Device bricked on OTA update when esp-idf is updated from v3.1 to v4.0 [IDFGH-3384]

[amruta]

## Environment

- Development Kit: [none, custom product using wrover module.]
- Module or chip used: [ESP32-WROVER 32Mbit]
- Operating System: [Windows]
- Power Supply: [on-board 3.3V]
- IDF version: v3.1

Application uses custom partition table as follows

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1. # additional nvs data
2. otadata,  data, ota,     0xd000,  0x2000,
3. phy_init, data, phy,     0xf000,  0x1000,
4. factory,  app,  ota_0,   0x10000, 0x178000,
5. ota_1,    app,  ota_1,   ,        0x178000,
6. nvs,      data, nvs,     ,        0x10000,

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## Issue
Updated IDF to version: 4.0 and performed OTA (followed native_ota_example from idf).
Initially I was getting error something similar to this viewtopic.php?t=13750
So, I checked bootloader using following command and it was intact

Code: Select all

esptool.py --chip esp32 image_info bootloader.bin

But now I am unable to reproduce that error and all I am getting is Guru meditation error.
Below are the logs:

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1. ets Jun  8 2016 00:22:57
2.  
3. rst:0xc (SW_CPU_RESET),boot:0x13 (SPI_FAST_FLASH_BOOT)
4. configsip: 0, SPIWP:0xee
5. clk_drv:0x00,q_drv:0x00,d_drv:0x00,cs0_drv:0x00,hd_drv:0x00,wp_drv:0x00
6. mode:DIO, clock div:1
7. load:0x3fff0018,len:4
8. load:0x3fff001c,len:6008
9. load:0x40078000,len:8428
10. load:0x40080000,len:6476
11. 0x40080000: _WindowOverflow4 at E:/ESP32/toolchain/v4.0/esp-idf/components/freertos/xtensa_vectors.S:1778
12.  
13. entry 0x40080330
14. 0x40080330: _KernelExceptionVector at ??:?
15.  
16. I (29) boot: ESP-IDF v3.1-dirty 2nd stage bootloader
17. I (29) boot: compile time 15:40:22
18. I (29) boot: Enabling RNG early entropy source...
19. I (34) qio_mode: Enabling default flash chip QIO
20. I (39) boot: SPI Speed      : 80MHz
21. I (43) boot: SPI Mode       : QIO
22. I (47) boot: SPI Flash Size : 4MB
23. I (51) boot: Partition Table:
24. I (55) boot: ## Label            Usage          Type ST Offset   Length
25. I (62) boot:  0 otadata          OTA data         01 00 0000d000 00002000
26. I (70) boot:  1 phy_init         RF data          01 01 0000f000 00001000
27. I (77) boot:  2 factory          OTA app          00 10 00010000 00178000
28. I (85) boot:  3 ota_1            OTA app          00 11 00190000 00178000
29. I (92) boot:  4 nvs              WiFi data        01 02 00308000 00010000
30. I (100) boot: End of partition table
31. I (104) esp_image: segment 0: paddr=0x00190020 vaddr=0x3f400020 size=0x1f22c (127532) map
32. I (147) esp_image: segment 1: paddr=0x001af254 vaddr=0x3ffbdb60 size=0x00dbc (  3516) load
33. I (148) esp_image: segment 2: paddr=0x001b0018 vaddr=0x400d0018 size=0xd2810 (862224) map
34. 0x400d0018: _stext at ??:?
35.  
36. I (381) esp_image: segment 3: paddr=0x00282830 vaddr=0x3ffbe91c size=0x05410 ( 21520) load
37. I (387) esp_image: segment 4: paddr=0x00287c48 vaddr=0x40080000 size=0x00400 (  1024) load
38. 0x40080000: _WindowOverflow4 at E:/ESP32/toolchain/v4.0/esp-idf/components/freertos/xtensa_vectors.S:1778
39.  
40. I (388) esp_image: segment 5: paddr=0x00288050 vaddr=0x40080400 size=0x12234 ( 74292) load
41. I (432) boot: Loaded app from partition at offset 0x190000
42. I (432) boot: Disabling RNG early entropy source...
43. Guru Meditation Error: Core  0 panic'ed (StoreProhibited). Exception was unhandled.
44. Core 0 register dump:
45. PC      : 0x40121fc5  PS      : 0x00060f30  A0      : 0x80080fd9  A1      : 0x3ffe3bd0
46. 0x40121fc5: esp_flash_init_default_chip at E:/ESP32/toolchain/v4.0/esp-idf/components/spi_flash/esp_flash_spi_init.c:205
47.  
48. A2      : 0xffffffff  A3      : 0x3ffc1f64  A4      : 0x3ffbdc14  A5      : 0x3ffc9a98
49. A6      : 0x40092634  A7      : 0x00000000  A8      : 0x00400000  A9      : 0x00400000
50. A10     : 0x00000000  A11     : 0x3ffc1f64  A12     : 0x00000108  A13     : 0x3ffc9a60
51. A14     : 0x00000000  A15     : 0x00000400  SAR     : 0x0000001f  EXCCAUSE: 0x0000001d
52. EXCVADDR: 0xffffffff  LBEG    : 0x4000c2e0  LEND    : 0x4000c2f6  LCOUNT  : 0xffffffff
53.  
54. ELF file SHA256: ffffffffffffffffffffffffffffffff0000000000000000000222bfffffffff
55.  
56. Backtrace: 0x40121fc2:0x3ffe3bd0 0x40080fd6:0x3ffe3c10 0x400810d3:0x3ffe3c60 0x40078da1:0x3ffe3ca0 |<-CORRUPTED
57. 0x40121fc2: esp_flash_init_default_chip at E:/ESP32/toolchain/v4.0/esp-idf/components/spi_flash/esp_flash_spi_init.c:205
58.  
59. 0x40080fd6: start_cpu0_default at E:/ESP32/toolchain/v4.0/esp-idf/components/esp32/cpu_start.c:400
60.  
61. 0x400810d3: call_start_cpu0 at E:/ESP32/toolchain/v4.0/esp-idf/components/esp32/cpu_start.c:260

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[ESP_Angus]

Thanks for the comprehensive report. I've edited this topic with an internal ID as we're tracking this issue internally.

Will get back to you ASAP.

[ESP_michael]

Hi amruta,

Sorry to hear that.. We are trying to reproduce that..

At the same time, could you provide your flash chip model? It's one of the regression for the new API of 4.0 compared to the legacy one. We have a fix for MXIC chip in commit 61ce037fc1f3c5747ee35328e3cd9cdfd2b8b86f, but it's not backported to 4.0 yet.

Michael

[amruta]

Currently I am working with ESP32 S node mcu dev board. You may test with the same

[amruta]

Additional update:
Tried same thing by updating to idf v3.3.2 as well as v4.0.1
Same issues. I can provide additional logs if required.
Basically, I would like to update to either v3.3.2 or v4.0.1 as they contain MQTT module with lot of bug fixes.

[ESP_michael]

Hi @amruta,

It's very helpful to know the model of your dev board! But unluckily I don't have that dev board in hand, so I can't debug easily.

I'm guessing it's related to the flash in the module, could you please help to run `esptool.py flash_id` to get the flash ID of the module, and post it here?

Michael

[amruta]

Hi @xiaoxufeng

I ran the command but I guess I am doing something wrong
Following is the output

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1. esptool.py v2.8
2. Found 1 serial ports
3. Serial port COM3
4. Connecting........_____.
5. Detecting chip type... ESP32
6. Chip is ESP32D0WDQ6 (revision 1)
7. Features: WiFi, BT, Dual Core, 240MHz, VRef calibration in efuse, Coding Scheme None
8. Crystal is 40MHz
9. MAC: cc:50:e3:b6:c8:d0
10. Uploading stub...
11. Running stub...
12. Stub running...
13. Manufacturer: 20
14. Device: 4016
15. Detected flash size: 4MB
16. Hard resetting via RTS pin...

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[ESP_michael]

Thanks amruta,

The result is correct, this is an XMC chip.

Thanks for your information, though I haven't got a clue...