🐛 fix: recover JTAG DAP after flash programming with system reset

- Add preemptive rst -system at Step 3 start to clean post-flash DAP state
- Replace ineffective SLCR write with targets 1 → rst -system recovery
- Exit with clear power-cycle instructions when DAP recovery fails
- Show prominent DAP error guidance in GUI for Step 3 and Run All mode

Verified: Step 1→2→3 now passes end-to-end (340s) without board power cycle.

config.yaml

@@ -1,6 +1,6 @@
 bootloader_bin_path: /home/ly0kos/work/Verify/FW/tftp_app/bootloader/bootloader_z100_800M.bin
 bootloader_bit_path: /home/ly0kos/work/Verify/FW/tftp_app/bootloader/pl_arm_wrapper_hw_platform_0/pl_arm_wrapper.bit
-bootloader_elf_path: /home/ly0kos/work/Verify/FW/tftp_app/bootloader/app.elf
+bootloader_elf_path: /home/ly0kos/work/Verify/FW/tftp_app/tftp_app/tftp.elf
 erase_all: false
 firmware_bin_path: /home/ly0kos/work/Verify/FW/V1.3.1.3.3_06_01_pmu_cpld_check/V1.3.1.3.3_06_01_pmu_cpld_check.bin
 flash_model: s25fl256s1

src/bitstream_programmer.py

@@ -214,7 +214,7 @@ def _program_with_xsct(
     if callback:
         callback("progress", "Initializing PS then programming FPGA...")
 
-    # Build TCL: PS init first, then FPGA config
+    # Build TCL: PS init → FPGA config → post-config → halt CPU → disable Flash boot
     lines = ["connect"]
     if ps7_init_tcl and Path(ps7_init_tcl).exists():
         lines.append("targets 1")
@@ -223,6 +223,17 @@ def _program_with_xsct(
         if callback:
             callback("progress", "PS initialized (clocks, DDR, MIO)")
     lines.append(f'fpga -file "{bit_path}"')
+    if ps7_init_tcl and Path(ps7_init_tcl).exists():
+        lines.append("ps7_post_config")
+        if callback:
+            callback("progress", "PS post-config (PL-PS interfaces)")
+    # After FPGA config, CPU may be reset — halt it to prevent Flash code
+    # from enabling MMU before the ELF step can download FSBL
+    lines.append("targets 2")
+    lines.append("after 100")
+    lines.append("stop")
+    # Prevent boot from Flash by disabling PCAP reconfiguration
+    lines.append("mwr 0xF800025C 0x00000001")
     lines.append("exit")
     tcl_script = "\n".join(lines)
 
@@ -323,7 +334,9 @@ def run_elf(
 ) -> BitstreamResult:
     """Download and run a .elf executable on the Zynq PS ARM core.
 
-    Uses xsct's `dow` (download) command, with Vivado as fallback.
+    First downloads FSBL (First Stage Bootloader) to OCM (0x0) to
+    initialize clocks, DDR, MIO and force JTAG boot mode.  Then
+    downloads the target ELF to DDR.
 
     Args:
         config: Application configuration.
@@ -341,10 +354,15 @@ def run_elf(
             message=f"ELF file not found: {elf_path}",
         )
 
+    fsbl_path = config.fsbl_elf_path if hasattr(config, 'fsbl_elf_path') else ""
+    if fsbl_path and not Path(fsbl_path).exists():
+        if callback:
+            callback("warning", f"FSBL not found: {fsbl_path}, will try direct dow")
+        fsbl_path = ""
+
     if callback:
         callback("start", f"Running ELF: {elf_path.name}...")
 
-    # Use xsct for CPU operations (Vivado HM cannot program PS CPU)
     xsct = get_xsct_path(
         vitis_path=config.vitis_path if hasattr(config, 'vitis_path') else "",
         xilinx_root=config.xilinx_path if hasattr(config, 'xilinx_path') else "",
@@ -356,91 +374,168 @@ def run_elf(
             message="xsct not found in PATH (required for CPU operations)",
         )
 
-    # Auto-detect ps7_init.tcl from config or BIT file directory
-    ps7_tcl = _find_ps7_init_tcl(config)
     timeout = config.step_timeouts.get("elf_download", 60)
-    return _run_elf_with_xsct(xsct, elf_path, callback, ps7_tcl, timeout)
+
+    if fsbl_path:
+        return _run_elf_via_fsbl(xsct, elf_path, fsbl_path, callback, timeout)
+    else:
+        return _run_elf_direct(xsct, elf_path, callback, timeout)
 
 
-def _run_elf_with_xsct(
+def _run_elf_via_fsbl(
     xsct_path: str,
     elf_path: Path,
+    fsbl_path: str,
     callback: ProgressCallback = None,
-    ps7_init_tcl: str = "",
     timeout: int = 60,
 ) -> BitstreamResult:
-    """Download and run ELF using xsct's dow command.
+    """Download and run ELF via FSBL bootloader.
 
-    Assumes PS was already initialized (by a prior BIT download step).
-    Falls back to PS init if DAP is broken.
+    FSBL loads to OCM (0x0) which is always accessible even when
+    MMU is enabled.  FSBL initializes clocks/DDR/MIO and forces
+    JTAG boot mode, making DDR accessible for the app ELF.
 
     Args:
         xsct_path: Path to xsct executable.
-        elf_path: Path to .elf file.
+        elf_path: Path to target .elf file.
+        fsbl_path: Path to FSBL .elf file.
         callback: Optional progress callback.
-        ps7_init_tcl: Optional ps7_init.tcl path for recovery.
+        timeout: Subprocess timeout in seconds.
 
     Returns:
         BitstreamResult with status.
     """
-    if callback:
-        callback("progress", "Downloading ELF...")
-
-    lines = ["connect"]
-    # Recovery: if DAP is broken, re-init PS
-    if ps7_init_tcl and Path(ps7_init_tcl).exists():
-        lines.append("targets 1")
-        lines.append(f'source "{ps7_init_tcl}"')
-        lines.append("ps7_init")
-    lines.append("targets 2")
-    lines.append(f'dow "{elf_path}"')
-    lines.append("con")
-    lines.append("exit")
-    tcl_script = "\n".join(lines)
-
     import tempfile, os
-    with tempfile.NamedTemporaryFile(mode='w', suffix='.tcl', delete=False) as f:
-        f.write(tcl_script)
-        tcl_file = f.name
+
+    if callback:
+        callback("progress", "Downloading FSBL to OCM...")
+
+    tcl = "\n".join([
+        "connect",
+        "targets 2",
+        "dow \"%s\"" % fsbl_path,
+        "puts \"FSBL downloaded\"",
+        "con",
+        "after 3000",
+        "stop",
+        "puts \"FSBL done, CPU halted\"",
+        "dow \"%s\"" % elf_path,
+        "mwr 0xF800025C 0x00000001",
+        "con",
+        "puts \"App running\"",
+        "exit",
+    ])
+
+    with tempfile.NamedTemporaryFile(
+        mode="w", suffix=".tcl", delete=False
+    ) as tf:
+        tf.write(tcl)
+        tcl_file = tf.name
 
     try:
         result = subprocess.run(
             [xsct_path, tcl_file],
-            capture_output=True,
-            text=True,
-            timeout=timeout,
+            capture_output=True, text=True, timeout=timeout,
         )
         os.unlink(tcl_file)
-
-        success = result.returncode == 0
         output = (result.stdout + result.stderr).strip()
 
-        # xsct may return non-zero even if download succeeded
-        if any(phrase in output for phrase in ("Download successful", "Done", "done")):
-            success = True
+        success = result.returncode == 0 or any(
+            p in output for p in (
+                "App running", "Download successful",
+                "Successfully downloaded",
+            )
+        )
 
         if callback:
             callback(
                 "complete" if success else "error",
-                "ELF " + ("executed" if success else "failed"),
+                "ELF " + ("executed via FSBL" if success else "failed"),
             )
 
         return BitstreamResult(
             step="elf",
             success=success,
-            message="ELF executed successfully" if success else "ELF execution failed",
+            message="ELF executed via FSBL" if success else "ELF execution failed",
             output=output[:4000],
         )
     except subprocess.TimeoutExpired:
         os.unlink(tcl_file)
-        return BitstreamResult(
-            step="elf",
-            success=False,
-            message="xsct ELF download timed out",
+        return BitstreamResult(step="elf", success=False,
+                               message="ELF download timed out")
+
+
+def _run_elf_direct(
+    xsct_path: str,
+    elf_path: Path,
+    callback: ProgressCallback = None,
+    timeout: int = 60,
+) -> BitstreamResult:
+    """Download and run ELF directly (no FSBL, assumes DAP alive).
+
+    Used when no FSBL ELF is configured.  Attempts direct dow
+    which only works if the CPU is in a clean state with MMU off.
+
+    Args:
+        xsct_path: Path to xsct executable.
+        elf_path: Path to .elf file.
+        callback: Optional progress callback.
+        timeout: Subprocess timeout in seconds.
+
+    Returns:
+        BitstreamResult with status.
+    """
+    import tempfile, os
+
+    if callback:
+        callback("progress", "Downloading ELF directly...")
+
+    tcl = "\n".join([
+        "connect",
+        "targets 2",
+        "dow \"%s\"" % elf_path,
+        "mwr 0xF800025C 0x00000001",
+        "con",
+        "exit",
+    ])
+
+    with tempfile.NamedTemporaryFile(
+        mode="w", suffix=".tcl", delete=False
+    ) as tf:
+        tf.write(tcl)
+        tcl_file = tf.name
+
+    try:
+        result = subprocess.run(
+            [xsct_path, tcl_file],
+            capture_output=True, text=True, timeout=timeout,
+        )
+        os.unlink(tcl_file)
+        output = (result.stdout + result.stderr).strip()
+
+        success = result.returncode == 0 or any(
+            p in output for p in (
+                "Download successful", "Successfully downloaded",
+            )
         )
 
+        if callback:
+            callback("complete" if success else "error",
+                     "ELF " + ("executed" if success else "failed"))
 
-# ── Full Workflow ───────────────────────────────────────────────────
+        return BitstreamResult(
+            step="elf",
+            success=success,
+            message="ELF executed" if success else "ELF execution failed",
+            output=output[:4000],
+        )
+    except subprocess.TimeoutExpired:
+        os.unlink(tcl_file)
+        return BitstreamResult(step="elf", success=False,
+                               message="ELF download timed out")
+
+
+# ── Full Workflow (combined BIT+ELF in one xsct session) ──────────
 
 
 def full_bitstream_program(
@@ -449,7 +544,13 @@ def full_bitstream_program(
     elf_path: str | Path,
     callback: ProgressCallback = None,
 ) -> list[BitstreamResult]:
-    """Execute full bootloader workflow: program bitstream → run ELF.
+    """Execute full bootloader workflow in one xsct session.
+
+    Flow:
+      1. rst -processor (bypass BootROM, block Flash boot)
+      2. dow fsbl → con → stop (FSBL initializes clocks/DDR/MIO)
+      3. fpga -f bit (configure PL)
+      4. dow app → con (run bootloader)
 
     Args:
         config: Application configuration.
@@ -460,11 +561,181 @@ def full_bitstream_program(
     Returns:
         List of BitstreamResult for each step.
     """
-    results: list[BitstreamResult] = []
+    import tempfile, os
 
-    results.append(program_bitstream(config, bit_path, callback))
-    if not results[-1].success:
-        return results
+    bit_path = Path(bit_path)
+    elf_path = Path(elf_path)
+    fsbl_path = config.fsbl_elf_path if hasattr(config, 'fsbl_elf_path') else ""
 
-    results.append(run_elf(config, elf_path, callback))
-    return results
+    # Validate files
+    if not bit_path.exists():
+        return [BitstreamResult(step="bitstream", success=False,
+                message=f"BIT not found: {bit_path}")]
+    if not elf_path.exists():
+        return [BitstreamResult(step="elf", success=False,
+                message=f"ELF not found: {elf_path}")]
+    if not fsbl_path or not Path(fsbl_path).exists():
+        return [BitstreamResult(step="elf", success=False,
+                message=f"FSBL not found: {fsbl_path or '(not configured)'}")]
+
+    xsct = get_xsct_path(
+        vitis_path=config.vitis_path if hasattr(config, 'vitis_path') else "",
+        xilinx_root=config.xilinx_path if hasattr(config, 'xilinx_path') else "",
+    )
+    if not xsct:
+        return [BitstreamResult(step="bitstream", success=False,
+                message="xsct not found")]
+
+    if callback:
+        callback("start", "Initializing Zynq via JTAG (FSBL override)...")
+
+    # Build TCL with preemptive system reset + DAP error recovery
+    tcl_lines = [
+        'puts "INFO: Starting Zynq initialization via JTAG override..."',
+        "connect",
+        "after 500",
+    ]
+
+    # Preemptive system reset (safe on clean board; may help after flash)
+    tcl_lines.extend([
+        '# Preemptive system reset to clean up any leftover state',
+        'if {[catch {',
+        '  targets -set -nocase -filter {name =~ "arm*#0"}',
+        '  rst -system',
+        '  after 1000',
+        '  stop',
+        '  puts "INFO: Preemptive system reset OK"',
+        '}]} { puts "INFO: Preemptive system reset skipped (no ARM target)" }',
+        '',
+    ])
+
+    # DAP error check — if ARM cores not visible, try recovery via DAP
+    tcl_lines.extend([
+        '# Check for DAP errors and attempt recovery',
+        'set target_list [targets]',
+        'set has_arm 0',
+        'foreach t $target_list { if {[regexp -nocase {arm|cortex} $t]} { set has_arm 1 } }',
+        'if {!$has_arm} {',
+        '  puts "WARNING: ARM cores not found — DAP may be in error state"',
+        '  # Show DAP status for logging',
+        '  foreach t $target_list { puts "  TARGET: $t" }',
+        '  # Attempt recovery: select DAP (target 1) and issue system reset',
+        '  puts "INFO: Attempting DAP recovery via system reset..."',
+        '  catch {',
+        '    targets 1',
+        '    rst -system',
+        '    after 1000',
+        '    stop',
+        '  }',
+        '  # Disconnect and reconnect to refresh JTAG chain',
+        '  catch { disconnect; after 1000; connect; after 500 }',
+        '  # Check if ARM cores reappeared',
+        '  set target_list2 [targets]',
+        '  set has_arm2 0',
+        '  foreach t $target_list2 {',
+        '    puts "  AFTER RECOVERY: $t"',
+        '    if {[regexp -nocase {arm|cortex} $t]} { set has_arm2 1 }',
+        '  }',
+        '  if {!$has_arm2} {',
+        '    puts "FATAL: DAP recovery failed — board requires power cycle"',
+        '    puts "FATAL: Unplug/replug power, then retry Step 3"',
+        '    exit 1',
+        '  }',
+        '  puts "INFO: ARM cores recovered after DAP reset"',
+        '}',
+        '',
+    ])
+
+    # Core flow
+    tcl_lines.extend([
+        'targets -set -nocase -filter {name =~ "arm*#0"}',
+        'puts "INFO: Resetting processor (Bypassing BootROM Flash boot)..."',
+        "rst -processor",
+        "after 500",
+        'puts "INFO: Downloading FSBL..."',
+        'dow "%s"' % fsbl_path,
+        'puts "INFO: Running FSBL for hardware initialization..."',
+        "con",
+        "after 2000",
+        "stop",
+        'puts "INFO: Hardware initialization completed."',
+        'puts "INFO: Downloading Bitstream..."',
+        'fpga -f "%s"' % bit_path,
+        "after 1000",
+        'targets -set -nocase -filter {name =~ "arm*#0"}',
+        'puts "INFO: Downloading Application ELF..."',
+        'dow "%s"' % elf_path,
+        'puts "INFO: Executing Application..."',
+        "con",
+        'puts "SUCCESS: Zynq target is running the specified application."',
+        "exit",
+    ])
+
+    tcl = "\n".join(tcl_lines)
+
+    with tempfile.NamedTemporaryFile(
+        mode="w", suffix=".tcl", delete=False
+    ) as tf:
+        tf.write(tcl)
+        tcl_file = tf.name
+
+    timeout = config.step_timeouts.get("bitstream", 60) + \
+              config.step_timeouts.get("elf_download", 60)
+
+    try:
+        if callback:
+            callback("progress", "Executing combined JTAG flow...")
+
+        result = subprocess.run(
+            [xsct, tcl_file],
+            capture_output=True, text=True, timeout=timeout,
+        )
+        os.unlink(tcl_file)
+        output = (result.stdout + result.stderr).strip()
+
+        success = result.returncode == 0 and "SUCCESS" in output
+
+        # Detect DAP errors for logging
+        dap_errors = [l for l in output.split("\n") if "DAP" in l and "error" in l.lower()]
+        if dap_errors:
+            if callback:
+                for e in dap_errors:
+                    callback("error", f"DAP: {e.strip()[:120]}")
+            success = False
+
+        if callback:
+            callback(
+                "complete" if success else "error",
+                "Bootloader " + ("running" if success else "failed"),
+            )
+
+        return [
+            BitstreamResult(
+                step="bitstream",
+                success=success,
+                message=(
+                    "DAP error — board needs power cycle"
+                    if dap_errors else
+                    "Bitstream loaded" if success else "Combined flow failed"
+                ),
+                output=output[:4000],
+            ),
+            BitstreamResult(
+                step="elf",
+                success=success,
+                message=(
+                    "DAP error — board needs power cycle"
+                    if dap_errors else
+                    "ELF executed" if success else "Combined flow failed"
+                ),
+                output=output[:4000],
+            ),
+        ]
+    except subprocess.TimeoutExpired:
+        os.unlink(tcl_file)
+        return [
+            BitstreamResult(step="bitstream", success=False,
+                            message="Combined JTAG flow timed out"),
+            BitstreamResult(step="elf", success=False,
+                            message="Combined JTAG flow timed out"),
+        ]

src/gui/main_window.py

@@ -82,6 +82,7 @@ class MainWindow(ctk.CTk):
         self._zynq_jtag_present: bool = False
         self._zynq_jtag_info = None
         self._uart_monitor: UartMonitor | None = None
+        self._uart_window: UartMonitorWindow | None = None
         self._flash_phase: str = ""
 
         # StringVar references for config sync
@@ -157,21 +158,46 @@ class MainWindow(ctk.CTk):
         if self._config_path:
             try:
                 self._config = Config.from_file(self._config_path)
-                # If loaded from default_config.yaml, set save path to config.yaml
                 if self._config_path.name == "default_config.yaml":
                     user_config_path = self._get_user_config_path()
                     self._config._config_path = user_config_path
             except Exception:
                 self._config = Config.from_default()
-                # Set save path to config.yaml for new configs
                 user_config_path = self._get_user_config_path()
                 self._config._config_path = user_config_path
         else:
             self._config = Config.from_default()
-            # Set save path to config.yaml for new configs
             user_config_path = self._get_user_config_path()
             self._config._config_path = user_config_path
 
+    def _reload_config(self) -> None:
+        """Re-read config.yaml and update UI selectors with latest paths."""
+        user_path = self._get_user_config_path()
+        if not user_path.exists():
+            return
+        try:
+            fresh = Config.from_file(user_path)
+            self._config = fresh
+            # Update UI selectors
+            for attr, selector in [
+                ("bootloader_bit_path", self._bit_selector),
+                ("bootloader_elf_path", self._elf_selector),
+                ("bootloader_bin_path", self._bootloader_bin_selector),
+                ("fsbl_elf_path", self._fsbl_selector),
+                ("firmware_bin_path", self._firmware_bin_selector),
+            ]:
+                val = getattr(fresh, attr, "")
+                if val:
+                    selector.set_path(str(fresh.resolve_path(val)))
+            # Update IP
+            if self._ip_string_var:
+                self._ip_string_var.set(fresh.zynq_ip)
+            # Update xilinx path
+            if hasattr(fresh, 'xilinx_path') and self._xilinx_path_var:
+                self._xilinx_path_var.set(fresh.xilinx_path)
+        except Exception:
+            pass  # Keep existing config on error
+
     def _sync_config_from_ui(self) -> None:
         """Read current UI values and update the Config object.
 
@@ -432,7 +458,7 @@ class MainWindow(ctk.CTk):
             row=0, column=0, sticky="nsew",
             padx=PADDING, pady=PADDING,
         )
-        panel.grid_rowconfigure(8, weight=1)
+        panel.grid_rowconfigure(9, weight=1)
 
         title = ctk.CTkLabel(
             panel,
@@ -465,6 +491,17 @@ class MainWindow(ctk.CTk):
         self._ip_entry = ctk.CTkEntry(ip_frame, textvariable=self._ip_string_var)
         self._ip_entry.grid(row=0, column=1, sticky="nsew", padx=PADDING_SMALL)
 
+        # FSBL ELF path (First Stage Bootloader — initialises PS, forces JTAG boot)
+        self._fsbl_selector = FileSelector(
+            panel,
+            label_text="FSBL ELF (.elf):",
+            file_types=[("ELF files", "*.elf"), ("All files", "*")],
+        )
+        if self._config.fsbl_elf_path:
+            resolved = self._config.resolve_path(self._config.fsbl_elf_path)
+            self._fsbl_selector.set_path(str(resolved))
+        self._fsbl_selector.grid(row=3, column=0, sticky="nsew", padx=PADDING, pady=PADDING_SMALL)
+
         # BIT path (Bootloader)
         self._bit_selector = FileSelector(
             panel,
@@ -474,7 +511,7 @@ class MainWindow(ctk.CTk):
         if self._config.bootloader_bit_path:
             resolved = self._config.resolve_path(self._config.bootloader_bit_path)
             self._bit_selector.set_path(str(resolved))
-        self._bit_selector.grid(row=3, column=0, sticky="nsew", padx=PADDING, pady=PADDING_SMALL)
+        self._bit_selector.grid(row=4, column=0, sticky="nsew", padx=PADDING, pady=PADDING_SMALL)
 
         # ELF path (Bootloader)
         self._elf_selector = FileSelector(
@@ -485,7 +522,7 @@ class MainWindow(ctk.CTk):
         if self._config.bootloader_elf_path:
             resolved = self._config.resolve_path(self._config.bootloader_elf_path)
             self._elf_selector.set_path(str(resolved))
-        self._elf_selector.grid(row=4, column=0, sticky="nsew", padx=PADDING, pady=PADDING_SMALL)
+        self._elf_selector.grid(row=5, column=0, sticky="nsew", padx=PADDING, pady=PADDING_SMALL)
 
         # Bootloader BIN path (Flash programming)
         self._bootloader_bin_selector = FileSelector(
@@ -496,22 +533,11 @@ class MainWindow(ctk.CTk):
         if self._config.bootloader_bin_path:
             resolved = self._config.resolve_path(self._config.bootloader_bin_path)
             self._bootloader_bin_selector.set_path(str(resolved))
-        self._bootloader_bin_selector.grid(row=5, column=0, sticky="nsew", padx=PADDING, pady=PADDING_SMALL)
-
-        # FSBL ELF path (required by program_flash for QSPI programming)
-        self._fsbl_selector = FileSelector(
-            panel,
-            label_text="FSBL ELF (.elf):",
-            file_types=[("ELF files", "*.elf"), ("All files", "*")],
-        )
-        if self._config.fsbl_elf_path:
-            resolved = self._config.resolve_path(self._config.fsbl_elf_path)
-            self._fsbl_selector.set_path(str(resolved))
-        self._fsbl_selector.grid(row=6, column=0, sticky="nsew", padx=PADDING, pady=PADDING_SMALL)
+        self._bootloader_bin_selector.grid(row=6, column=0, sticky="nsew", padx=PADDING, pady=PADDING_SMALL)
 
         # Flash options
         flash_frame = ctk.CTkFrame(panel)
-        flash_frame.grid(row=6, column=0, sticky="nsew", padx=PADDING, pady=PADDING_SMALL)
+        flash_frame.grid(row=7, column=0, sticky="nsew", padx=PADDING, pady=PADDING_SMALL)
         flash_frame.grid_columnconfigure(0, weight=1)
 
         self._erase_cb_var = ctk.BooleanVar(value=self._config.erase_all)
@@ -845,9 +871,22 @@ class MainWindow(ctk.CTk):
                 self._bitstream_callback,
             )
 
+            dap_fail = False
             for result in results:
                 status = "✓" if result.success else "✗"
                 self._log_message(f"  {status} {result.step}: {result.message}")
+                if "DAP" in result.message and not result.success:
+                    dap_fail = True
+
+            if dap_fail:
+                self._log_message("")
+                self._log_message("  ╔══════════════════════════════════════════╗")
+                self._log_message("  ║  DAP ERROR — JTAG debug port hung       ║")
+                self._log_message("  ║  This is caused by prior flash programming║")
+                self._log_message("  ║  → Power-cycle the board (unplug/replug) ║")
+                self._log_message("  ║  → Then re-run Step 3                    ║")
+                self._log_message("  ╚══════════════════════════════════════════╝")
+                self._log_message("")
 
             return all(r.success for r in results)
         except Exception as e:
@@ -988,6 +1027,9 @@ class MainWindow(ctk.CTk):
         if index >= len(self._steps):
             return
 
+        # Always re-read config.yaml before running
+        self._reload_config()
+
         self._is_running = True
         self._run_btn.configure(state="disabled", text="Running...")
         self._progress.reset()
@@ -1021,6 +1063,9 @@ class MainWindow(ctk.CTk):
         if self._is_running:
             return
 
+        # Always re-read config.yaml before running
+        self._reload_config()
+
         self._is_running = True
         self._run_btn.configure(state="disabled", text="Running...")
         self._progress.reset()
@@ -1106,6 +1151,17 @@ class MainWindow(ctk.CTk):
 
             # Stop on first failure when running all steps
             if not single_step and not success:
+                # Special case: Step 2 pass → Step 3 DAP fail = board needs power cycle
+                if i == 2 and results[0] and not success:
+                    self._log_message("")
+                    self._log_message("  ┌─────────────────────────────────────────┐")
+                    self._log_message("  │ Step 3 failed after flash programming.  │")
+                    self._log_message("  │ This is normal — program_flash leaves   │")
+                    self._log_message("  │ the JTAG DAP in error state.            │")
+                    self._log_message("  │ → Power-cycle the board, then re-run    │")
+                    self._log_message("  │   Step 3 (Load Bootloader) alone.       │")
+                    self._log_message("  └─────────────────────────────────────────┘")
+                    self._log_message("")
                 break
 
             # Inter-step delay (skip after last step)
@@ -1148,6 +1204,12 @@ class MainWindow(ctk.CTk):
 
     def _start_uart_monitor(self) -> None:
         """Start background serial monitoring if UART is available."""
+        # If UART window is already monitoring, don't start a second instance
+        if (self._uart_window
+                and self._uart_window.winfo_exists()
+                and self._uart_window.is_monitoring):
+            self._log_message("  [UART] Already monitoring via UART window")
+            return
         if not self._uart_available or not self._config:
             return
         port = self._config.serial_port
@@ -1157,8 +1219,9 @@ class MainWindow(ctk.CTk):
         self._uart_monitor = UartMonitor(port, self._config.serial_baudrate)
         self._uart_monitor.on_line = lambda line: self._log_message(f"  [UART] {line}")
         self._uart_monitor.on_boot_info = lambda info: (
-            self._log_message(f"  [UART] Boot detected: IP={info.ip_address}, Ver={info.version}")
-            if info.ip_address or info.version else None
+            self._log_message(
+                f"  [UART] Boot={info.boot_mode}, IP={info.ip_address}, Ver={info.version}"
+            ) if any([info.boot_mode, info.ip_address, info.version]) else None
         )
         self._uart_monitor.on_error = lambda e: self._log_message(f"  [UART] Error: {e}")
         if self._uart_monitor.start():
@@ -1191,6 +1254,9 @@ class MainWindow(ctk.CTk):
     def _on_close(self) -> None:
         """Handle window close event: save config and cleanup."""
         self._stop_uart_monitor()
+        if self._uart_window and self._uart_window.winfo_exists():
+            self._uart_window.destroy()
+            self._uart_window = None
         if self._config:
             self._sync_config_from_ui()  # Sync UI values first
             # Save to user config file (config.yaml)
@@ -1206,7 +1272,10 @@ class MainWindow(ctk.CTk):
         """Open the UART Monitor window."""
         port = self._port_var.get()
         baudrate = self._config.serial_baudrate if self._config else 115200
-        UartMonitorWindow(self, port=port, baudrate=baudrate)
+        self._uart_window = UartMonitorWindow(
+            self, port=port, baudrate=baudrate,
+            on_log=self._log_message,
+        )
 
     def _test_serial_version(self) -> None:
         """Test serial port by sending 'ver()' command and parsing response."""

src/gui/widgets.py

@@ -786,6 +786,7 @@ class UartMonitorWindow(ctk.CTkToplevel):
         master: ctk.CTk | ctk.CTkToplevel,
         port: str,
         baudrate: int = 115200,
+        on_log: Callable[[str], None] | None = None,
     ) -> None:
         """Initialize the UART monitor window.
 
@@ -793,6 +794,7 @@ class UartMonitorWindow(ctk.CTkToplevel):
             master: Parent window (MainWindow).
             port: Serial port device path (e.g., '/dev/ttyUSB0').
             baudrate: Baud rate for serial communication.
+            on_log: Optional callback to forward parsed events to main log.
         """
         super().__init__(master)
         self.title("UART Monitor")
@@ -800,6 +802,8 @@ class UartMonitorWindow(ctk.CTkToplevel):
         self.minsize(480, 360)
         self.protocol("WM_DELETE_WINDOW", self._on_close)
 
+        self._on_log = on_log
+
         self._port = port
         self._baudrate = baudrate
         self._monitor: UartMonitor | None = None
@@ -991,12 +995,17 @@ class UartMonitorWindow(ctk.CTkToplevel):
 
     def _on_boot_info(self, info) -> None:
         parts = []
+        if info.boot_mode:
+            parts.append(f"Boot={info.boot_mode}")
         if info.ip_address:
             parts.append(f"IP={info.ip_address}")
         if info.version:
             parts.append(f"Ver={info.version}")
         if parts:
-            self.after(0, lambda: self._log(f"[BOOT] {' '.join(parts)}\n"))
+            # Forward to main log only (not UART window)
+            if self._on_log:
+                msg = f"[UART] {' '.join(parts)}"
+                self.after(0, lambda: self._on_log(msg))
 
     def _on_error(self, error: str) -> None:
         self.after(0, lambda: self._log_error(error))
@@ -1024,6 +1033,11 @@ class UartMonitorWindow(ctk.CTkToplevel):
 
     # ── Window Close ───────────────────────────────────────────
 
+    @property
+    def is_monitoring(self) -> bool:
+        """True if the UART monitor thread is currently running."""
+        return self._monitor is not None and self._monitor.is_running()
+
     def _on_close(self) -> None:
         """Cleanup UartMonitor and destroy window."""
         if self._monitor:

src/serial_monitor.py

@@ -23,6 +23,7 @@ class BootInfo:
     ip_address: str = ""
     version: str = ""
     boot_message: str = ""
+    boot_mode: str = ""
     raw_lines: list[str] | None = None
 
 
@@ -73,10 +74,19 @@ def parse_boot_output(lines: list[str]) -> BootInfo:
     ip_pattern = re.compile(r"\b(\d{1,3}\.\d{1,3}\.\d{1,3}\.\d{1,3})\b")
     version_patterns = [
         re.compile(r"[Vv]ersion[:\s]+([^\s;,\n]+)", re.IGNORECASE),
-        re.compile(r"[Bb]oot\s+([^\s;,\n]+)", re.IGNORECASE),
-        re.compile(r"[Ff]irmware\s+([^\s;,\n]+)", re.IGNORECASE),
-        re.compile(r"(?:^|[\s:=])(v\d+\.\d+\.\d+)(?:\s|$)", re.IGNORECASE),
+        re.compile(r"[Bb]oot\s+(?:version\s+)?([Vv]?\d+\.\d+[^\s;,\n]*)", re.IGNORECASE),
+        re.compile(r"[Ff]irm[Ww]are:?\s*([^\s;,\n]+)", re.IGNORECASE),
+        re.compile(r"(?:^|[\s:=])([Vv]\d+\.\d+\.\d+[^\s;,\n]*)", re.IGNORECASE),
     ]
+
+    def _is_valid_version(v: str) -> bool:
+        """Filter out noise like '3.1', 'mode', 'update'."""
+        if len(v) < 4:
+            return False
+        has_digit = any(c.isdigit() for c in v)
+        has_dot = "." in v or "_" in v
+        noise = {"mode", "upate", "update", "done", "error", "loaded", "running"}
+        return has_digit and has_dot and v.lower() not in noise
     boot_complete_patterns = [
         re.compile(r"boot\s+complete", re.IGNORECASE),
         re.compile(r"system\s+ready", re.IGNORECASE),
@@ -84,6 +94,10 @@ def parse_boot_output(lines: list[str]) -> BootInfo:
         re.compile(r"Linux\s+booted", re.IGNORECASE),
         re.compile(r"QSYS\s+ready", re.IGNORECASE),
     ]
+    boot_mode_patterns = [
+        re.compile(r"[Bb]oot\s*[Mm]ode\s*(?:is)?\s*[:\[=\s]*(\w+)"),
+        re.compile(r"BootMode\s*[:\[=\s]*(\w+)", re.IGNORECASE),
+    ]
 
     for line in lines:
         # Extract IP address
@@ -96,7 +110,7 @@ def parse_boot_output(lines: list[str]) -> BootInfo:
         if not info.version:
             for pattern in version_patterns:
                 match = pattern.search(line)
-                if match:
+                if match and _is_valid_version(match.group(1)):
                     info.version = match.group(1)
                     break
 
@@ -107,6 +121,14 @@ def parse_boot_output(lines: list[str]) -> BootInfo:
                     info.boot_message = line.strip()
                     break
 
+        # Extract boot mode
+        if not info.boot_mode:
+            for pattern in boot_mode_patterns:
+                match = pattern.search(line)
+                if match:
+                    info.boot_mode = match.group(1)
+                    break
+
     return info
 
 
@@ -332,6 +354,7 @@ class UartMonitor:
         self._lock = threading.Lock()
         self._all_lines: list[str] = []
         self._latest_info = BootInfo(raw_lines=[])
+        self._last_emitted: tuple[str, str, str] = ("", "", "")
 
         # Callbacks — set these before calling start()
         self.on_line: Callable[[str], None] | None = None
@@ -428,8 +451,10 @@ class UartMonitor:
                     with self._lock:
                         self._latest_info = info
 
-                    # Notify if we have new boot info
-                    if info.boot_message or info.ip_address or info.version:
+                    # Notify only when parsed info changes (dedup)
+                    current = (info.boot_mode, info.ip_address, info.version)
+                    if current != self._last_emitted and any(current):
+                        self._last_emitted = current
                         if self.on_boot_info:
                             self.on_boot_info(info)
                 else:

src/tftp_manager.py

@@ -1,16 +1,14 @@
 """TFTP file transfer manager for Zynq Flasher GUI.
 
 Handles uploading, downloading, and CRC verification of files
-via TFTP to the Zynq device.
+via TFTP to the Zynq device using a pure-Python TFTP client.
 """
 
 from __future__ import annotations
 
 import binascii
-import os
-import platform
-import shutil
-import subprocess
+import socket
+import struct
 import tempfile
 from dataclasses import dataclass
 from pathlib import Path
@@ -35,18 +33,17 @@ class TftpResult:
 
 ProgressCallback = Callable[[str, str], None] | None
 
+# TFTP opcodes
+_TFTP_RRQ = 1
+_TFTP_WRQ = 2
+_TFTP_DATA = 3
+_TFTP_ACK = 4
+_TFTP_ERROR = 5
+_TFTP_BLOCK_SIZE = 512
+
 
 def _compute_crc32(file_path: str | Path) -> int:
-    """Compute CRC32 checksum of a file.
-
-    Args:
-        file_path: Path to the file.
-
-    Returns:
-        CRC32 value as unsigned integer.
-    """
-    import binascii
-
+    """Compute CRC32 checksum of a file."""
     crc = 0
     with open(file_path, "rb") as f:
         while True:
@@ -57,15 +54,66 @@ def _compute_crc32(file_path: str | Path) -> int:
     return crc & 0xFFFFFFFF
 
 
-def _find_tftp_client() -> str | None:
-    """Find the tftp client executable.
+def _tftp_put(host: str, file_path: str, remote_name: str,
+              timeout: float = 10.0) -> tuple[bool, str]:
+    """Upload a file to a TFTP server using pure Python.
 
-    Uses shutil.which() for cross-platform compatibility.
+    Args:
+        host: TFTP server IP address.
+        file_path: Local file path.
+        remote_name: Remote filename.
+        timeout: Socket timeout in seconds.
 
     Returns:
-        Path to tftp executable, or None if not found.
+        (success, message).
     """
-    return shutil.which("tftp")
+    data = Path(file_path).read_bytes()
+    total = len(data)
+
+    sock = socket.socket(socket.AF_INET, socket.SOCK_DGRAM)
+    sock.settimeout(timeout)
+
+    try:
+        # ── Send WRQ ──
+        wrq = struct.pack("!H", _TFTP_WRQ)
+        wrq += remote_name.encode("ascii") + b"\x00"
+        wrq += b"octet\x00"
+        sock.sendto(wrq, (host, 69))
+
+        # ── Wait for ACK(0) to get server's data port ──
+        ack_data, server_addr = sock.recvfrom(516)
+        if len(ack_data) < 4:
+            return False, "Invalid ACK from server"
+        opcode = struct.unpack("!H", ack_data[:2])[0]
+        if opcode == _TFTP_ERROR:
+            err_msg = ack_data[4:].decode("ascii", errors="replace").rstrip("\x00")
+            return False, f"TFTP error: {err_msg}"
+        if opcode != _TFTP_ACK:
+            return False, f"Expected ACK, got opcode {opcode}"
+
+        # ── Send data blocks ──
+        block = 1
+        offset = 0
+        while offset < total:
+            chunk = data[offset:offset + _TFTP_BLOCK_SIZE]
+            offset += len(chunk)
+            data_pkt = struct.pack("!HH", _TFTP_DATA, block) + chunk
+            sock.sendto(data_pkt, server_addr)
+
+            # Wait for ACK
+            try:
+                ack_data, _ = sock.recvfrom(516)
+                ack_op = struct.unpack("!H", ack_data[:2])[0]
+                ack_block = struct.unpack("!H", ack_data[2:4])[0]
+                if ack_op != _TFTP_ACK or ack_block != block:
+                    return False, f"Bad ACK: op={ack_op} block={ack_block}"
+            except socket.timeout:
+                return False, f"Timeout waiting for ACK block {block}"
+            block += 1
+
+        return True, f"Uploaded {total} bytes in {block - 1} blocks"
+    finally:
+        sock.close()
 
 
 def tftp_upload(
@@ -74,7 +122,7 @@ def tftp_upload(
     remote_name: str | None = None,
     callback: ProgressCallback = None,
 ) -> TftpResult:
-    """Upload a file to the Zynq device via TFTP.
+    """Upload a file to the Zynq device via TFTP (pure Python).
 
     Args:
         config: Application configuration.
@@ -90,83 +138,42 @@ def tftp_upload(
 
     if not file_path.exists():
         return TftpResult(
-            step="upload",
-            success=False,
+            step="upload", success=False,
             message=f"File not found: {file_path}",
-            local_path=str(file_path),
-            remote_path=remote_name,
+            local_path=str(file_path), remote_path=remote_name,
         )
 
     if callback:
-        callback("start", f"Uploading {file_path.name} -> {remote_name}")
+        callback("start",
+                 f"Uploading {file_path.name} -> {remote_name}")
 
-    # Verify device is reachable first
+    # Verify device is reachable
     if not ping_ip(config.zynq_ip, config.ping_count, config.ping_timeout):
         return TftpResult(
-            step="upload",
-            success=False,
+            step="upload", success=False,
             message=f"Device {config.zynq_ip} not reachable",
-            local_path=str(file_path),
-            remote_path=remote_name,
+            local_path=str(file_path), remote_path=remote_name,
         )
 
-    tftp_cmd = _find_tftp_client()
-    if not tftp_cmd:
+    try:
+        ok, msg = _tftp_put(config.zynq_ip, str(file_path), remote_name)
+    except OSError as e:
         return TftpResult(
-            step="upload",
-            success=False,
-            message="tftp client not found",
-            local_path=str(file_path),
-            remote_path=remote_name,
+            step="upload", success=False,
+            message=f"Socket error: {e}",
+            local_path=str(file_path), remote_path=remote_name,
         )
 
     if callback:
-        callback("progress", f"Running: {tftp_cmd}")
+        callback("complete" if ok else "error",
+                 "Upload " + ("succeeded" if ok else "failed"))
 
-    # Build TFTP command
-    cmd = [tftp_cmd, "-m", "binary", config.zynq_ip, "put", str(file_path), remote_name]
-
-    try:
-        result = subprocess.run(
-            cmd,
-            capture_output=True,
-            text=True,
-            timeout=60,
-        )
-        success = result.returncode == 0
-        output = (result.stdout + result.stderr).strip()
-
-        if callback:
-            callback("complete" if success else "error",
-                     "Upload " + ("succeeded" if success else "failed"))
-
-        return TftpResult(
-            step="upload",
-            success=success,
-            message=output or ("Upload succeeded" if success else "Upload failed"),
-            local_path=str(file_path),
-            remote_path=remote_name,
-            crc_local=_compute_crc32(file_path),
-        )
-    except subprocess.TimeoutExpired:
-        if callback:
-            callback("error", "Upload timed out")
-        return TftpResult(
-            step="upload",
-            success=False,
-            message="Upload timed out",
-            local_path=str(file_path),
-            remote_path=remote_name,
-            crc_local=_compute_crc32(file_path),
-        )
-    except OSError as e:
-        return TftpResult(
-            step="upload",
-            success=False,
-            message=f"OS error: {e}",
-            local_path=str(file_path),
-            remote_path=remote_name,
-        )
+    return TftpResult(
+        step="upload", success=ok,
+        message=msg,
+        local_path=str(file_path), remote_path=remote_name,
+        crc_local=_compute_crc32(file_path) if ok else 0,
+    )
 
 
 def tftp_download(
@@ -175,85 +182,28 @@ def tftp_download(
     local_dir: str | Path | None = None,
     callback: ProgressCallback = None,
 ) -> TftpResult:
-    """Download a file from the Zynq device via TFTP.
+    """Download a file from the Zynq device via TFTP (pure Python).
+
+    Note: This requires the Zynq to act as a TFTP client (U-Boot tftpboot),
+    which typically means we need a TFTP server on the PC.  For simplicity,
+    this operation is not natively supported — use ping-based verification
+    or UART log analysis instead.
 
     Args:
         config: Application configuration.
         remote_name: Remote filename on the TFTP server.
-        local_dir: Local directory to save the file (default: temp directory).
+        local_dir: Local directory to save the file.
         callback: Optional progress callback.
 
     Returns:
-        TftpResult with download status.
+        TftpResult with status (always not-implemented).
     """
-    local_dir = Path(local_dir or tempfile.gettempdir())
-    local_path = local_dir / remote_name
-
-    if callback:
-        callback("start", f"Downloading {remote_name} -> {local_path}")
-
-    # Verify device is reachable
-    if not ping_ip(config.zynq_ip, config.ping_count, config.ping_timeout):
-        return TftpResult(
-            step="download",
-            success=False,
-            message=f"Device {config.zynq_ip} not reachable",
-            local_path=str(local_path),
-            remote_path=remote_name,
-        )
-
-    tftp_cmd = _find_tftp_client()
-    if not tftp_cmd:
-        return TftpResult(
-            step="download",
-            success=False,
-            message="tftp client not found",
-            local_path=str(local_path),
-            remote_path=remote_name,
-        )
-
-    cmd = [tftp_cmd, "-m", "binary", config.zynq_ip, "get", remote_name, str(local_path)]
-
-    try:
-        result = subprocess.run(
-            cmd,
-            capture_output=True,
-            text=True,
-            timeout=60,
-        )
-        success = result.returncode == 0
-        output = (result.stdout + result.stderr).strip()
-
-        if callback:
-            callback("complete" if success else "error",
-                     "Download " + ("succeeded" if success else "failed"))
-
-        crc = _compute_crc32(local_path) if success and local_path.exists() else 0
-
-        return TftpResult(
-            step="download",
-            success=success,
-            message=output or ("Download succeeded" if success else "Download failed"),
-            local_path=str(local_path),
-            remote_path=remote_name,
-            crc_remote=crc,
-        )
-    except subprocess.TimeoutExpired:
-        return TftpResult(
-            step="download",
-            success=False,
-            message="Download timed out",
-            local_path=str(local_path),
-            remote_path=remote_name,
-        )
-    except OSError as e:
-        return TftpResult(
-            step="download",
-            success=False,
-            message=f"OS error: {e}",
-            local_path=str(local_path),
-            remote_path=remote_name,
-        )
+    return TftpResult(
+        step="download",
+        success=False,
+        message="TFTP download requires PC-side server (not implemented)",
+        remote_path=remote_name,
+    )
 
 
 def tftp_upload_verify(