Strange MCUBoot behaviour on ESP32

[LB-ITP]

Hey Everyone,

hopefully someone can help me or least point in the right direction.
I am using Zephyr Version 4.2.99 on a custom board with an ESP32-Wrover-E. module. I am using mcuBoot to boot an application image which worked quite well for a while, but then I added some additional code to my application and suddenly I can no longer boot my application.

Everytime MCUboot reaches esp_rom_flash_unmmap in load_segment it jumps to spi_flash_encrypt_ll_plaintext_save and freezes. I suspected some stack corruption, so I increased the MAIN_STACK_SIZE (mcuboot) to the maximum possible. So far no success.
If I change the code I added to my application (or even add more code), mcuBoot jumps to another flash related method.

Is there anyone that already faced such problems?

Below is my mcuboot.conf

CONFIG_WIFI=n
CONFIG_WIFI_ESP32=n
CONFIG_SINGLE_APPLICATION_SLOT=y
CONFIG_MCUBOOT_BOOT_BANNER=y
CONFIG_MCUBOOT_LOG_LEVEL_DBG=y
CONFIG_MCUBOOT_LOG_LEVEL_OFF=n
CONFIG_ESP_SPIRAM=n
CONFIG_BOOT_BANNER=y
CONFIG_MAIN_STACK_SIZE=10240
CONFIG_HEAP_MEM_POOL_SIZE=4096
CONFIG_BOOT_BANNER=y
CONFIG_DEBUG=y
CONFIG_ASSERT=y
CONFIG_DEBUG_OPTIMIZATIONS=y

and my prj.conf

CONFIG_GPIO=y
CONFIG_SERIAL=y
CONFIG_UART_INTERRUPT_DRIVEN=y
CONFIG_UART_LINE_CTRL=n

# Wi-Fi Configuration
CONFIG_WIFI=y
CONFIG_WIFI_ESP32=y
CONFIG_ESP32_WIFI_STA_AUTO_DHCPV4=n
CONFIG_ESP32_WIFI_AP_STA_MODE=y
CONFIG_WIFI_NM=y
CONFIG_WIFI_NM_MAX_MANAGED_INTERFACES=2
# CONFIG_WIFI_NM_WPA_SUPPLICANT=y

# Network Configuration
CONFIG_NET_CONFIG_AUTO_INIT=y
CONFIG_NET_CONNECTION_MANAGER=y
CONFIG_NET_DHCPV4=n
CONFIG_NET_DHCPV4_SERVER=n
CONFIG_NET_IF_MAX_IPV4_COUNT=2

CONFIG_NET_IPV4=y
CONFIG_NET_IPV6=n

CONFIG_NET_L2_ETHERNET=y
CONFIG_NET_L2_WIFI_MGMT=y
CONFIG_NET_MGMT=y
CONFIG_NET_MGMT_EVENT=y
CONFIG_NET_MGMT_EVENT_INFO=y
CONFIG_NET_MGMT_EVENT_QUEUE_SIZE=10
CONFIG_NET_MGMT_EVENT_STACK_SIZE=4096

CONFIG_NET_CONNECTION_MANAGER_MONITOR_STACK_SIZE=2048
CONFIG_NET_PKT_RX_COUNT=32
CONFIG_NET_PKT_TX_COUNT=32
CONFIG_NET_CONTEXT_NET_PKT_POOL=y

CONFIG_NET_MGMT_EVENT_QUEUE_SIZE=20
CONFIG_NET_TCP_WORKQ_STACK_SIZE=8192

CONFIG_NET_SOCKETS=y
CONFIG_NET_SOCKETS_SERVICE_STACK_SIZE=8192
CONFIG_NET_TCP=y
CONFIG_NET_UDP=y
CONFIG_NETWORKING=y

CONFIG_NET_ICMPV4_ACCEPT_BROADCAST=y
CONFIG_NET_IPV4_ACCEPT_ZERO_BROADCAST=y

CONFIG_INIT_STACKS=y
CONFIG_HEAP_MEM_POOL_SIZE=60000
CONFIG_SYSTEM_WORKQUEUE_STACK_SIZE=10000
CONFIG_MAIN_STACK_SIZE=10000
CONFIG_ISR_STACK_SIZE=8192

CONFIG_NET_BUF_RX_COUNT=128
CONFIG_NET_BUF_TX_COUNT=128
CONFIG_NET_BUF_DATA_SIZE=256

CONFIG_NET_RX_STACK_SIZE=8192
CONFIG_NET_TX_STACK_SIZE=8192

# Eventfd
CONFIG_ZVFS_OPEN_MAX=32
CONFIG_ZVFS_EVENTFD_MAX=32
CONFIG_POSIX_API=y
CONFIG_FDTABLE=y
CONFIG_ZVFS_POLL_MAX=32
CONFIG_EVENTFD=y
CONFIG_POSIX_API=y

# JSON
CONFIG_JSON_LIBRARY=y

# HTTP parser
CONFIG_HTTP_PARSER_URL=y
CONFIG_HTTP_PARSER=y
CONFIG_HTTP_SERVER=y
CONFIG_HTTP_SERVER_WEBSOCKET=y
CONFIG_NET_SOCKETS_SERVICE=y
CONFIG_HTTP_SERVER_STACK_SIZE=8192

CONFIG_NET_CONFIG_SETTINGS=y
CONFIG_WIFI_CREDENTIALS_BACKEND_SETTINGS=y
CONFIG_FLASH=y
CONFIG_FLASH_PAGE_LAYOUT=y
CONFIG_FLASH_MAP=y
CONFIG_NVS=y
CONFIG_SETTINGS=y
CONFIG_SETTINGS_NVS=y

CONFIG_NET_CONFIG_NEED_IPV4=y
CONFIG_NET_CONFIG_NEED_IPV6=n
CONFIG_NET_CONFIG_MY_IPV4_ADDR="192.0.2.1"
CONFIG_NET_CONFIG_PEER_IPV4_ADDR="192.0.2.2"
CONFIG_NET_CONFIG_MY_IPV4_GW="192.0.2.2"


CONFIG_ESP_SPIRAM=y
CONFIG_ESP32_WIFI_NET_ALLOC_SPIRAM=y

# Bootloader
# CONFIG_MCUBOOT_IMGTOOL_SIGN_VERSION="0.1.0+0"
CONFIG_IMG_MANAGER=y
CONFIG_MCUBOOT_IMG_MANAGER=y
CONFIG_FLASH_MAP=y
CONFIG_FLASH=y
CONFIG_STREAM_FLASH=y
CONFIG_BOOTLOADER_MCUBOOT=y