nrf52: fix loop-task stack overflow causing reset on BLE pairing/first-sync (#10944)

The Arduino loop task runs Meshtastic's entire cooperative OSThread
scheduler on the Adafruit core's stock 4 KB (1024-word) stack. The 2.8
first-sync path - AdminModule::handleSetConfig -> saveChanges ->
configChanged -> RadioInterface::reloadConfig -> LR11x0 reconfigure ->
SPI Lock::lock, with vsnprintf/USB-CDC logging frames stacked on top -
overflows it.

SWD fault capture on a T1000-E (pyocd vector_catch=h) proved it: the
loop task's SP was driven 40 bytes BELOW its own pxStack base, the
stack paint was consumed to the floor, and the crash was a BusFault in
xQueueSemaphoreTake dereferencing a semaphore handle that adjacent-heap
corruption had overwritten with log text (0x3f3f207c = "| ??"). The
core's HardFault handler is a bare NVIC_SystemReset, so in the field
this presents as a silent reboot ~seconds after a phone pairs (or a 30 s
zombie hang -> supervision timeout 0x8 when the corruption lands on task
TCBs instead). Also explains the set_time_only -> immediate-NodeInfo
crash variant reported on empty-DB nodes: same task, different deep
chain. 2.7.26 is unaffected because the deep frames (XEdDSA, satellite
map conversion, replay engine) did not exist.

Fix: set -DLOOP_STACK_SZ=2048 (words = 8 KB) for all nrf52840 targets.
Requires the #ifndef guard from meshtastic/Adafruit_nRF52_Arduino#7;
until that merges the flag is a harmless redefinition warning. Validated
on hardware: pairing + full sync completes, stack paint shows healthy
margin under load.

Also fix the boot-time reset-reason log: the core's init() caches
RESETREAS and W1C-clears the register before setup() runs, so the raw
read here has always printed 0. Use readResetReason() instead.
(preFSBegin's RESETREAS==0 gate is intentionally left as-is - its
degenerate GPREGRET-only behavior is what makes lfs recovery work.)
This commit is contained in:
Ben Meadors
2026-07-08 17:11:32 -05:00
committed by GitHub
co-authored by GitHub
parent 9b5b2889e7
commit b4b1ece8f1
2 changed files with 12 additions and 1 deletions
+5 -1
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@@ -378,7 +378,11 @@ void nrf52Setup()
pinMode(ADC_V, INPUT);
#endif
uint32_t why = NRF_POWER->RESETREAS;
// The Adafruit core's init() (cores/nRF5/wiring.c) caches RESETREAS into a static and then
// W1C-clears the hardware register before setup() ever runs, so a raw NRF_POWER->RESETREAS
// read here is ALWAYS 0. Use the core's cached copy so this log line is actually meaningful
// (0x1 pin reset, 0x2 watchdog, 0x4 soft reset/SREQ, 0x8 CPU lockup, 0x10000 System OFF wake).
uint32_t why = readResetReason();
// per
// https://infocenter.nordicsemi.com/index.jsp?topic=%2Fcom.nordic.infocenter.nrf52832.ps.v1.1%2Fpower.html
LOG_DEBUG("Reset reason: 0x%x", why);
+7
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@@ -23,6 +23,13 @@ build_flags =
${arduino_base.build_flags}
-Wno-unused-variable
-Isrc/platform/nrf52
; The Arduino loop task runs the entire cooperative OSThread scheduler; the core's stock
; 4 KB (1024-word) stack overflows during BLE first-sync (admin config-apply -> radio
; reconfigure with XEdDSA/satmap/log frames stacked) - SWD-proven on T1000-E: SP driven
; 40 B below pxStack, corrupting adjacent heap -> silent HardFault reset on phone pairing.
; 2048 words = 8 KB, validated on hardware. Value is in WORDS; requires the #ifndef guard
; from meshtastic/Adafruit_nRF52_Arduino#7 (harmless redefinition warning until it merges).
-DLOOP_STACK_SZ=2048
-DLFS_NO_ASSERT ; Disable LFS assertions , see https://github.com/meshtastic/firmware/pull/3818
-DMESHTASTIC_EXCLUDE_AUDIO=1
-DMESHTASTIC_EXCLUDE_PAXCOUNTER=1