avrdude upload error when fuses are present in the elf file (AVR Dx)

[kiiv-cz]

I'm getting error:

avrdude error: address 0x820009 out of range at line 665 of .pio\build\test_fuses_in_elf\firmware.hex

caused by having C source file containing FUSES setting (src/fuses.c):

#include <avr/io.h>

#ifdef MVIO_ENABLED
  #define MVIO_SETTING MVSYSCFG_DUAL_gc
#else
  #define MVIO_SETTING MVSYSCFG_SINGLE_gc
#endif

FUSES = {
    .WDTCFG   = WINDOW_OFF_gc | PERIOD_OFF_gc,
    .BODCFG   = LVL_BODLEVEL0_gc | SAMPFREQ_128Hz_gc | ACTIVE_DISABLE_gc | SLEEP_DISABLE_gc,
    .OSCCFG   = CLKSEL_OSCHF_gc,
    .SYSCFG0  = CRCSRC_NOCRC_gc | CRCSEL_CRC16_gc | RSTPINCFG_RST_gc | FUSE_EESAVE_bm,
    .SYSCFG1  = MVIO_SETTING | SUT_16MS_gc,
    .CODESIZE = 0x00,
    .BOOTSIZE = 0x00,
};

Fix is adding "-R" ".fuse" into ElfToHex Builder builder/main.py#L129:

        ElfToHex=Builder(
            action=env.VerboseAction(" ".join([
                "$OBJCOPY",
                "-O",
                "ihex",
                "-R",
                ".eeprom",
                "-R",
                ".fuse",
                "$SOURCES",
                "$TARGET"
            ]), "Building $TARGET"),
            suffix=".hex"
        )

Another workaround is using custom upload protocol and just copy hex file to CURIOSITY NANO drive:

upload_protocol = custom
upload_command = copy $SOURCE d:\

Board: Curiosity Nano DB / AVRxDB (but should be valid for any supported MCU)
Plaform version: 1.9.0

[brunob45]

Fuses are usually set by options in the platformio.ini file as documented here. Setting the fuses manually elsewhere can have unforeseen consequences.

What fuse were you unable to set correctly?

[kiiv-cz]

My aim is creating single production file (= elf) that contains code + eeprom and fuses so my coworker can just run Quick Programming tool from Microchip studio and not care about anything.

I can pass those fuses into program as defines to have it consistent (but only with magic numbers), however it still can't be present inside of hex (or I could use avrdude v8 that now supports flashing everything inside single file - released recently).

Another way is another env with purpose only generate production file as changing platform localy will work only until it gets updated.

[kiiv-cz]

Solved by custom upload command:
upload_command = $UPLOADER $UPLOADERFLAGS -U flash:w:$PROGPATH:e -U fuses:w:$PROGPATH:e
The $PROGPATH contains location of current firmware.elf (instead of SOURCE for hex).

With avrdude 8.x it's possible to use -U all:w:firmware:hex:i and all memories in hex would be programmed at once (currently it'd be fuses and flash).

The --target fuses wasn't very helpful as for example get_wdtcfg_fuse() returns 0 when there is board_hardware.bod = 4.2v. When it's not configured, it'll use some default value (0x54 or similar).