[nrf52] add OTA for Adafruit_nRF52_Bootloader (#17381)

Co-authored-by: Jonathan Swoboda <154711427+swoboda1337@users.noreply.github.com>

esphome/components/nrf52/__init__.py

@@ -877,6 +877,21 @@ def run_compile(args, config: ConfigType) -> bool:
 
     zephyr_dir = build_dir / "zephyr"
     framework_ver = CORE.data[KEY_CORE][KEY_FRAMEWORK_VERSION]
+    bootloader = zephyr_data()[KEY_BOOTLOADER]
+
+    # (dev_type, sd_req) per bootloader — values from Nordic SoftDevice release notes
+    _GENPKG_PARAMS = {
+        BOOTLOADER_ADAFRUIT_NRF52_SD132: ("0x0051", "0x009D"),
+        BOOTLOADER_ADAFRUIT_NRF52_SD140_V6: ("0x0052", "0x00B6"),
+        BOOTLOADER_ADAFRUIT_NRF52_SD140_V7: ("0x0052", "0x00CA"),
+    }
+    # UF2 family IDs — nRF52832 vs nRF52840 per SoftDevice variant
+    _UF2_FAMILY_IDS = {
+        BOOTLOADER_ADAFRUIT_NRF52_SD132: "0x7EAED30A",
+        BOOTLOADER_ADAFRUIT_NRF52_SD140_V6: "0xADA52840",
+        BOOTLOADER_ADAFRUIT_NRF52_SD140_V7: "0xADA52840",
+    }
+
     # SDK < 2.9.2 places artifacts directly in build_dir/zephyr/.
     # SDK >= 2.9.2 nests them one level deeper (build_dir/zephyr/zephyr/);
     # copy files to match get_download_types layout.
@@ -888,20 +903,43 @@ def run_compile(args, config: ConfigType) -> bool:
         _copy_if_exists(west_out / "zephyr.signed.bin", zephyr_dir / "app_update.bin")
         _copy_if_exists(build_dir / "merged.hex", zephyr_dir / "merged.hex")
 
-    # (dev_type, sd_req) per bootloader — values from Nordic SoftDevice release notes
-    _GENPKG_PARAMS = {
-        BOOTLOADER_ADAFRUIT_NRF52_SD132: ("0x0051", "0x009D"),
-        BOOTLOADER_ADAFRUIT_NRF52_SD140_V6: ("0x0052", "0x00B6"),
-        BOOTLOADER_ADAFRUIT_NRF52_SD140_V7: ("0x0052", "0x00CA"),
-    }
-    bootloader = zephyr_data()[KEY_BOOTLOADER]
+    # For Adafruit bootloader builds, regenerate the UF2 from merged.hex,
+    # whose records carry the correct flash addresses. The build's own
+    # zephyr.uf2 uses the board's default offset, which is wrong in some cases.
+    merged_hex = zephyr_dir / "merged.hex"
+    if bootloader in _UF2_FAMILY_IDS and merged_hex.is_file():
+        # Drop the build's own wrong-offset UF2 so it isn't shipped alongside.
+        app_uf2 = west_out / "zephyr.uf2"
+        if app_uf2.is_file():
+            app_uf2.unlink()
+        uf2conv = (
+            paths["framework_path"] / "zephyr" / "scripts" / "build" / "uf2conv.py"
+        )
+        if not run_command_ok(
+            [
+                str(paths["python_executable"]),
+                str(uf2conv),
+                "-f",
+                _UF2_FAMILY_IDS[bootloader],
+                "-c",
+                "-o",
+                str(zephyr_dir / "zephyr.uf2"),
+                str(merged_hex),
+            ],
+            env=env,
+            stream_output=True,
+        ):
+            raise EsphomeError("Failed to generate UF2 from merged hex")
+
     if bootloader in (
         BOOTLOADER_ADAFRUIT,
         BOOTLOADER_ADAFRUIT_NRF52_SD132,
         BOOTLOADER_ADAFRUIT_NRF52_SD140_V6,
         BOOTLOADER_ADAFRUIT_NRF52_SD140_V7,
     ):
-        hex_file = west_out / "zephyr.hex"
+        # no fallback is needed for adafruit case. merged merged.hex is always generated.
+        # get_download_types needs fallback for mcuboot (non adafruit)
+        hex_file = zephyr_dir / "merged.hex"
         dfu_package = build_dir / "firmware.zip"
         genpkg_cmd = [
             str(paths["python_executable"]),

esphome/components/zephyr/__init__.py

@@ -26,7 +26,26 @@ from .const import (
 
 CODEOWNERS = ["@tomaszduda23"]
 
-PrjConfValueType = bool | str | int
+
+class HexValue:
+    """Wrap an integer so it is written as 0x... in prj.conf (required for hex Kconfig types)."""
+
+    def __init__(self, value: int) -> None:
+        self.value = value
+
+    def __eq__(self, other: object) -> bool:
+        if isinstance(other, HexValue):
+            return self.value == other.value
+        return NotImplemented
+
+    def __repr__(self) -> str:
+        return f"HexValue(0x{self.value:X})"
+
+    def __str__(self) -> str:
+        return f"0x{self.value:X}"
+
+
+PrjConfValueType = bool | str | int | HexValue
 
 
 class Section:
@@ -164,6 +183,8 @@ def zephyr_setup_preferences():
 def _format_prj_conf_val(value: PrjConfValueType) -> str:
     if isinstance(value, bool):
         return "y" if value else "n"
+    if isinstance(value, HexValue):
+        return hex(value.value)
     if isinstance(value, int):
         return str(value)
     if isinstance(value, str):
@@ -249,7 +270,7 @@ def copy_files() -> None:
         )
 
         if image:
-            path = CORE.relative_build_path(f"sysbuild/{image}.conf")
+            path = CORE.relative_build_path(f"zephyr/sysbuild/{image}.conf")
         else:
             path = CORE.relative_build_path("zephyr/prj.conf")
 
@@ -257,7 +278,7 @@ def copy_files() -> None:
 
     for image, content in zephyr_data()[KEY_OVERLAY].items():
         if image:
-            path = CORE.relative_build_path(f"sysbuild/{image}.overlay")
+            path = CORE.relative_build_path(f"zephyr/sysbuild/{image}.overlay")
         else:
             path = CORE.relative_build_path("zephyr/app.overlay")
         changed |= write_file_if_changed(path, content)

esphome/components/zephyr_mcumgr/ota/__init__.py

@@ -1,6 +1,8 @@
 import esphome.codegen as cg
+from esphome.components.nrf52.boards import BOOTLOADER_CONFIG
 from esphome.components.ota import BASE_OTA_SCHEMA, OTAComponent, ota_to_code
 from esphome.components.zephyr import (
+    HexValue,
     zephyr_add_cdc_acm,
     zephyr_add_overlay,
     zephyr_add_prj_conf,
@@ -72,12 +74,6 @@ CONFIG_SCHEMA = cv.All(
 )
 
 
-def _validate_mcumgr_bootloader(config: ConfigType) -> None:
-    bootloader = zephyr_data()[KEY_BOOTLOADER]
-    if bootloader != BOOTLOADER_MCUBOOT:
-        raise cv.Invalid(f"'{bootloader}' bootloader does not support OTA")
-
-
 KEY_ZEPHYR_BLE_SERVER = "zephyr_ble_server"
 
 
@@ -89,9 +85,22 @@ def _validate_ble_server(config: ConfigType) -> None:
         raise cv.Invalid(f"'{KEY_ZEPHYR_BLE_SERVER}' component is required for BLE OTA")
 
 
+def _validate_bootloader(config: ConfigType) -> None:
+    bootloader = zephyr_data()[KEY_BOOTLOADER]
+    if bootloader == BOOTLOADER_MCUBOOT:
+        return
+    if bootloader not in BOOTLOADER_CONFIG:
+        raise cv.Invalid(f"{bootloader} does not support OTA")
+    framework_ver: cv.Version = CORE.data[KEY_CORE][KEY_FRAMEWORK_VERSION]
+    if framework_ver < cv.Version(2, 9, 2):
+        raise cv.Invalid(
+            "OTA with Adafruit_nRF52_Bootloader requires at least SDK 2.9.2"
+        )
+
+
 def _final_validate(config: ConfigType) -> None:
-    _validate_mcumgr_bootloader(config)
     _validate_ble_server(config)
+    _validate_bootloader(config)
 
 
 FINAL_VALIDATE_SCHEMA = _final_validate
@@ -152,3 +161,70 @@ async def to_code(config: ConfigType) -> None:
     framework_ver = CORE.data[KEY_CORE][KEY_FRAMEWORK_VERSION]
     if framework_ver >= cv.Version(2, 9, 2):
         zephyr_data()[KEY_SYSBUILD] = True
+
+    bootloader = zephyr_data()[KEY_BOOTLOADER]
+    if bootloader != BOOTLOADER_MCUBOOT:
+        sections = BOOTLOADER_CONFIG[bootloader]
+        # Derive partition addresses from the SoftDevice and bootloader sections so
+        # that the DTS flash map matches what the Partition Manager produces:
+        #   MCUboot sits immediately after the SoftDevice, then slot0, then slot1.
+        mcuboot_size = 0x9000
+        sd_end = next(s.address + s.size for s in sections if "SoftDevice" in s.name)
+        bl_start = next(s.address for s in sections if "Adafruit" in s.name)
+        slot0_start = sd_end + mcuboot_size
+        # Align slot size down to a 4 KB sector boundary
+        slot_size = ((bl_start - slot0_start) // 2 // 0x1000) * 0x1000
+        slot1_start = slot0_start + slot_size
+
+        def _mcuboot_partition_overlay() -> str:
+            def part(name, start, size):
+                return f"""
+                {name}: partition@{start:x} {{
+                    reg = <0x{start:x} 0x{size:x}>;
+                }};"""
+
+            return f"""
+                /delete-node/ &boot_partition;
+                /delete-node/ &storage_partition;
+                /delete-node/ &code_partition;
+                /delete-node/ &reserved_partition_0;
+
+                &flash0 {{
+                    partitions {{
+                        compatible = "fixed-partitions";
+                        #address-cells = <1>;
+                        #size-cells = <1>;
+                        {part("slot0_partition", slot0_start, slot_size)}
+                        {part("slot1_partition", slot1_start, slot_size)}
+                    }};
+                }};
+            """
+
+        def _code_partition_overlay() -> str:
+            return """
+                / {
+                    chosen {
+                        zephyr,code-partition = &slot0_partition;
+                    };
+                };
+                """
+
+        zephyr_add_overlay(_mcuboot_partition_overlay())
+        zephyr_add_overlay(_mcuboot_partition_overlay(), "mcuboot")
+        zephyr_add_overlay(_code_partition_overlay())
+        zephyr_add_overlay(_code_partition_overlay(), "mcuboot")
+        # mcuboot is second bootloader. It's only task is to swap partitions.
+        # recovery can be done by first bootloader. Keep it small.
+        zephyr_add_overlay(
+            """
+                &zephyr_udc0 {
+                    status = "disabled";
+                };
+            """,
+            "mcuboot",
+        )
+        zephyr_add_prj_conf("USB_DEVICE_STACK", False, image="mcuboot")
+        zephyr_add_prj_conf("CONSOLE", False, image="mcuboot")
+        zephyr_add_prj_conf(
+            "PM_PARTITION_SIZE_MCUBOOT", HexValue(mcuboot_size), image="mcuboot"
+        )

tests/components/ota/test.nrf52-adafruit.yaml

@@ -0,0 +1,4 @@
+zephyr_ble_server:
+
+ota:
+  - platform: zephyr_mcumgr