fix: replace Popen readline loop with subprocess.run for Windows pipe reliability; add close_hw before quit in TCL; revert console=True

- ping_ip returns bool, not tuple — fixed 2 unpack errors
- TftpSubStepFrame: _skipped set prevents set_phase from overwriting Skip
- set_expanded(True) before skip marking so UI shows it immediately
- After Step 3 success, fix IP to 192.168.100.11

.gitignore

@@ -33,7 +33,8 @@ htmlcov/
 # ── Opencode (internal tooling) ──────────────────────────────
 .opencode/
 
-# ── Config overrides (user-specific) ─────────────────────────
+# ── Config (user-specific, auto-generated if missing) ─────────
+config.yaml
 config/zynq_flasher.yaml
 
 # ── Logs ─────────────────────────────────────────────────────

ZynqFlasher.spec

@@ -0,0 +1,63 @@
+# -*- mode: python ; coding: utf-8 -*-
+"""PyInstaller spec for Zynq Flasher — Windows x64 single-exe build.
+
+Usage:
+    pyinstaller --clean --noconfirm ZynqFlasher.spec
+    → output: dist/ZynqFlasher.exe
+"""
+
+from PyInstaller.utils.hooks import collect_data_files, collect_submodules
+
+block_cipher = None
+
+a = Analysis(
+    ['app.py'],
+    pathex=['src'],
+    binaries=[],
+    datas=[
+        # CustomTkinter themes, fonts, icons — auto-collected
+        *collect_data_files('customtkinter'),
+        # Default config shipped as template
+        ('config/default_config.yaml', 'config'),
+    ],
+    hiddenimports=[
+        *collect_submodules('customtkinter'),
+        'darkdetect',
+        'yaml',
+        'serial',
+        'serial.tools',
+        'serial.tools.list_ports',
+    ],
+    hookspath=[],
+    hooksconfig={},
+    runtime_hooks=[],
+    excludes=[],
+    win_no_prefer_redirects=False,
+    win_private_assemblies=False,
+    cipher=block_cipher,
+    noarchive=False,
+)
+
+pyz = PYZ(a.pure)
+
+exe = EXE(
+    pyz,
+    a.scripts,
+    a.binaries,
+    a.zipfiles,
+    a.datas,
+    [],
+    name='ZynqFlasher',
+    debug=False,
+    bootloader_ignore_signals=False,
+    strip=False,
+    upx=True,
+    upx_exclude=[],
+    runtime_tmpdir=None,
+    console=True,       # show console for terminal log output
+    disable_windowed_traceback=False,
+    argv_emulation=False,
+    target_arch=None,
+    codesign_identity=None,
+    entitlements_file=None,
+)

build_windows.bat

@@ -0,0 +1,47 @@
+@echo off
+setlocal
+
+echo ============================================================
+echo   Zynq Flasher — Windows x64 Build Script
+echo ============================================================
+echo.
+
+REM ── 1. Check Python ─────────────────────────────────────────
+python --version >nul 2>&1
+if %errorlevel% neq 0 (
+    echo [ERROR] Python not found. Install Python 3.9+ first.
+    pause
+    exit /b 1
+)
+echo [1/4] Python: OK
+
+REM ── 2. Install dependencies ─────────────────────────────────
+echo [2/4] Installing Python packages...
+pip install -r requirements.txt --quiet
+pip install pyinstaller --quiet
+echo        Done.
+
+REM ── 3. Clean previous builds ────────────────────────────────
+echo [3/4] Cleaning previous builds...
+if exist build rmdir /s /q build
+if exist dist\ZynqFlasher.exe del /q dist\ZynqFlasher.exe
+if not exist dist mkdir dist
+
+REM ── 4. Build ────────────────────────────────────────────────
+echo [4/4] Building ZynqFlasher.exe...
+pyinstaller --clean --noconfirm ZynqFlasher.spec
+
+echo.
+if exist dist\ZynqFlasher.exe (
+    echo ============================================================
+    echo   Build successful!
+    echo   Output: dist\ZynqFlasher.exe
+    echo ============================================================
+) else (
+    echo [ERROR] Build failed — dist\ZynqFlasher.exe not found.
+    pause
+    exit /b 1
+)
+
+endlocal
+pause

config.yaml

@@ -1,27 +0,0 @@
-boot_wait_delay: 10
-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/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
-flash_type: qspi-x4-single
-fsbl_elf_path: /home/ly0kos/work/Verify/FPGA/Xilinx/Z100/fsbl_qspi_bypass.elf
-inter_step_delay: 2
-ping_count: 3
-ping_timeout: 5
-reboot_timeout: 30
-serial_baudrate: 115200
-serial_port: /dev/ttyUSB0
-step_timeouts:
-  bitstream: 60
-  check_env: 30
-  elf_download: 60
-  flash_erase: 120
-  flash_program: 600
-  tftp_reboot: 120
-tftp_upload_name: z7bin
-uart_delay: 3
-xilinx_path: /data/xilinx
-zynq_ip: 192.168.100.11
-zynq_part: XC7Z100

src/bitstream_programmer.py

@@ -271,12 +271,14 @@ def _program_with_vivado(
         callback("progress", "Using Vivado Hardware Manager...")
 
     tcl_content = f"""
-open_hw_manager
+open_hw
 connect_hw_server
 open_hw_target
 current_hw_device [lindex [get_hw_devices] 0]
 program_hw_device -file "{bit_path}"
 refresh_hw_device
+close_hw
+disconnect_hw_server
 quit
 """
     tcl_path = bit_path.parent / "temp_program.tcl"

src/config_manager.py

@@ -28,13 +28,14 @@ DEFAULT_CONFIG: dict[str, Any] = {
     "flash_type": "qspi-x4-single",
     "flash_model": "s25fl256s1",
     "erase_all": False,
+    "download_verify": True,
     "firmware_bin_path": "",
     "reboot_timeout": 30,
     "ping_timeout": 5,
     "ping_count": 3,
     "uart_delay": 3,
     "inter_step_delay": 2,
-    "boot_wait_delay": 10,
+    "boot_wait_delay": 30,
     "step_timeouts": {
         "check_env": 120,
         "flash_erase": 120,
@@ -67,13 +68,14 @@ class Config:
     flash_type: str = "qspi-x4-single"
     flash_model: str = "s25fl256s1"
     erase_all: bool = False
+    download_verify: bool = True
     firmware_bin_path: str = ""
     reboot_timeout: int = 30
     ping_timeout: int = 5
     ping_count: int = 3
     uart_delay: int = 3
     inter_step_delay: int = 2
-    boot_wait_delay: int = 10
+    boot_wait_delay: int = 30
     step_timeouts: dict[str, int] = field(default_factory=lambda: {})
 
     # Internal: path to the config file on disk
@@ -176,6 +178,7 @@ class Config:
             "flash_type": self.flash_type,
             "flash_model": self.flash_model,
             "erase_all": self.erase_all,
+            "download_verify": self.download_verify,
             "firmware_bin_path": self._relative_path(self.firmware_bin_path),
             "reboot_timeout": self.reboot_timeout,
             "ping_timeout": self.ping_timeout,
@@ -190,8 +193,11 @@ class Config:
     def _relative_path(self, path: str) -> str:
         """Convert an absolute path to a relative path from the config file.
 
+        Uses :func:`os.path.relpath` which works across filesystem
+        boundaries (unlike :meth:`Path.relative_to`).
+
         Args:
-            path: Absolute path string.
+            path: Absolute or relative path string.
 
         Returns:
             Relative path string, or the original if conversion fails.
@@ -201,7 +207,8 @@ class Config:
         try:
             target = Path(path)
             if target.is_absolute():
-                return str(target.relative_to(self._config_path.parent))
+                base = str(self._config_path.parent)
+                return os.path.relpath(str(target), base)
         except (ValueError, OSError):
             pass
         return path
@@ -219,6 +226,34 @@ class Config:
             return Path()
         return (self._config_path.parent / relative_path).resolve()
 
+    def validate_paths(self) -> list[str]:
+        """Validate file paths in config and clear those that don't exist.
+
+        Checks each file path field, resolves it against the config
+        directory, and clears it if the target file does not exist
+        on the current filesystem.
+
+        Returns:
+            List of field names that were cleared.
+        """
+        cleared: list[str] = []
+        path_fields = [
+            "bootloader_bit_path",
+            "bootloader_elf_path",
+            "bootloader_bin_path",
+            "fsbl_elf_path",
+            "firmware_bin_path",
+        ]
+        for attr in path_fields:
+            val = getattr(self, attr, "")
+            if not val:
+                continue
+            resolved = self.resolve_path(val)
+            if not resolved.is_file():
+                setattr(self, attr, "")
+                cleared.append(attr)
+        return cleared
+
     @property
     def config_path(self) -> Path | None:
         """Return the path to the config file on disk."""

src/file_utils.py

@@ -0,0 +1,82 @@
+"""File metadata utilities — CRC32, human-readable size, timestamps."""
+
+from __future__ import annotations
+
+import datetime
+import os
+import zlib
+from dataclasses import dataclass
+from pathlib import Path
+
+
+@dataclass
+class FileInfo:
+    """Computed metadata for a single file."""
+
+    path: str
+    exists: bool = False
+    size: int = 0
+    crc32: int = 0
+    mtime: float = 0.0
+
+    @property
+    def size_human(self) -> str:
+        """Human-readable file size (KiB / MiB / GiB)."""
+        if self.size >= 1_073_741_824:
+            return f"{self.size / 1_073_741_824:.2f} GiB"
+        if self.size >= 1_048_576:
+            return f"{self.size / 1_048_576:.2f} MiB"
+        if self.size >= 1_024:
+            return f"{self.size / 1_024:.2f} KiB"
+        return f"{self.size} B"
+
+    @property
+    def mtime_iso(self) -> str:
+        """ISO-formatted modification time, or empty string."""
+        if not self.mtime:
+            return ""
+        return datetime.datetime.fromtimestamp(self.mtime).strftime(
+            "%Y-%m-%d %H:%M:%S"
+        )
+
+    @property
+    def crc32_hex(self) -> str:
+        """8-character hex CRC32 representation."""
+        return f"{self.crc32 & 0xFFFFFFFF:08X}"
+
+
+def compute_file_info(file_path: str | Path) -> FileInfo:
+    """Compute size, CRC32, and modification time for a file.
+
+    If the file does not exist or cannot be read, the returned
+    ``FileInfo`` will have ``exists=False`` and all numeric fields
+    set to zero.
+
+    Args:
+        file_path: Absolute or relative path to the file.
+
+    Returns:
+        FileInfo dataclass with computed metadata.
+    """
+    path = Path(file_path)
+    info = FileInfo(path=str(path))
+    if not path.is_file():
+        return info
+    info.exists = True
+    try:
+        stat = path.stat()
+        info.size = stat.st_size
+        info.mtime = stat.st_mtime
+    except OSError:
+        return info
+
+    # CRC32
+    try:
+        value = 0
+        with open(path, "rb") as f:
+            while chunk := f.read(1_048_576):  # 1 MiB chunks
+                value = zlib.crc32(chunk, value)
+        info.crc32 = value
+    except OSError:
+        pass
+    return info

src/gui/main_window.py

@@ -7,6 +7,7 @@ built with CustomTkinter.
 from __future__ import annotations
 
 import os
+import sys
 import threading
 import time
 import tkinter as tk
@@ -25,6 +26,7 @@ from tftp_manager import tftp_upload, tftp_download, tftp_upload_verify, TftpRes
 from reboot_manager import reboot_zynq, RebootResult
 from boot_verifier import verify_boot, verify_zynq_status, BootVerificationResult
 from serial_monitor import detect_serial_ports, parse_boot_output, check_uart_available, UartMonitor
+from file_utils import compute_file_info, FileInfo
 from gui.styles import (
     WINDOW_WIDTH,
     WINDOW_HEIGHT,
@@ -92,6 +94,35 @@ class MainWindow(ctk.CTk):
 
         self._load_config()
         self._build_ui()
+
+        # Validate file paths — clear any that don't exist on this machine
+        if self._config and self._config._config_path:
+            try:
+                cleared = self._config.validate_paths()
+                if cleared:
+                    joined = ", ".join(cleared)
+                    self._log_message(f"  ⚠ Cleared stale paths from config: {joined}")
+                    # Also clear the UI selectors so stale paths don't
+                    # get re-saved by subsequent _auto_save_config calls
+                    _selector_map = {
+                        "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,
+                    }
+                    for attr in cleared:
+                        sel = _selector_map.get(attr)
+                        if sel:
+                            sel.set_path("")
+                    self._config.save()
+                    self._log_message(f"  ✓ Config saved after clearing stale paths")
+            except Exception as e:
+                self._log_message(f"  ✗ Config validation failed: {e}")
+
+        # Log file metadata for all configured paths
+        self._log_all_file_info()
+
         self._update_step_dependencies()
 
         # Handle window close
@@ -109,6 +140,18 @@ class MainWindow(ctk.CTk):
 
     # ── Config ─────────────────────────────────────────────────
 
+    @staticmethod
+    def _get_app_dir() -> Path:
+        """Return the application directory (where config.yaml lives).
+
+        When running as a PyInstaller bundle (frozen), uses the
+        directory of the .exe file. Otherwise navigates from
+        ``__file__`` up to the project root.
+        """
+        if getattr(sys, 'frozen', False):
+            return Path(sys.executable).parent
+        return Path(__file__).parent.parent.parent
+
     def _find_config(self) -> Path | None:
         """Find the user configuration file.
 
@@ -120,8 +163,7 @@ class MainWindow(ctk.CTk):
         Returns:
             Path to user config file, or None if not found.
         """
-        # Navigate from src/gui/main_window.py -> project root
-        app_dir = Path(__file__).parent.parent.parent
+        app_dir = self._get_app_dir()
 
         # 1. Check for user config at project root
         user_config = app_dir / "config.yaml"
@@ -144,33 +186,39 @@ class MainWindow(ctk.CTk):
     def _get_user_config_path(self) -> Path:
         """Get the path to the user config file (config.yaml).
 
-        Creates config.yaml in project root if it doesn't exist.
+        Creates config.yaml in app directory if it doesn't exist.
 
         Returns:
             Path to user config file.
         """
-        # Navigate from src/gui/main_window.py -> project root
-        app_dir = Path(__file__).parent.parent.parent
+        app_dir = self._get_app_dir()
         config_path = app_dir / "config.yaml"
         config_path.parent.mkdir(parents=True, exist_ok=True)
         return config_path
 
     def _load_config(self) -> None:
-        """Load configuration from file or create default."""
+        """Load configuration from file or create a blank one on disk.
+        
+        If config.yaml does not exist or cannot be read, a new one
+        is created with default values and written to disk immediately.
+        """
+        user_config_path = self._get_user_config_path()
         if self._config_path:
             try:
                 self._config = Config.from_file(self._config_path)
                 if self._config_path.name == "default_config.yaml":
-                    user_config_path = self._get_user_config_path()
                     self._config._config_path = user_config_path
+                return
             except Exception:
-                self._config = Config.from_default()
-                user_config_path = self._get_user_config_path()
-                self._config._config_path = user_config_path
-        else:
-            self._config = Config.from_default()
-            user_config_path = self._get_user_config_path()
-            self._config._config_path = user_config_path
+                pass  # Fall through and create default
+
+        # Config file missing or unreadable — create a blank one
+        self._config = Config.from_default()
+        self._config._config_path = user_config_path
+        try:
+            self._config.save()
+        except Exception:
+            pass  # Will be saved later by _auto_save_config
 
     def _reload_config(self) -> None:
         """Re-read config.yaml and update UI selectors with latest paths.
@@ -185,8 +233,15 @@ class MainWindow(ctk.CTk):
         try:
             fresh = Config.from_file(user_path)
             self._config = fresh
-            # Update UI selectors with resolved (absolute) paths — selectors
-            # display only the filename internally.
+            # Update UI selectors — suppress callbacks to avoid
+            # redundant file-info logging and status-panel rewrites.
+            _sels = [
+                self._bit_selector, self._elf_selector,
+                self._bootloader_bin_selector, self._fsbl_selector,
+                self._firmware_bin_selector,
+            ]
+            for s in _sels:
+                s._suppress_callback = True
             for attr, selector in [
                 ("bootloader_bit_path", self._bit_selector),
                 ("bootloader_elf_path", self._elf_selector),
@@ -199,6 +254,8 @@ class MainWindow(ctk.CTk):
                     resolved = fresh.resolve_path(val)
                     selector.set_relative_path(val)
                     selector.set_path(str(resolved))
+            for s in _sels:
+                s._suppress_callback = False
             # Update IP
             if self._ip_string_var:
                 self._ip_string_var.set(fresh.zynq_ip)
@@ -234,7 +291,8 @@ class MainWindow(ctk.CTk):
         if hasattr(self, '_port_var'):
             self._config.serial_port = self._port_var.get()
         # Sync file paths from FileSelectors
-        files = self._get_selected_files()
+        # Always derive relative from absolute — the _relative_path
+        # stored in FileSelector can be stale after Browse.
         for attr, selector in [
             ("bootloader_bit_path", self._bit_selector),
             ("bootloader_elf_path", self._elf_selector),
@@ -242,17 +300,17 @@ class MainWindow(ctk.CTk):
             ("fsbl_elf_path", self._fsbl_selector),
             ("firmware_bin_path", self._firmware_bin_selector),
         ]:
-            rel = selector.get_relative_path()
-            if rel:
-                setattr(self._config, attr, rel)
+            abs_path = selector.get_path()
+            if abs_path:
+                setattr(self._config, attr, self._config._relative_path(abs_path))
             else:
-                abs_path = selector.get_path()
-                if abs_path:
-                    self._config._config_path  # ensure _config_path is set
-                    setattr(self._config, attr, self._config._relative_path(abs_path))
+                setattr(self._config, attr, "")
         # Sync erase checkbox (may not exist yet)
         if hasattr(self, '_erase_cb_var'):
             self._config.erase_all = self._erase_cb_var.get()
+        # Sync download verify checkbox
+        if hasattr(self, '_download_verify_var'):
+            self._config.download_verify = self._download_verify_var.get()
 
     def _auto_save_config(self) -> None:
         """Auto-save config to disk after UI changes.
@@ -297,6 +355,11 @@ class MainWindow(ctk.CTk):
         if self._config:
             self._config.erase_all = self._erase_cb_var.get()
 
+    def _on_download_verify_toggle(self) -> None:
+        """Update config.download_verify immediately when checkbox toggles."""
+        if self._config:
+            self._config.download_verify = self._download_verify_var.get()
+
     def _browse_xilinx_path(self) -> None:
         """Open directory dialog to select Xilinx root folder."""
         from tkinter import filedialog
@@ -318,13 +381,58 @@ class MainWindow(ctk.CTk):
             self._config.zynq_ip = self._ip_string_var.get()
 
     def _on_file_selected(self, path: str) -> None:
-        """Handle file selection — sync and auto-save to disk.
-
-        When the user selects a file via the browse dialog, immediately
-        sync the path to the Config object and persist it to YAML so
-        that subsequent step executions pick up the new value.
-        """
+        """Handle file selection — sync, auto-save, and log file info."""
+        from file_utils import compute_file_info
         self._auto_save_config()
+        if path:
+            info = compute_file_info(path)
+            self._log_file_info(info)
+            # Update status info panel
+            self._log_all_file_info()
+
+    def _log_file_info(self, info: FileInfo) -> None:
+        """Log file metadata in the log window.
+
+        Args:
+            info: FileInfo dataclass with computed metadata.
+        """
+        filename = os.path.basename(info.path) if info.path else "(unknown)"
+        if not info.exists:
+            self._log_message(f"  ⚠ {filename}: file not found")
+            return
+        self._log_message(
+            f"  ✓ {filename}: "
+            f"{info.size_human} | CRC {info.crc32_hex} | {info.mtime_iso}"
+        )
+
+    def _log_all_file_info(self) -> None:
+        """Update file metadata in the status info panel (preserves other info).
+
+        Each file line is updated in-place via ``set_info()`` — existing
+        Zynq info, tool versions, etc. are left untouched.
+        """
+        if not self._config:
+            return
+        paths = [
+            ("FSBL ELF", self._config.fsbl_elf_path),
+            ("Bitstream", self._config.bootloader_bit_path),
+            ("Bootloader ELF", self._config.bootloader_elf_path),
+            ("Bootloader BIN", self._config.bootloader_bin_path),
+            ("Firmware BIN", self._config.firmware_bin_path),
+        ]
+        for label, path in paths:
+            if not path:
+                self._status.set_info(label, "(not set)")
+                continue
+            resolved = self._config.resolve_path(path)
+            info = compute_file_info(resolved)
+            if info.exists:
+                self._status.set_info(
+                    label,
+                    f"{info.size_human}  CRC {info.crc32_hex}  {info.mtime_iso}"
+                )
+            else:
+                self._status.set_info(label, "(not found)")
 
     # ── UI Construction ────────────────────────────────────────
 
@@ -334,7 +442,8 @@ class MainWindow(ctk.CTk):
         self.main_frame = ctk.CTkScrollableFrame(self)
         self.main_frame.pack(fill="both", expand=True, padx=PADDING_LARGE, pady=PADDING_LARGE)
         self.main_frame.grid_rowconfigure(1, weight=1)
-        self.main_frame.grid_columnconfigure(0, weight=1)
+        self.main_frame.grid_columnconfigure(0, weight=7, uniform="main_col")
+        self.main_frame.grid_columnconfigure(1, weight=3, uniform="main_col")
 
         # ── Header ──
         self._build_header(self.main_frame)
@@ -351,7 +460,7 @@ class MainWindow(ctk.CTk):
         # ── Right Panel: Configuration ──
         right_frame = ctk.CTkFrame(self.main_frame)
         right_frame.grid(row=1, column=1, sticky="nsew", padx=(PADDING, 0))
-        right_frame.grid_rowconfigure(3, weight=1)
+        right_frame.grid_rowconfigure(3, weight=3)  # status panel — main info area
         right_frame.grid_columnconfigure(0, weight=1)
 
         self._build_config_panel(right_frame)
@@ -550,6 +659,7 @@ class MainWindow(ctk.CTk):
             padx=PADDING, pady=PADDING,
         )
         panel.grid_rowconfigure(9, weight=1)
+        panel.grid_columnconfigure(0, weight=1)  # let content stretch
 
         title = ctk.CTkLabel(
             panel,
@@ -664,6 +774,17 @@ class MainWindow(ctk.CTk):
         )
         flash_model_label.grid(row=1, column=0, sticky="w", padx=PADDING_SMALL, pady=(2, 0))
 
+        # Download verify checkbox (Step 4.2)
+        self._download_verify_var = ctk.BooleanVar(value=self._config.download_verify)
+        self._download_verify_cb = ctk.CTkCheckBox(
+            flash_frame,
+            text="下载校验 + CRC (Step 4.2)",
+            variable=self._download_verify_var,
+            font=FONT_SMALL,
+            command=self._on_download_verify_toggle,
+        )
+        self._download_verify_cb.grid(row=2, column=0, sticky="w", padx=PADDING_SMALL, pady=(2, 0))
+
         # Firmware BIN path (TFTP upload)
         self._firmware_bin_selector = FileSelector(
             panel,
@@ -812,23 +933,27 @@ class MainWindow(ctk.CTk):
         self._status = StatusDisplay(panel)
         self._status.grid(row=0, column=0, sticky="nsew", padx=PADDING, pady=PADDING)
 
-        # UART warning label (persistent, not overwritten by other status updates)
-        self._uart_warning_label = ctk.CTkLabel(
+        # UART warning — multi-line textbox, wraps long messages instead
+        # of expanding the right panel horizontally
+        self._uart_warning = ctk.CTkTextbox(
             panel,
-            text="",
             font=FONT_BODY,
-            anchor="w",
-            text_color=WARNING_COLOR,
+            height=40,
+            corner_radius=4,
+            fg_color="transparent",
+            state="disabled",
+            wrap="word",
         )
-        self._uart_warning_label.grid(
+        self._uart_warning.grid(
             row=1, column=0, sticky="ew", padx=PADDING, pady=(0, PADDING_SMALL)
         )
-        self._uart_warning_label.grid_remove()  # Hide by default
+        self._uart_warning.grid_remove()  # Hide by default
 
     # ── Workflow Steps ─────────────────────────────────────────
 
     def _log_message(self, message: str) -> None:
-        """Append a message to the log display (thread-safe)."""
+        """Append a message to the log display and terminal (thread-safe)."""
+        print(message, flush=True)
         self.after(0, lambda: self._log_display.append(message))
 
     def _set_step_status(self, index: int, status: str) -> None:
@@ -885,6 +1010,10 @@ class MainWindow(ctk.CTk):
         if result.is_ready:
             self._vitis_status.configure(text="Vitis: Ready", text_color=SUCCESS_COLOR)
             self._log_message("  Vitis/Vivado tools available")
+            # Show tool versions in status display
+            for tool_name, tool_info in status_dict["tools"].items():
+                if tool_info["found"] and tool_info.get("version"):
+                    self._status.set_info(tool_name, f"v{tool_info['version']}")
             # Report all found versions for diagnostics
             if self._config.xilinx_path:
                 try:
@@ -938,6 +1067,7 @@ class MainWindow(ctk.CTk):
 
             self._log_message(f"  ✓ Zynq {part} detected on JTAG chain")
             self._jtag_status.configure(text=f"JTAG: {part} ✓", text_color=SUCCESS_COLOR)
+            self._status.set_info("Zynq", part)
         else:
             self._zynq_jtag_present = False
             self._zynq_jtag_info = None
@@ -949,7 +1079,8 @@ class MainWindow(ctk.CTk):
         self._log_message("  Checking UART serial port...")
         port = self._config.serial_port
         if port:
-            available, reason = check_uart_available(port, self._config.serial_baudrate)
+            available, reason = check_uart_available(port, self._config.serial_baudrate,
+                                                     monitor=self._uart_monitor)
             self._uart_available = available
             self._uart_message = reason
             if available:
@@ -977,17 +1108,26 @@ class MainWindow(ctk.CTk):
         self.after(0, lambda: self._show_uart_warning(msg))
 
     def _show_uart_warning(self, msg: str) -> None:
-        """Display the persistent UART warning message.
+        """Display the persistent UART warning message (multi-line).
 
         Args:
             msg: Warning message to display.
         """
-        self._uart_warning_label.configure(text=msg)
-        self._uart_warning_label.grid()
+        self._uart_warning.configure(state="normal")
+        self._uart_warning.delete("1.0", "end")
+        self._uart_warning.insert("1.0", msg)
+        self._uart_warning.tag_config("warn", foreground=WARNING_COLOR)
+        self._uart_warning.tag_add("warn", "1.0", "end")
+        self._uart_warning.configure(state="disabled")
+        self._uart_warning.grid()
+
+        # Auto-size height based on line count
+        line_count = msg.count("\n") + 1
+        self._uart_warning.configure(height=max(2, line_count))
 
     def _hide_uart_warning(self) -> None:
-        """Hide the persistent UART warning label."""
-        self._uart_warning_label.grid_remove()
+        """Hide the persistent UART warning."""
+        self._uart_warning.grid_remove()
 
     def _on_window_resize(self, event) -> None:
         """Handle window resize / maximize events.
@@ -1285,54 +1425,65 @@ class MainWindow(ctk.CTk):
         self._log_message("  ⏳ Waiting 2s before download...")
         time.sleep(2)
 
-        # 4b: TFTP Download Verify
-        self._log_message("Step 4b: TFTP download verify...")
-        self._tftp_phase = "Download Verify"
-        if hasattr(self, '_tftp_sub_step_frame'):
-            self._tftp_sub_step_frame.set_phase("Download Verify")
-        try:
-            download_result = tftp_download(
-                self._config, remote_name,
-                callback=self._tftp_sub_callback,
-                expected_size=bin_path.stat().st_size,
-            )
-            status = "✓" if download_result.success else "✗"
-            self._log_message(f"  {status} {download_result.message}")
+        # 4b+4c: TFTP Download Verify + CRC Check
+        if not self._config.download_verify:
+            self._log_message("Step 4b+4c: Download verify & CRC — skipped (disabled in config)")
+            all_results.append(True)  # 4b
+            all_results.append(True)  # 4c
             if hasattr(self, '_tftp_sub_step_frame'):
-                self._tftp_sub_step_frame.set_step_complete("Download Verify") if download_result.success else self._tftp_sub_step_frame.set_step_error("Download Verify")
-            all_results.append(download_result.success)
-        except Exception as e:
-            self._log_message(f"  ✗ TFTP download error: {e}")
-            if hasattr(self, '_tftp_sub_step_frame'):
-                self._tftp_sub_step_frame.set_step_error("Download Verify")
-            all_results.append(False)
-
-        if not all_results[-1]:
-            self._log_message("  Skipping CRC check (download failed)")
-            return False
-
-        # 4c: CRC Check
-        self._log_message("Step 4c: CRC check...")
-        if hasattr(self, '_tftp_sub_step_frame'):
-            self._tftp_sub_step_frame.set_phase("CRC Check")
-        original_crc = _compute_crc32(bin_path)
-        downloaded_crc = download_result.crc_local
-        crc_match = original_crc == downloaded_crc
-        self._log_message(f"  Original CRC: {original_crc:#010x}")
-        self._log_message(f"  Downloaded CRC: {downloaded_crc:#010x}")
-        if crc_match:
-            self._log_message("  ✓ CRC match")
-            if hasattr(self, '_tftp_sub_step_frame'):
-                self._tftp_sub_step_frame.set_step_complete("CRC Check")
-            all_results.append(True)
+                self._tftp_sub_step_frame.set_expanded(True)
+                self._tftp_sub_step_frame.set_step_skipped("Download Verify")
+                self._tftp_sub_step_frame.set_step_skipped("CRC Check")
+                self._log_message("  ◌ Download Verify: Skip")
+                self._log_message("  ◌ CRC Check: Skip")
         else:
-            self._log_message("  ✗ CRC mismatch")
+            # 4b: Download Verify
+            self._log_message("Step 4b: TFTP download verify...")
+            self._tftp_phase = "Download Verify"
             if hasattr(self, '_tftp_sub_step_frame'):
-                self._tftp_sub_step_frame.set_step_error("CRC Check")
-            all_results.append(False)
+                self._tftp_sub_step_frame.set_phase("Download Verify")
+            try:
+                download_result = tftp_download(
+                    self._config, remote_name,
+                    callback=self._tftp_sub_callback,
+                    expected_size=bin_path.stat().st_size,
+                )
+                status = "✓" if download_result.success else "✗"
+                self._log_message(f"  {status} {download_result.message}")
+                if hasattr(self, '_tftp_sub_step_frame'):
+                    self._tftp_sub_step_frame.set_step_complete("Download Verify") if download_result.success else self._tftp_sub_step_frame.set_step_error("Download Verify")
+                all_results.append(download_result.success)
+            except Exception as e:
+                self._log_message(f"  ✗ TFTP download error: {e}")
+                if hasattr(self, '_tftp_sub_step_frame'):
+                    self._tftp_sub_step_frame.set_step_error("Download Verify")
+                all_results.append(False)
+
+            if not all_results[-1]:
+                self._log_message("  Skipping CRC check (download failed)")
+            else:
+                # 4c: CRC Check
+                self._log_message("Step 4c: CRC check...")
+                if hasattr(self, '_tftp_sub_step_frame'):
+                    self._tftp_sub_step_frame.set_phase("CRC Check")
+                original_crc = _compute_crc32(bin_path)
+                downloaded_crc = download_result.crc_local
+                crc_match = original_crc == downloaded_crc
+                self._log_message(f"  Original CRC: {original_crc:#010x}")
+                self._log_message(f"  Downloaded CRC: {downloaded_crc:#010x}")
+                if crc_match:
+                    self._log_message("  ✓ CRC match")
+                    if hasattr(self, '_tftp_sub_step_frame'):
+                        self._tftp_sub_step_frame.set_step_complete("CRC Check")
+                    all_results.append(True)
+                else:
+                    self._log_message("  ✗ CRC mismatch")
+                    if hasattr(self, '_tftp_sub_step_frame'):
+                        self._tftp_sub_step_frame.set_step_error("CRC Check")
+                    all_results.append(False)
 
         if not all_results[-1]:
-            self._log_message("  Skipping reboot (CRC mismatch)")
+            self._log_message("  Skipping reboot (download/CRC failed)")
             return False
 
         # 4d: Reboot
@@ -1429,16 +1580,38 @@ class MainWindow(ctk.CTk):
                     discovered_ip = parsed.ip_address
                     self._log_message(f"  IP from UART buffer: {discovered_ip}")
 
-        # Discover actual IP after reboot (may have changed via DHCP)
+        # Fallback: if no IP from UART, try ping → UDP scan, then extra delay
         if not discovered_ip:
             self._log_message("  ⏳ Network stack — waiting 3s...")
             time.sleep(3)
-            self._log_message("  Scanning for Zynq IP (192.168.100.11–30)...")
-            discovered_ip = self._discover_zynq_ip()
-            if discovered_ip:
-                self._log_message(f"  ✓ Found Zynq at {discovered_ip}")
+
+            # Try ping configured IP first (fast, reliable)
+            self._log_message(f"  Pinging {self._config.zynq_ip}...")
+            ok = ping_ip(self._config.zynq_ip, timeout=2)
+            if ok:
+                discovered_ip = self._config.zynq_ip
+                self._log_message(f"  ✓ Zynq responds to ping at {discovered_ip}")
             else:
-                self._log_message("  ⚠ Zynq not found on any scanned IP")
+                # Fallback: UDP broadcast scan
+                self._log_message("  Scanning for Zynq IP (192.168.100.11–30)...")
+                discovered_ip = self._discover_zynq_ip()
+                if discovered_ip:
+                    self._log_message(f"  ✓ Found Zynq at {discovered_ip}")
+                else:
+                    self._log_message("  ⚠ Zynq not found — extra boot delay...")
+                    self._log_message(f"  ⏳ Waiting {boot_delay}s for late boot...")
+                    time.sleep(boot_delay)
+                    # Retry ping + scan after extra delay
+                    ok2 = ping_ip(self._config.zynq_ip, timeout=2)
+                    if ok2:
+                        discovered_ip = self._config.zynq_ip
+                        self._log_message(f"  ✓ Zynq responds to ping at {discovered_ip}")
+                    else:
+                        discovered_ip = self._discover_zynq_ip()
+                        if discovered_ip:
+                            self._log_message(f"  ✓ Found Zynq at {discovered_ip}")
+                        else:
+                            self._log_message("  ⚠ Zynq not found on any scanned IP")
 
         if discovered_ip and discovered_ip != self._config.zynq_ip:
             self._log_message(
@@ -1647,6 +1820,13 @@ class MainWindow(ctk.CTk):
                 elapsed = time.time() - t_step_start
                 self._log_message(f"  ⏱ Step {i+1} completed in {elapsed:.0f}s")
 
+                # Step 3: After bootloader load, fix IP to 192.168.100.11
+                if i == 2 and success:
+                    self._config.zynq_ip = "192.168.100.11"
+                    if self._ip_string_var:
+                        self._ip_string_var.set("192.168.100.11")
+                    self._log_message("  IP set to 192.168.100.11")
+
                 # Step 2: mark sub-steps based on result
                 if i == 1 and hasattr(self, '_sub_step_frame'):
                     if success:
@@ -1663,6 +1843,11 @@ class MainWindow(ctk.CTk):
                 results.append(False)
                 self._set_step_status(i, "error")
                 self._log_message(f"  Exception in step {i+1}: {e}")
+                # Mark sub-step frames as error too
+                if i == 1 and hasattr(self, '_sub_step_frame'):
+                    self._sub_step_frame.set_phase("error")
+                if i == 3 and hasattr(self, '_tftp_sub_step_frame'):
+                    self._tftp_sub_step_frame.set_step_error("Boot Verify")
 
             self._progress.set_value((step_idx + 1) / total)
 
@@ -1814,6 +1999,7 @@ class MainWindow(ctk.CTk):
                 success, message, version = test_serial_version(
                     port,
                     self._config.serial_baudrate if self._config else 115200,
+                    monitor=self._uart_monitor,
                 )
 
                 if success:

src/gui/widgets.py

@@ -437,63 +437,82 @@ class ProgressIndicator(ctk.CTkFrame):
 
 
 class StatusDisplay(ctk.CTkFrame):
-    """Status display widget for operation results.
+    """Info display widget — persistent key-value file/device info.
 
-    Shows status messages in a multi-line, expandable text area that
-    uses the full available space.  Messages are color-coded and
-    automatically wrapped.
+    Shows aligned ``key : value`` lines for file metadata, Zynq
+    part info, tool versions, etc.
     """
 
     def __init__(self, master, **kwargs):
-        """Initialize the status display.
-
-        Args:
-            master: Parent widget.
-        """
         super().__init__(master, **kwargs)
-
+        self._info_items: list[tuple[str, str]] = []
         self._create_widgets()
 
     def _create_widgets(self) -> None:
-        """Create the status display UI — multi-line expandable area."""
         self.grid_rowconfigure(0, weight=1)
         self.grid_columnconfigure(0, weight=1)
 
-        self._status_text = ctk.CTkTextbox(
+        self._info_text = ctk.CTkTextbox(
             self,
             font=FONT_BODY,
             corner_radius=CORNER_RADIUS,
             state="disabled",
             wrap="word",
         )
-        self._status_text.grid(
+        self._info_text.grid(
             row=0, column=0, sticky="nsew", padx=PADDING, pady=PADDING_SMALL
         )
 
+        # Pre-configure tags
+        for name, color in [
+            ("info_label", PRIMARY_COLOR),
+            ("info_value", DESC_TEXT_COLOR if _is_dark() else DESC_TEXT_COLOR_LIGHT),
+        ]:
+            self._info_text.tag_config(name, foreground=color)
+
     def set_status(self, message: str, status: str = "info") -> None:
-        """Update the status message and color.
+        """Compatibility stub — status messages go to log now."""
+
+    def set_info(self, key: str, value: str) -> None:
+        """Set or update a persistent info line.
+
+        Displays as ``key : value`` in the info block.
 
         Args:
-            message: Status message text.
-            status: Status type for coloring ('info', 'success', 'error', 'warning').
+            key: Label for the info line.
+            value: Value string.
         """
-        self._status_text.configure(state="normal")
-        self._status_text.delete("1.0", "end")
+        for i, (k, _) in enumerate(self._info_items):
+            if k == key:
+                self._info_items[i] = (key, value)
+                break
+        else:
+            self._info_items.append((key, value))
+        self._refresh_info()
 
-        colors = {
-            "info": INFO_COLOR,
-            "success": SUCCESS_COLOR,
-            "error": DANGER_COLOR,
-            "warning": WARNING_COLOR,
-        }
-        color = colors.get(status, INFO_COLOR)
+    def clear_info(self) -> None:
+        """Remove all persistent info lines."""
+        self._info_items.clear()
+        self._info_text.configure(state="normal")
+        self._info_text.delete("1.0", "end")
+        self._info_text.configure(state="disabled")
 
-        self._status_text.insert("1.0", message)
-        # Tag the entire text with the color (CTkTextbox uses tag_config)
-        self._status_text.tag_config("status", foreground=color)
-        self._status_text.tag_add("status", "1.0", "end")
-
-        self._status_text.configure(state="disabled")
+    def _refresh_info(self) -> None:
+        """Rebuild the info text block from current items."""
+        self._info_text.configure(state="normal")
+        self._info_text.delete("1.0", "end")
+        if not self._info_items:
+            self._info_text.configure(state="disabled")
+            return
+        max_key = max(len(k) for k, _ in self._info_items)
+        for key, value in self._info_items:
+            line = f"{key.ljust(max_key + 2)} {value}\n"
+            start = self._info_text.index("end-1c")
+            self._info_text.insert("end", line)
+            end = self._info_text.index("end-1c")
+            self._info_text.tag_add("info_label", start, f"{start}+{len(key)}c")
+            self._info_text.tag_add("info_value", f"{start}+{len(key)}c", end)
+        self._info_text.configure(state="disabled")
 
 
 class FileSelector(ctk.CTkFrame):
@@ -525,6 +544,7 @@ class FileSelector(ctk.CTkFrame):
 
         self._callback = callback
         self._file_types = file_types or [("All files", "*")]
+        self._hint_text = label_text.rstrip(":")  # e.g. "FSBL ELF (.elf)"
         self._full_path: str = ""           # absolute path (internal)
         self._relative_path: str = ""       # relative path (synced to Config)
         self._display_text = ctk.StringVar(value="")
@@ -574,7 +594,7 @@ class FileSelector(ctk.CTkFrame):
         from tkinter import filedialog
 
         file_path = filedialog.askopenfilename(
-            title="Select file",
+            title=f"Select {self._hint_text}",
             filetypes=self._file_types,
         )
         if file_path:
@@ -851,6 +871,7 @@ class TftpSubStepFrame(ctk.CTkFrame):
 
         self._collapsed = True
         self._pulse_job: str | None = None
+        self._skipped: set[int] = set()
         self._substep_names = substep_names or ["Upload", "Download Verify", "CRC Check", "Reboot", "Boot Verify"]
         self._num_steps = len(self._substep_names)
 
@@ -916,6 +937,8 @@ class TftpSubStepFrame(ctk.CTkFrame):
 
         pct_text = f"{pct}%" if pct >= 0 else ""
         for i, item in enumerate(self._sub_items):
+            if i in self._skipped:
+                continue  # leave skipped items untouched
             if i < idx:
                 item["dot"].configure(text="●", text_color=_C_DONE)
                 item["label"].configure(text_color=_C_DONE)
@@ -955,6 +978,18 @@ class TftpSubStepFrame(ctk.CTkFrame):
         item["label"].configure(text_color=_C_ERROR)
         self._stop_pulse()
 
+    def set_step_skipped(self, phase: str) -> None:
+        """Mark a specific step as skipped (warning color, Skip text)."""
+        idx = self._substep_names.index(phase) if phase in self._substep_names else -1
+        if idx < 0:
+            return
+        self._skipped.add(idx)
+        item = self._sub_items[idx]
+        item["dot"].configure(text="◌", text_color=WARNING_COLOR)
+        item["label"].configure(text_color=WARNING_COLOR)
+        item["pct"].configure(text="Skip", text_color=WARNING_COLOR)
+        self._stop_pulse()
+
     def _start_pulse(self, idx: int) -> None:
         """Start pulsing the running sub-step."""
         _LIGHT = RUNNING_FADE_LIGHT
@@ -979,6 +1014,7 @@ class TftpSubStepFrame(ctk.CTkFrame):
 
     def reset(self) -> None:
         self._stop_pulse()
+        self._skipped.clear()
         _C = ACCENT_PENDING
         for i, item in enumerate(self._sub_items):
             item["dot"].configure(text="○", text_color=_C)

src/serial_monitor.py

@@ -137,6 +137,7 @@ def check_uart_available(
     port: str,
     baudrate: int = 115200,
     timeout: float = 3.0,
+    monitor: UartMonitor | None = None,
 ) -> tuple[bool, str]:
     """Check whether the UART serial port is available and readable.
 
@@ -145,19 +146,24 @@ def check_uart_available(
     considered available (the device may simply not be outputting yet).
     If the port cannot be opened at all, it is unavailable.
 
+    If *monitor* is provided and currently running, the function
+    skips the port-open test (which would fail on Windows with
+    Error 13 due to exclusive access) and returns True immediately.
+
     Args:
         port: Serial port device path (e.g., '/dev/ttyUSB0').
         baudrate: Baud rate for serial communication.
         timeout: Seconds to wait for data after opening.
+        monitor: Optional running UartMonitor — if active, reuse it.
 
     Returns:
         Tuple of (is_available, reason_string).
-        - (True,  "Port open") — port is usable
-        - (True,  "Port open, no data yet") — port open, no data currently
-        - (False, "No serial ports detected") — system has no serial ports
-        - (False, "Port not in detected ports") — configured port missing
-        - (False, "Failed to open: <error>") — port open error
     """
+    # Reuse existing monitor when available (avoids Error 13 on Windows)
+    if monitor is not None and monitor.is_running():
+        return True, "Already monitoring"
+
+    # 1. Quick port list check
     # 1. Quick port list check
     ports = detect_serial_ports()
     if not ports:
@@ -223,25 +229,31 @@ def test_serial_version(
     port: str,
     baudrate: int = 115200,
     timeout: float = 5.0,
+    monitor: UartMonitor | None = None,
 ) -> tuple[bool, str, str]:
     """Test serial port by sending 'ver()' command and parsing response.
 
-    Sends 'ver\\r\\n' to the serial port and reads the response.
-    Attempts to parse version string from the response.
+    If *monitor* is running, skips opening a new connection and
+    returns the latest parsed version from the monitor instead.
 
     Args:
         port: Serial port device path (e.g., '/dev/ttyUSB0').
         baudrate: Baud rate for serial communication.
         timeout: Read timeout in seconds.
+        monitor: Optional running UartMonitor — if active, reuse it.
 
     Returns:
         Tuple of (success, message, version_string).
-        - (True, "Version: x.y.z", "x.y.z") — version detected
-        - (True, "Port responded", "") — port responded but no version
-        - (False, "Error message", "") — error occurred
     """
     import serial
 
+    # Reuse existing monitor when available (avoids Error 13 on Windows)
+    if monitor is not None and monitor.is_running():
+        info = monitor.latest_info
+        if info and info.version:
+            return True, f"Version: {info.version}", info.version
+        return True, "Port monitored, no version parsed yet", ""
+
     try:
         with serial.Serial(port, baudrate, timeout=timeout) as ser:
             ser.reset_input_buffer()

src/vitis_checker.py

@@ -60,7 +60,8 @@ TOOL_ALIASES: dict[str, list[str]] = {
 }
 
 # Product subdirectories under xilinx_root to scan (in preference order)
-_PRODUCT_DIRS = ("Vitis", "Vivado")
+# SDK covers pre-2019 installations where xsct lived in SDK/*/bin/
+_PRODUCT_DIRS = ("Vitis", "Vivado", "SDK")
 
 
 # ── Version helpers ──────────────────────────────────────────────────
@@ -163,9 +164,9 @@ def _find_executable(
     """Find an executable by name using PATH, Vitis, and Xilinx root.
 
     Search order:
-    1. System PATH (shutil.which)
+    1. System PATH (shutil.which) — tries bare name, .exe, .bat on Windows
     2. vitis_path/bin (legacy config)
-    3. xilinx_root/Vitis/*/bin and Vivado/*/bin — pick NEWEST version
+    3. xilinx_root/Vitis/*/bin, Vivado/*/bin, SDK/*/bin — pick NEWEST version
     4. Common install paths (cross-platform)
 
     Args:
@@ -179,16 +180,22 @@ def _find_executable(
     """
     exec_suffix = ".exe" if system == "windows" else ""
 
-    # 1. System PATH
-    found = shutil.which(f"{exec_name}{exec_suffix}")
+    # 1. System PATH — search without explicit extension first
+    #    so Windows PATHEXT resolves .bat/.exe/.cmd automatically
+    found = shutil.which(exec_name)
+    if not found and exec_suffix:
+        found = shutil.which(f"{exec_name}{exec_suffix}")
+        if not found:
+            found = shutil.which(f"{exec_name}.bat")
     if found:
         return found
 
     # 2. Legacy vitis_path/bin
     if vitis_path:
-        candidate = Path(vitis_path) / "bin" / f"{exec_name}{exec_suffix}"
-        if candidate.is_file():
-            return str(candidate)
+        for sfx in (".bat", ".exe") if system == "windows" else (exec_suffix,):
+            candidate = Path(vitis_path) / "bin" / f"{exec_name}{sfx}"
+            if candidate.is_file():
+                return str(candidate)
 
     # 3. Scan xilinx_root — pick newest version across Vitis + Vivado
     if xilinx_root:
@@ -203,8 +210,8 @@ def _find_executable(
     if system == "windows":
         common: list[str] = []
         for sfx in (".bat", ".exe"):
-            for ver in ("2023.2", "2022.2"):
-                for prod in ("Vitis", "Vivado"):
+            for ver in ("2023.2", "2022.2", "2018.3"):
+                for prod in ("Vitis", "Vivado", "SDK"):
                     common.append(f"C:/Xilinx/{prod}/{ver}/bin/{exec_name}{sfx}")
     else:
         common = [

src/zynq_checker.py

@@ -125,7 +125,7 @@ def check_zynq_jtag(
     if callback:
         callback("progress", "Scanning JTAG chain...")
 
-    # ── 3. Run Vivado TCL (stream output to callback) ──────────
+    # ── 3. Run Vivado TCL ──────────────────────────────────────
     tcl = _build_jtag_query_tcl()
     python_timeout = config.step_timeouts.get("check_env", 120)
 
@@ -141,31 +141,27 @@ def check_zynq_jtag(
 
     output_lines: list[str] = []
     try:
-        proc = subprocess.Popen(
-            build_tool_command(vivado_path, *vivado_args),
-            stdout=subprocess.PIPE, stderr=subprocess.STDOUT,
+        cmd = build_tool_command(vivado_path, *vivado_args)
+        # Use run() with communicate() under the hood — reliably
+        # drains pipes on Windows even when .bat wrappers are involved
+        result = subprocess.run(
+            cmd,
+            capture_output=True,
             text=True,
+            timeout=python_timeout,
+        )
+        output = result.stdout + result.stderr
+        for line in output.splitlines():
+            stripped = line.strip()
+            if stripped:
+                output_lines.append(stripped)
+                if callback:
+                    callback("progress", stripped)
+    except subprocess.TimeoutExpired:
+        return _fail(
+            f"JTAG scan timed out after {python_timeout}s",
+            hw_server_url,
         )
-        # Read line by line so user sees real-time progress
-        deadline = time.monotonic() + python_timeout
-        while True:
-            line = proc.stdout.readline() if proc.stdout else ""
-            if not line:
-                if proc.poll() is not None:
-                    break
-                if time.monotonic() > deadline:
-                    proc.kill()
-                    proc.wait()
-                    return _fail(
-                        f"JTAG scan timed out after {python_timeout}s",
-                        hw_server_url,
-                    )
-                time.sleep(0.1)
-                continue
-            line = line.rstrip("\n\r")
-            output_lines.append(line)
-            if callback and line.strip():
-                callback("progress", line)
     except OSError as e:
         return _fail(f"Failed to run Vivado: {e}", hw_server_url)
     finally:
@@ -173,7 +169,6 @@ def check_zynq_jtag(
             Path(tcl).unlink(missing_ok=True)
         except Exception:
             pass
-        # Clean up Vivado temp files we redirected
         for f in ("vivado_jtag.jou", "vivado_jtag.log"):
             try:
                 (Path(tmp) / f).unlink(missing_ok=True)
@@ -257,7 +252,7 @@ def _extract_relevant(output: str) -> str:
 def _build_jtag_query_tcl() -> str:
     """Build Vivado TCL script file for JTAG device enumeration."""
     content = """\
-open_hw_manager
+open_hw
 connect_hw_server
 open_hw_target
 puts "===JTAG_START==="
@@ -267,6 +262,8 @@ foreach dev [get_hw_devices] {
   puts "DEVICE:$name IDCODE:$idcode"
 }
 puts "===JTAG_END==="
+close_hw
+disconnect_hw_server
 quit
 """
     import os