E (127) esp_image: Segment 0 0x3fcd5820-0x3fcd6f2c invalid: overlaps bootloader stack E (135) boot: OTA app partition slot 1 is not bootable (IDFGH-11068)

[SeanYang-7]

Answers checklist.

• I have read the documentation ESP-IDF Programming Guide and the issue is not addressed there.
• I have updated my IDF branch (master or release) to the latest version and checked that the issue is present there.
• I have searched the issue tracker for a similar issue and not found a similar issue.

IDF version.

v5.1.1

Operating System used.

Windows

How did you build your project?

Command line with Make

If you are using Windows, please specify command line type.

None

Development Kit.

ESP32-C3-13

Power Supply used.

USB

What is the expected behavior?

run the new firmware after the ota upgrade is successfu

What is the actual behavior?

I (35) boot: ESP-IDF v5.1.1-dirty 2nd stage bootloader
I (35) boot: compile time Sep 14 2023 14:10:48
I (35) boot: chip revision: v0.3
I (39) boot.esp32c3: SPI Speed : 80MHz
I (43) boot.esp32c3: SPI Mode : DIO
I (48) boot.esp32c3: SPI Flash Size : 4MB
I (53) boot: Enabling RNG early entropy source...
I (58) boot: Partition Table:
I (62) boot: ## Label Usage Type ST Offset Length
I (69) boot: 0 nvs WiFi data 01 02 00009000 00010000
I (77) boot: 1 otadata OTA data 01 00 00019000 00002000
I (84) boot: 2 phy_init RF data 01 01 0001b000 00001000
I (91) boot: 3 ota_0 OTA app 00 10 00020000 001e0000
I (99) boot: 4 ota_1 OTA app 00 11 00200000 001e0000
I (106) boot: 5 fctry WiFi data 01 02 003e0000 00010000
I (114) boot: End of partition table
I (118) esp_image: segment 0: paddr=00200020 vaddr=3fcd5820 size=0170ch ( 5900) load
E (127) esp_image: Segment 0 0x3fcd5820-0x3fcd6f2c invalid: overlaps bootloader stack
E (135) boot: OTA app partition slot 1 is not bootable

Steps to reproduce.

1. Step
2. Step
3. Step
   ...

Debug Logs.

I (118684) wifi:flush txq
I (118685) wifi:stop sw txq
I (118688) wifi:lmac stop hw txq
ESP-ROM:esp32c3-api1-20210207
Build:Feb  7 2021
rst:0x3 (RTC_SW_SYS_RST),boot:0xd (SPI_FAST_FLASH_BOOT)
Saved PC:0x40048b82
0x40048b82: ets_secure_boot_verify_bootloader_with_keys in ROM

SPIWP:0xee
mode:DIO, clock div:1
load:0x3fcd5820,len:0x170c
load:0x403cc710,len:0x968
load:0x403ce710,len:0x2f68
entry 0x403cc710
I (35) boot: ESP-IDF v5.1.1-dirty 2nd stage bootloader
I (35) boot: compile time Sep 14 2023 14:10:48
I (35) boot: chip revision: v0.3
I (39) boot.esp32c3: SPI Speed      : 80MHz
I (43) boot.esp32c3: SPI Mode       : DIO
I (48) boot.esp32c3: SPI Flash Size : 4MB
I (53) boot: Enabling RNG early entropy source...
I (58) boot: Partition Table:
I (62) boot: ## Label            Usage          Type ST Offset   Length
I (69) boot:  0 nvs              WiFi data        01 02 00009000 00010000
I (77) boot:  1 otadata          OTA data         01 00 00019000 00002000
I (84) boot:  2 phy_init         RF data          01 01 0001b000 00001000
I (91) boot:  3 ota_0            OTA app          00 10 00020000 001e0000
I (99) boot:  4 ota_1            OTA app          00 11 00200000 001e0000
I (106) boot:  5 fctry            WiFi data        01 02 003e0000 00010000
I (114) boot: End of partition table
I (118) esp_image: segment 0: paddr=00200020 vaddr=3fcd5820 size=0170ch (  5900) load
E (127) esp_image: Segment 0 0x3fcd5820-0x3fcd6f2c invalid: overlaps bootloader stack
E (135) boot: OTA app partition slot 1 is not bootable
I (141) esp_image: segment 0: paddr=00020020 vaddr=3c150020 size=491b8h (299448) map
I (197) esp_image: segment 1: paddr=000691e0 vaddr=3fc95200 size=0366ch ( 13932) load
I (200) esp_image: segment 2: paddr=0006c854 vaddr=40380000 size=037c4h ( 14276) load
I (206) esp_image: segment 3: paddr=00070020 vaddr=42000020 size=147b94h (1342356) map
I (426) esp_image: segment 4: paddr=001b7bbc vaddr=403837c4 size=11968h ( 72040) load
I (446) boot: Loaded app from partition at offset 0x20000
I (446) boot: Disabling RNG early entropy source...

More Information.

oat_file.csv:
nvs, data, nvs, , 0x10000,
otadata, data, ota, , 0x2000,
phy_init, data, phy, , 0x1000,
ota_0, app, ota_0, , 0x1E0000,
ota_1, app, ota_1, , 0x1E0000,
fctry, data, nvs, , 0x10000

Firmware size :Project build complete. To flash, run this command:
D:\idf5.1.1\Espressif\python_env\idf5.1_py3.11_env\Scripts\python.exe ....\idf5.1.1\Espressif\frameworks\esp-idf-v5.1.1\components\esptool_py\esptool\esptool.py -p (PORT) -b 460800 --before default_reset --after hard_reset --chip esp32c3 write_flash --flash_mode dio --flash_size 4MB --flash_freq 80m 0x0 build\bootloader\bootloader.bin 0x8000 build\partition_table\partition-table.bin 0x19000 build\ota_data_initial.bin 0x20000 build\ESP32_C3_Framework.bin
or run 'idf.py -p (PORT) flash'

[mahavirj]

@LHYYSY

• Can you please share your sample application that recreates this problem? Maybe you could modify the IDF OTA example and share the patch on top of it.
• Do you have any changes of your own, e.g. changes in the LD script? If yes, please share them.
• Please update the Step to reproduce section from the issue template

[SeanYang-7]

@mahavirj hello，this problem occurs only if the bin file size of my ota is greater than 1.6MB. Can the ota_0 and ota_1 of the partition table be set beyond 0x1C0000?

[mahavirj]

this problem occurs only if the bin file size of my ota is greater than 1.6MB. Can the ota_0 and ota_1 of the partition table be set beyond 0x1C0000?

Yes, it should work.

[SeanYang-7]

this problem occurs only if the bin file size of my ota is greater than 1.6MB. Can the ota_0 and ota_1 of the partition table be set beyond 0x1C0000?

Yes, it should work.

It is not that the partition table is set too small, I am not clear, which is the direction leading to this problem

[SeanYang-7]

@mahavirj ,The size of the bin file is 1.68 MB(1768176 bytes). This problem occurs when the device is restarted after the bin file is successfully written.

[mahavirj]

@LHYYSY Need more information per #12243 (comment) to comment on this issue

[SeanYang-7]

@mahavirj I checked the firmware and found a failure log in the heade

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