circuitpython: ESP32-S3: Crash into the HardFault_Handler

CircuitPython version

Adafruit CircuitPython 7.3.2 on 2022-07-20; FeatherS3 with ESP32S3
Board ID:unexpectedmaker_feathers3

and 

Adafruit CircuitPython 8.0.0-beta.0 on 2022-08-18; FeatherS3 with ESP32S3
Board ID:unexpectedmaker_feathers3

Code/REPL

# SPDX-FileCopyrightText: 2022 DJDevon3 for Adafruit Industries
# SPDX-License-Identifier: MIT
"""DJDevon3 UM ESP32 Feather S3 Online Weatherstation"""
import gc
import time
import board
import feathers3
import displayio
import terminalio
from adafruit_display_text import label
from adafruit_bitmap_font import bitmap_font
from adafruit_bitmap_font import bitmap_font
import adafruit_imageload
import ssl
import wifi
import socketpool
import adafruit_requests
from adafruit_bme280 import basic as adafruit_bme280
from adafruit_hx8357 import HX8357

# 3.5" TFT Featherwing is 480x320
displayio.release_displays()
DISPLAY_WIDTH = 480
DISPLAY_HEIGHT = 320
sleep_time = 3600  # Time between weather updates

# Initialize TFT Display
spi = board.SPI()
tft_cs = board.IO1
tft_dc = board.IO3
display_bus = displayio.FourWire(spi,
                                 command=tft_dc,
                                 chip_select=tft_cs,
                                 baudrate=50000000,
                                 phase=0,
                                 polarity=0)
display = HX8357(display_bus, width=DISPLAY_WIDTH, height=DISPLAY_HEIGHT)

# Initialize BME280 Sensor
i2c = board.I2C()  # uses board.SCL and board.SDA
bme280 = adafruit_bme280.Adafruit_BME280_I2C(i2c)

Bat_S3 = feathers3.get_battery_voltage()
# print(Bat_S3)

try:
    from secrets import secrets
except ImportError:
    print("Secrets File Import Error")
    raise

# Friendly time instead of seconds for next weather update
if (sleep_time) < 60:
    sleep_time_conversion = "seconds"
    sleep_int = sleep_time
elif (sleep_time) >= 60 and (sleep_time) < 3600:
    sleep_int = sleep_time / 60
    sleep_time_conversion = "minutes"
elif (sleep_time) >= 3600:
    sleep_int = sleep_time / 60 / 60
    sleep_time_conversion = "hours"

# Quick Colors for Labels
text_black = 0x000000
text_blue = 0x0000FF
text_cyan = 0x00FFFF
text_gray = 0x8B8B8B
text_green = 0x00FF00
text_lightblue = 0x90C7FF
text_magenta = 0xFF00FF
text_orange = 0xFFA500
text_purple = 0x800080
text_red = 0xFF0000
text_white = 0xFFFFFF
text_yellow = 0xFFFF00

# Fonts are optional
medium_font = bitmap_font.load_font("/fonts/Arial-16.bdf")
huge_font = bitmap_font.load_font("/fonts/GoodTimesRg-Regular-121.bdf")

# Fill OpenWeather 2.5 API with token data
# OpenWeather free account & token are required
timezone = secrets['timezone']
tz_offset_seconds = int(secrets['timezone_offset'])

# OpenWeather 2.5 Free API
# Map source currently unused because PNG
MAP_SOURCE = "https://tile.openweathermap.org/map"
MAP_SOURCE += "/precipitation_new"
MAP_SOURCE += "/9"
MAP_SOURCE += "/"+secrets['openweather_lat']
MAP_SOURCE += "/"+secrets['openweather_lon']
MAP_SOURCE += "/.png"
MAP_SOURCE += "&appid="+secrets['openweather_token']

DATA_SOURCE = "https://api.openweathermap.org/data/2.5/onecall?"
DATA_SOURCE += "lat="+secrets['openweather_lat']
DATA_SOURCE += "&lon="+secrets['openweather_lon']
DATA_SOURCE += "&timezone="+timezone
DATA_SOURCE += "&timezone_offset="+str(tz_offset_seconds)
DATA_SOURCE += "&exclude=hourly,daily"
DATA_SOURCE += "&appid="+secrets['openweather_token']
DATA_SOURCE += "&units=imperial"

def _format_datetime(datetime):
    return "{:02}/{:02}/{} {:02}:{:02}:{:02}".format(
        datetime.tm_mon,
        datetime.tm_mday,
        datetime.tm_year,
        datetime.tm_hour,
        datetime.tm_min,
        datetime.tm_sec,
    )

def _format_date(datetime):
    return "{:02}/{:02}/{:02}".format(
        datetime.tm_year,
        datetime.tm_mon,
        datetime.tm_mday,
    )

def _format_time(datetime):
    return "{:02}:{:02}".format(
        datetime.tm_hour,
        datetime.tm_min,
        # datetime.tm_sec,
    )

# Weatherstation environment display labels
date_label = label.Label(medium_font)
date_label.anchor_point = (0.0, 0.0)
date_label.anchored_position = (5, 5)
date_label.scale = 1
date_label.color = text_lightblue

time_label = label.Label(medium_font)
time_label.anchor_point = (0.0, 0.0)
time_label.anchored_position = (5, 25)
time_label.scale = 2
time_label.color = text_lightblue

temp_label = label.Label(medium_font)
temp_label.anchor_point = (1.0, 1.0)
temp_label.anchored_position = (475, 145)
temp_label.scale = 2
temp_label.color = text_white

temp_data_label = label.Label(huge_font)
temp_data_label.anchor_point = (0.5, 1.0)
temp_data_label.anchored_position = (DISPLAY_WIDTH / 2, 200)
temp_data_label.scale = 1
temp_data_label.color = text_orange

temp_data_shadow = label.Label(huge_font)
temp_data_shadow.anchor_point = (0.5, 1.0)
temp_data_shadow.anchored_position = (DISPLAY_WIDTH / 2 + 2, 200 + 2)
temp_data_shadow.scale = 1
temp_data_shadow.color = text_black

owm_temp_data_label = label.Label(medium_font)
owm_temp_data_label.anchor_point = (0.5, 1.0)
owm_temp_data_label.anchored_position = (DISPLAY_WIDTH / 2, 100)
owm_temp_data_label.scale = 2
owm_temp_data_label.color = text_lightblue

owm_temp_data_shadow = label.Label(medium_font)
owm_temp_data_shadow.anchor_point = (0.5, 1.0)
owm_temp_data_shadow.anchored_position = (DISPLAY_WIDTH / 2 + 2, 100 + 2)
owm_temp_data_shadow.scale = 2
owm_temp_data_shadow.color = text_black

humidity_label = label.Label(medium_font)
humidity_label.anchor_point = (0.0, 1.0)
humidity_label.anchored_position = (5, DISPLAY_HEIGHT - 23)
humidity_label.scale = 1
humidity_label.color = text_gray

humidity_data_label = label.Label(medium_font)
humidity_data_label.anchor_point = (0.0, 1.0)
humidity_data_label.anchored_position = (5, DISPLAY_HEIGHT)
humidity_data_label.scale = 1
humidity_data_label.color = text_orange

owm_humidity_data_label = label.Label(medium_font)
owm_humidity_data_label.anchor_point = (0.0, 1.0)
owm_humidity_data_label.anchored_position = (5, DISPLAY_HEIGHT - 55)
owm_humidity_data_label.scale = 1
owm_humidity_data_label.color = text_lightblue

barometric_label = label.Label(medium_font)
barometric_label.anchor_point = (1.0, 1.0)
barometric_label.anchored_position = (470, DISPLAY_HEIGHT - 27)
barometric_label.scale = 1
barometric_label.color = text_gray

barometric_data_label = label.Label(medium_font)
barometric_data_label.anchor_point = (1.0, 1.0)
barometric_data_label.anchored_position = (470, DISPLAY_HEIGHT)
barometric_data_label.scale = 1
barometric_data_label.color = text_orange

owm_barometric_data_label = label.Label(medium_font)
owm_barometric_data_label.anchor_point = (1.0, 1.0)
owm_barometric_data_label.anchored_position = (470, DISPLAY_HEIGHT - 55)
owm_barometric_data_label.scale = 1
owm_barometric_data_label.color = text_lightblue

# Battery gauge display labels
vbat_label = label.Label(medium_font)
vbat_label.anchor_point = (1.0, 1.0)
vbat_label.anchored_position = (DISPLAY_WIDTH-15, 20)
vbat_label.scale = (1)

plugbmp_label = label.Label(terminalio.FONT)
plugbmp_label.anchor_point = (1.0, 1.0)
plugbmp_label.scale = (1)

greenbmp_label = label.Label(terminalio.FONT)
greenbmp_label.anchor_point = (1.0, 1.0)
greenbmp_label.scale = (1)

bluebmp_label = label.Label(terminalio.FONT)
bluebmp_label.anchor_point = (1.0, 1.0)
bluebmp_label.scale = (1)

yellowbmp_label = label.Label(terminalio.FONT)
yellowbmp_label.anchor_point = (1.0, 1.0)
yellowbmp_label.scale = (1)

orangebmp_label = label.Label(terminalio.FONT)
orangebmp_label.anchor_point = (1.0, 1.0)
orangebmp_label.scale = (1)

redbmp_label = label.Label(terminalio.FONT)
redbmp_label.anchor_point = (1.0, 1.0)
redbmp_label.scale = (1)

# Load Bitmap to tile grid first (Background layer)
DiskBMP = displayio.OnDiskBitmap("/images/Astral_Fruit_8bit.bmp")
tile_grid = displayio.TileGrid(
    DiskBMP,
    pixel_shader=DiskBMP.pixel_shader,
    width=1,
    height=1,
    tile_width=DISPLAY_WIDTH,
    tile_height=DISPLAY_HEIGHT)

# Load battery voltage icons (from 1 sprite sheet image)
sprite_sheet, palette = adafruit_imageload.load("/icons/vbat_spritesheet.bmp",
                                                bitmap=displayio.Bitmap,
                                                palette=displayio.Palette)
sprite = displayio.TileGrid(sprite_sheet, pixel_shader=palette,
                            width=1,
                            height=1,
                            tile_width=11,
                            tile_height=20)
sprite_group = displayio.Group(scale=1)
sprite_group.append(sprite)
sprite_group.x = 470
sprite_group.y = 0

# Create subgroups
text_group = displayio.Group()
text_group.append(tile_grid)
temp_group = displayio.Group()
main_group = displayio.Group()

# Add subgroups to main display group
main_group.append(text_group)
main_group.append(temp_group)
main_group.append(sprite_group)

# Label Display Group (foreground layer)
text_group.append(date_label)
text_group.append(time_label)
temp_group.append(temp_label)
temp_group.append(temp_data_shadow)
temp_group.append(temp_data_label)
temp_group.append(owm_temp_data_shadow)
temp_group.append(owm_temp_data_label)
text_group.append(humidity_label)
text_group.append(humidity_data_label)
text_group.append(owm_humidity_data_label)
text_group.append(barometric_label)
text_group.append(barometric_data_label)
text_group.append(owm_barometric_data_label)
text_group.append(vbat_label)
text_group.append(plugbmp_label)
text_group.append(greenbmp_label)
text_group.append(bluebmp_label)
text_group.append(yellowbmp_label)
text_group.append(orangebmp_label)
text_group.append(redbmp_label)
display.show(main_group)

# Connect to WiFi
print("\n===============================")
print("Connecting to WiFi...")
pool = socketpool.SocketPool(wifi.radio)
requests = adafruit_requests.Session(pool, ssl.create_default_context())
wifi.radio.connect(secrets["ssid"], secrets["password"])
print("Connected!\n")

vbat_label.text = "{:.2f}".format(Bat_S3)
# source_index = 0

while True:
    gc.collect()

    # Change battery voltage label color with charge level
    if vbat_label.text >= "4.23":
        vbat_label.color = text_white
        sprite[0] = 3
    elif vbat_label.text >= "4.10" and vbat_label.text <= "4.22":
        vbat_label.color = text_green
        sprite[0] = 1
    elif vbat_label.text >= "4.00" and vbat_label.text <= "4.09":
        vbat_label.color = text_lightblue
        sprite[0]
    elif vbat_label.text >= "3.90" and vbat_label.text <= "3.99":
        vbat_label.color = text_yellow
        sprite[0] = 5
    elif vbat_label.text >= "3.80" and vbat_label.text <= "3.89":
        vbat_label.color = text_orange
        sprite[0] = 2
    elif vbat_label.text <= "3.79":
        vbat_label.color = text_red
        sprite[0] = 4
    else:
        vbat_label.color = text_white

    # tile_grid[0] = source_index % 21
    # source_index += 1

    vbat_label.text

    temp_label.text = "°F"
    temperature = "{:.1f}".format(bme280.temperature * 1.8 + 32)
    temp_data_shadow.text = temperature
    temp_data_label.text = temperature
    humidity_label.text = "Humidity"
    humidity_data_label.text = "{:.1f} %".format(bme280.relative_humidity)
    barometric_label.text = "Pressure"
    barometric_data_label.text = "{:.1f}".format(bme280.pressure)

    try:
        print("Attempting to GET Weather!")
        # Uncomment line below to print API URL with all data filled in
        #print("Full API GET URL: ", DATA_SOURCE)
        print("\n===============================")
        response = requests.get(DATA_SOURCE).json()

        # uncomment the 2 lines below to see full json response
        # dump_object = json.dumps(response)
        # print("JSON Dump: ", dump_object)

        get_timestamp = int(response['current']['dt'] + tz_offset_seconds)
        current_unix_time = time.localtime(get_timestamp)
        current_struct_time = time.struct_time(current_unix_time)
        current_date = "{}".format(_format_date(current_struct_time))
        current_time = "{}".format(_format_time(current_struct_time))

        sunrise = int(response['current']['sunrise'] + tz_offset_seconds)
        sunrise_unix_time = time.localtime(sunrise)
        sunrise_struct_time = time.struct_time(sunrise_unix_time)
        sunrise_time = "{}".format(_format_time(sunrise_struct_time))

        sunset = int(response['current']['sunset'] + tz_offset_seconds)
        sunset_unix_time = time.localtime(sunset)
        sunset_struct_time = time.struct_time(sunset_unix_time)
        sunset_time = "{}".format(_format_time(sunset_struct_time))

        owm_temp = response['current']['temp']
        owm_pressure = response['current']['pressure']
        owm_humidity = response['current']['humidity']
        weather_type = response['current']['weather'][0]['main']

        print("Timestamp:", current_date + " " + current_time)
        print("Sunrise:", sunrise_time)
        print("Sunset:", sunset_time)
        print("Temp:", owm_temp)
        print("Pressure:", owm_pressure)
        print("Humidity:", owm_humidity)
        print("Weather Type:", weather_type)

        print("\nNext Update in %s %s" % (int(sleep_int), sleep_time_conversion))
        print("===============================")

        gc.collect()
        date_label.text = current_date
        time_label.text = current_time
        owm_temp_data_shadow.text = "{:.1f}".format(owm_temp)
        owm_temp_data_label.text = "{:.1f}".format(owm_temp)
        owm_humidity_data_label.text = "{:.1f} %".format(owm_humidity)
        owm_barometric_data_label.text = "{:.1f}".format(owm_pressure)

    except (ValueError, RuntimeError) as e:
        print("Failed to get data, retrying\n", e)
        wifi.reset()
        time.sleep(60)
        continue
    response = None
    time.sleep(sleep_time)

Behavior

Auto-reload is off. Running in safe mode! Not running saved code.

You are in safe mode because: CircuitPython core code crashed hard. Whoops! Crash into the HardFault_Handler. Please file an issue with the contents of your CIRCUITPY drive at https://github.com/adafruit/circuitpython/issues

Press any key to enter the REPL. Use CTRL-D to reload.

Adafruit CircuitPython 7.3.2 on 2022-07-20; FeatherS3 with ESP32S3

Description

Issue documented in discord dev channel. https://discord.com/channels/327254708534116352/327298996332658690/1010913898708336681

Additional information

Issue is worse on 8.0 beta than 7.3 because it still crashes to safe mode but without any error describing it in repl like it shows in 7.3. but issue occurs in both UF2 versions.

after a certain period of time when i hit save in Mu the USB drive disconnects, reconnects, i pull up repl immediately, and it shows that message. usually about 2-3 minutes. i have to physically hit reset on the board, get to save my code once or twice before 2-3 minutes, and the process repeats itself. It’s a safe mode crashing loop.

Here’s the full contents of my CIRCUITPY drive, including /lib and everything. https://github.com/DJDevon3/CircuitPython/tree/main/UM_ESP32-S3 Online-Offline Weatherstation