Flash Memory Corruption Issue

[Ritesh]

Hello Team,

We have used ESP32-WROVER-I module into one of our running EV Charging based product which is working fine and already went into couple of field testing.

Suddenly we received news from customer that Board is not working which was working earlier and found after doing some analysis that Board is contineoulsy rebooting.

st:0x10 (RTCWDT_RTC_RESET),boot:0x1f (SPI_FAST_FLASH_BOOT)
configsip: 0, SPIWP:0xee
clk_drv:0x00,q_drv:0x00,d_drv:0x00,cs0_drv:0x00,hd_drv:0x00,wp_drv:0x00
mode:DIO, clock div:2
load:0x3fff0018,len:4
load:0xff001cff,len:1568831
1150 mmu set 00010000, pos 00010000
1150 mmu set 00020000, pos 00020000
1150 mmu set 00030000, pos 00030000
1150 mmu set 00040000, pos 00040000
1150 mmu set 00050000, pos 00050000
1150 mmu set 00060000, pos 00060000
1150 mmu set 00070000, pos 00070000
1150 mmu set 00080000, pos 00080000
1150 mmu set 00090000, pos 00090000
ets Jul 29 2019 12:21:46

rst:0x10 (RTCWDT_RTC_RESET),boot:0x1f (SPI_FAST_FLASH_BOOT)
configsip: 0, SPIWP:0xee
clk_drv:0x00,q_drv:0x00,d_drv:0x00,cs0_drv:0x00,hd_drv:0x00,wp_drv:0x00
mode:DIO, clock div:2
load:0x3fff0018,len:4
load:0xff001cff,len:1568831
1150 mmu set 00010000, pos 00010000
1150 mmu set 00020000, pos 00020000
1150 mmu set 00030000, pos 00030000
1150 mmu set 00040000, pos 00040000
1150 mmu set 00050000, pos 00050000
1150 mmu set 00060000, pos 00060000
1150 mmu set 00070000, pos 00070000
1150 mmu set 00080000, pos 00080000
1150 mmu set 00090000, pos 00090000
ets Jul 29 2019 12:21:46

rst:0x10 (RTCWDT_RTC_RESET),boot:0x1f (SPI_FAST_FLASH_BOOT)
configsip: 0, SPIWP:0xee
clk_drv:0x00,q_drv:0x00,d_drv:0x00,cs0_drv:0x00,hd_drv:0x00,wp_drv:0x00
mode:DIO, clock div:2
load:0x3fff0018,len:4
load:0xff001cff,len:1568831
1150 mmu set 00010000, pos 00010000
1150 mmu set 00020000, pos 00020000
1150 mmu set 00030000, pos 00030000
1150 mmu set 00040000, pos 00040000
1150 mmu set 00050000, pos 00050000
1150 mmu set 00060000, pos 00060000
1150 mmu set 00070000, pos 00070000
1150 mmu set 00080000, pos 00080000
1150 mmu set 00090000, pos 00090000
ets Jul 29 2019 12:21:46

Then We also checked Flash Size and Flash ID using command which are below

Chip is ESP32D0WDQ5 (revision 1)
Features: WiFi, BT, Dual Core, 240MHz, VRef calibration in efuse, Coding Scheme None
MAC: 44:17:93:42:fd:70
Uploading stub...
Running stub...
Stub running...
Manufacturer: 00
Device: 0000
Detected flash size: Unknown

Chip is ESP32D0WDQ5 (revision 1)
Features: WiFi, BT, Dual Core, 240MHz, VRef calibration in efuse, Coding Scheme None
MAC: 44:17:93:42:fd:70
Uploading stub...
Running stub...
Stub running...
Status value: 0x0000

Would you please suggest us what can be the issue for this kind of damage? Can it be due to Voltage Fluctuation or something else?

Let me know if need anything else from my end.

[WiFive]

https://github.com/espressif/esp-idf/issues/7994

[Ritesh]

https://github.com/espressif/esp-idf/issues/7994

Thanks for providing response with link.

I have checked into that link but into that Flash ID is detected correctly in which they are having same issues.

But, In to our case, Flash ID is also not detected which seems to be little bit different as per issue link which you have shared. Correct?

[WiFive]

Yes but this part is suspiciously similar

Code: Select all

load:0xff001cff

[Ritesh]

Yes but this part is suspiciously similar

Code: Select all

load:0xff001cff

Thanks. Will check into details and let you know if find anything regarding that issue.

We have also discussed with Espressif Sales Team and they want our board to investigate issue from their end. So, We will plan it in parallel to send one faulty device at their end.

Let me know if you find anything regarding this issue from your end.

[Ritesh]

Hello WiFive,

We have checked and found that there are couple of more boards in which we have faced same issues. So, We are now into trouble like how to receive it as our complete product will be useless if ESP32 Module itself is damaged.

Would you please suggest us like can it be possible to have faulty batch of Flash Memory which is being used into those modules?

Because we are genarally purchasing reels for ESP32-WROVER or ESP32-WROVER-I modules.

Do you have any idea like Espressif Modules itself are went through QC process of each and every modules at the time of QC?

[WiFive]

Anything is possible. Have you checked all the flash id and 3 byte status registers of the failing modules? What is the flash id of a working module?

[LittleRain]

I just had a module with bad flash, had to take the shield off and replace the chip. Works now.

If you have an EEPROM programmer, try reading the chip and see if it fully erases.

[Ritesh]

Anything is possible. Have you checked all the flash id and 3 byte status registers of the failing modules? What is the flash id of a working module?

Hello WiFive,

Please find following details for Non Working Modules having issues of Flash Memory

Flash ID Command Output
Chip is ESP32D0WDQ5 (revision 1)
Features: WiFi, BT, Dual Core, 240MHz, VRef calibration in efuse, Coding Scheme None
MAC: 44:17:93:42:fd:70
Uploading stub...
Running stub...
Stub running...
Manufacturer: 00
Device: 0000
Detected flash size: Unknown

3 Bytes Status registers
Chip is ESP32D0WDQ5 (revision 1)
Features: WiFi, BT, Dual Core, 240MHz, VRef calibration in efuse, Coding Scheme None
MAC: 44:17:93:42:fd:70
Uploading stub...
Running stub...
Stub running...
Status value: 0x0000

Also find same details for working modules

Flash ID Command Output
Detecting chip type... ESP32
Chip is ESP32D0WDQ6 (revision 1)
Features: WiFi, BT, Dual Core, 240MHz, VRef calibration in efuse, Coding Scheme None
MAC: c4:4f:33:09:75:f5
Uploading stub...
Running stub...
Stub running...
Manufacturer: c8
Device: 6018
Detected flash size: 16MB
Hard resetting via RTS pin...

3 Bytes Status registers
Chip is ESP32D0WDQ6 (revision 1)
Features: WiFi, BT, Dual Core, 240MHz, VRef calibration in efuse, Coding Scheme None
MAC: c4:4f:33:09:75:f5
Uploading stub...
Running stub...
Stub running...
Status value: 0xff0000

Let me know if need anything else from our end

[Ritesh]

I just had a module with bad flash, had to take the shield off and replace the chip. Works now.

If you have an EEPROM programmer, try reading the chip and see if it fully erases.

Thanks

Have you faced same issue which i have mentioned into this post?

Because what happened like module was working fine as we did QC check of our board before sending to client then it stopped working at client end.