maroof]

Hi Gerard,

Thank you for contacting DevZone at NordicSemi.

I am not sure what could be the problem as your project builds correctly and we don't have any errors to look at.

Nonetheless, as your project is working good with the SDK v1.9.1 (vs v2.3.0), can you compare the build output for both versions.

"No SOURCES given to Zephyr library: drivers__console"
Do you see this while building with v1.9.1 as well?

There are other warnings as well. Were you getting same warnings with v1.9.1, or somethings has changed while migrating to v2.3.0?

You can put status = "disabled" for the uart1 (and other instances/peripherals) that are not used. Check the compiled zephyr DTS and see that devices are on and off as per settings.

I also suggest to check out Release Notes for sdk v2.3.0 and check if any item applies to your project.

Regards,
Naeem

[GerardB]

Hi Naeem - thanks for getting back to me - much appreciated!

Naeem Maroof said:

Nonetheless, as your project is working good with the SDK v1.9.1 (vs v2.3.0), can you compare the build output for both versions.

Yes - I have done that and I can't see any major differences. That is sort of why I contacted you guys. 

Naeem Maroof said:

"No SOURCES given to Zephyr library: drivers__console"
Do you see this while building with v1.9.1 as well?

I have just checked this & the v1.9.1 output is identical. See below:

-- libmetal version: 1.1.0 (/opt/nordic/ncs/v1.9.1/zephyr/samples/bluetooth/hci_rpmsg)
-- Build type:  
-- Host:    Darwin/x86_64
-- Target:  Generic/arm
-- Machine: arm
-- Looking for include file stdatomic.h
-- Looking for include file stdatomic.h - found
-- open-amp version: 1.1.0 (/opt/nordic/ncs/v1.9.1/modules/lib/open-amp/open-amp)
-- Host:    Darwin/x86_64
-- Target:  Generic/arm
-- Machine: arm
-- C_FLAGS :  -Wall -Wextra
-- Looking for include file fcntl.h
-- Looking for include file fcntl.h - found
CMake Warning at /opt/nordic/ncs/v1.9.1/zephyr/CMakeLists.txt:764 (message):
  No SOURCES given to Zephyr library: drivers__console

  Excluding target from build.

Naeem Maroof said:

There are other warnings as well. Were you getting same warnings with v1.9.1, or somethings has changed while migrating to v2.3.0?

Warnings seem to be similar between 1.9.1 & 2.3.0. However, in v1.9.1 ALL logging is disabled (so all uarts, USB, serial, etc is disabled) as the project must also run on our custom nrf5340 based board (in addition to the nrf5340DK). The reason for this is of course power savings as well as the fact that our custom nrf5340 based board has no USB & no accessible uarts - it has a battery & BLE only). After having these problems with v2.3.0, I tried to switch on logging (& therefore needed to enable console, serial, uart0 & USB) in the v2.3.0 build only, to see if logging could help me debug the problem. However, as the v2.3.0 build goes into an endless reset loop immediately after power-on or reset (with or without logging enabled!), I can't seem to find a way to debug this problem.

Having said all that, I will go back & remove all logging from v2.3.0 config again so that it is 100% identical to the v1.9.1 build - just to make sure (again) that enabling logging is not causing this problem. Once I have done that I could send you the build output logs for BOTH v1.9.1 & v2.3.0 - just in case you can see some differences that I may have missed. Is that OK?

Naeem Maroof said:

You can put status = "disabled" for the uart1 (and other instances/peripherals) that are not used.

Thanks - I was worried that the "status = "disabled" format was no longer supported in v2.3.0 (due to the v2 pin control changes in dts related files). So good to know that we can still use that format to disable devices.

Naeem Maroof said:

I also suggest to check out Release Notes for sdk v2.3.0

Thanks for that link. I looked at it but don't see anything obvious there.

Let me try/check a few more things & I will get back to you after that. Obviously debugging becomes very tricky/difficult when the code seems to crash immediately on power-on/reset. It is not clear to me how one debugs that (other than almost starting from scratch & adding little pieces of new code at a time - I was hoping not to have to do that as the project is quite complicated and has evolved over a period of more than one year using the v1.8 & 1.9 SDK's).

[Naeem Maroof]

Hi Gerard,

GerardB said:

just in case you can see some differences that I may have missed. Is that OK?

Yes, that is okay.

I would also like you to check MCUboot release notes (as your prject is using mcuboot) as well.

You may also like to check the resulting zephyr DTS of your project,

and the resulting partitions in the memory report.

Please note that due to holiday season (Easter) in Norway, we are a bit low in staff. So please expect some delays and thanks for your patience in advance.

Happy Easter.

[GerardB]

Hi again Naeem..

Hope you had a Happy Easter...!? 

While you guys were having fun, I spend a lot more time debugging the conversion issues from SDK v1.9.1 to v2.3.0.

I now seem to have it all working! Below are my notes on all the issues I found - maybe they can help someone else who has similar issues!

11-Apr-2023 - Gerard's Notes

Changes made to our firmware for moving from nrf SDK v1.9.1 to v2.3.0 for nrf5340

1. Add prefix “zephyr/“ to all zephyr specific include pathnames in all source files

2. Remove all log_strdup( ) functions from LOG_… statements (settings.c & main.c) 
to fix compile/build errors.
So "transient strings" no longer seem to need special handling (using log_strdup()).

3. Remove these 6 lines from main.c
#include <mgmt/mcumgr/smp_bt.h>
#include "os_mgmt/os_mgmt.h"
#include "img_mgmt/img_mgmt.h"

os_mgmt_register_group();
img_mgmt_register_group();
smp_bt_register(); 

4. Add this line to includes in main.c:
#include <zephyr/mgmt/mcumgr/transport/smp_bt.h>

5. Change:
#include <zephyr.h>
To:
#include <zephyr/kernel.h>

6. Apparently the "old" device initialization/binding for devices (like "gpio0_dev = device_get_binding("GPIO_0");" 
no longer works in v2.3.0 even though it compiles and builds without errors! 
In the case of GPIO_0 & GPIO_1 it actually crashes the whole "cpuapp" 
- so the whole device goes into an endless reset loop (making this problem VERY hard to debug!).

So change those all those "device_get_binding" functions to "DEVICE_DT_GET(DT_NODELABEL(..)".
For example, change:
gpio0_dev = device_get_binding("GPIO_0");
TO:
gpio0_dev = DEVICE_DT_GET(DT_NODELABEL(gpio0));
Etc.. 

7. For some reason or other the default "i2c1" configuration in the nrf5340DK_nrf5340_cpuapp DT has been changed, 
so we could no longer access i2c devices. To fix this, we had to redefine the "i2c1" device in the overlay file 
and add (back?) the pull-up bias and drive strength. So added a new pinctrl entry in the overlay file like this:

i2c1_default: i2c1_default {
    group1 {
	psels = <NRF_PSEL(TWIM_SDA, 1, 2)>,
		<NRF_PSEL(TWIM_SCL, 1, 3)>;
		bias-pull-up;
		nordic,drive-mode = < NRF_DRIVE_S0D1 >;
    };
};

i2c1_sleep: i2c1_sleep {
    group1 {
	psels = <NRF_PSEL(TWIM_SDA, 1, 2)>,
		<NRF_PSEL(TWIM_SCL, 1, 3)>;
		low-power-enable;
	};
};
 

8. There also seem to be a problem with DFU OTA (across BLE) now. 
OTA DFU across BLE appears to work ONLY with images that are generated by SDK v2.3.0 (or probably SDK v2.x?). 
Probably due to some change in default key used to sign DFU images? 
Need to check this out with Nordic as it is a real hassle 
(as field units can't be upgraded using OTA due to this problem).  

9. Everything now seems to work with SDK v2.3.0 builds. 
The most frustrating thing was that when one made the (obvious) changes 1 thru 5 (as described above)
the system would compile & build without any errors and no new warning (compared to SDK v1.9.1) 
but the image built would NOT run (went into endless reset loop). 
So it was very time consuming to debug or track down the more subtle changes required.   

Maybe you can comment on any issues you see in the notes.

My only major question for you now is whether or not the backward compatible OTA issue mentioned in my notes can be resolved? I know we need our own image signing key once we go into production but right now we have been using the default image signing key generated by the SDK. Is it possible to use the default key used in SDK v1.9.1 also in v2.3.0 (only for our pre-production test units)? I assume yes, so can you tell me how I can do that?

I look forward to hearing from you.

Best Regards

Gerard

[Naeem Maroof]

Hi Gerard,

Thank you for being proactive, and great to know that your project is working.

Thank you for compiling and putting your notes here for migrating from ncs v1.9.1 to ncs v2.3.0 for your nrf5340 based project.

I will agree that it might not be an easy task and the trivial solutions might not be helpful to provide complete solution.

Nonetheless, many of these issues are spread over DevZone / zephyr forums (OTA doesn't compile , Zephyr.h , Pin Ctrl and DT migration , Device get binding )

Coming to the 'signing keys' issue,

Yes, you can have your own signing keys or you can use default signing keys.

"Probably due to some change in default key used to sign DFU images? "

I have checked and the keys are same. They are not changed. Can you point to resource which says so?

You can check these .pem files in different SDKs

Also, following links might be useful (default keys, creating keys, and setting custom key file).

Default Key File

Creating signing keys

Keys and Signatures

Setting custom key

With regards,

Naeem

[GerardB]

Hi again Naeem,

Naeem Maroof said:

I have checked and the keys are same. They are not changed.

Ok - I have checked this again - and I see they are in fact the same for v1.9.1 & 2.3.0 (mcuboot signing keys).

So I need some help with the serious problem (for me/us) I am seeing, which is:

1. When I try to do an OTA DFU update on a device running my v1.9.1 builds, OTA DFU updates only seems to work when the new image has been built with SDK v1.9.1. When the image has been built with v2.3.0, then the image is properly uploaded & the device is reset (as expected) BUT the new image will not run (the swap algorithm always seems to select "Slot 1" - after the successful upload - but the image won't boot and the device hangs). The only way to recover is to erase the 5430 and reflash with J-Link. So with my v1.9.1 built system I only seem to be able to OTA DFU upload v1.9.1 (or maybe v1.x?) images.

2.  The same symptoms happen when I first flash the device (using J-link) with my v2.3.0 build. In that case OTA DFU only works when I supply an image built in v2.3.0 and any images built with v1.9.1 will no longer boot with the v2.3.0 built system (even though they upload perfectly). So with the  v2.3.0 built system, I can only successfully boot OTA images that are built with SDK v2.3.0.

This may be a stupid (or naive!) question, but the more I think about it, maybe the "problem" is that our OTA DFU only updates the "cpuapp" (user application core) and the "network" application (BLE stack) that is already there is not compatible with the new "cpuapp" that is being uploaded? So what I am "suspecting" is that the v1.9.1 "SoftDevice" (or BLE stack) is not compatible with the v2.3.0 "cpuapp" (user application loaded into 2nd core with OTA DFU) and vice versa (ie: the v2.3.0 "SoftDevice/BLEStack" is not compatible with a v1.9.1 built application image)?

The image file being uploaded by OTA DFU is ONLY the "build/zephyr/app_update.bin" file. So guess I am confused as to whether or not that is the problem (ie: v1.9.1 & v2.3.0 built images can't be "mixed" - as both CPU cores need to be loaded with images built by the same SDK)? We have our own iOS app that uses the latest version of the iOSMcuManagerLibrary to do the OTA. It has always worked flawlessly (but right now it only updates the "app" image & not the "net/BLE" image)... :)  

So my conclusion is that the SoftDevice version number (or rather the netApp) has changed (from v1.9.1 to 2.3.0) and that due to this change, we now need to do a multi-image OTA update (for BOTH cores). However, how can I programmatically determine that this is the case, so that I can do a multi-image OTA update (when I detect that in the iOS app) instead of only updating one core with "app_update.bin" as we would "normally" do..!?

Sorry for the long discussion but it's difficult to explain (for me). Any ideas on how I can resolve this problem!?

FYI - for more info on our nrf5340 based product check out the main video on our website: https://wear-sense.com :) 

Thanks

Gerard

[Naeem Maroof]

Hi Gerard,

Thank you for your patience.

I have discussed it with experts, and below are some comments, guidelines or testing to perform.

1) The rebooting issue might be linked with the external flash if it is used in the project. So it might be good idea to look into error / error-code you are getting. Also, it is good idea to just check external flash working before trying it with the MCUBoot/DFU.

2) 

GerardB said:

the "problem" is that our OTA DFU only updates the "cpuapp" (user application core) and the "network" application (BLE stack) that is already there is not compatible with the new "cpuapp" that is being uploaded?

To test this hypothesis, you can just update the app-core without MCUBOOT/DFU and see if it is working or not.
This will confirm whether the (newer) application is compatible with the old build of the (SD Controller) netcore application, and the vice-versa. Just update app-core without MCUboot/DFU for testing.

3) Typicall guideline for migrating is to do incremental changes / updates: from 1.9.1 --> 2.0.0 and then from 2.0.0 to 2.1.0 and so on.

However, as you have successfully migrated from 1.9.1 to 2.3.0; one important question / check can be to look at partitioning and see if anything has changed from 1.9.1 to 2.3.0. So you can compare build/partitions.yml for different version.

Also, you can check build/mcuboot/zephyr/.config and build/mcuboot/zephyr/zephyr.dts to see if anything has changed between two versions.

4) For nrf5340, you can have one by one or simultaneous update of cores. Here are unofficial (but good) samples for this. Bootloader Samples 5340

5) You can use sdc_build_revision_get() function from sdc.h to get the build revision. SDC_Build_Rev

I just ran same sample using different SDKs and here you can see different version of controller with log enable.

You can read more about SD Controller changes/revisions.

Softdevice Controller Changelog

Regards,
Naeem