tests: fota: add MCUboot bootloader FOTA test

Add `test_bootloader_fota` to verify B1 MCUboot FOTA on Thingy:91 X.
Checks `bootloaderVersion` in nRF Cloud shadow before (v2) and after
(v3) the update, and verifies B0 UART output post-swap.

Also refactor the FOTA poll loop into `trigger_fota_poll`, pass
`MCUBOOT_BUNDLEID` env var through CI, and set a default signing key
for nRF9151 DK in sysbuild config.

Setting the signing key will allow us to run the test on the DK as well.
This will be added once the new DTS partition schema is in place.

Signed-off-by: Simen S. Røstad <simen.rostad@nordicsemi.no>

Author: simensrostad

.github/workflows/target-test.yml

@@ -188,6 +188,7 @@ jobs:
           MEMFAULT_ORGANIZATION_SLUG: ${{ vars.MEMFAULT_ORGANIZATION_SLUG }}
           MEMFAULT_PROJECT_SLUG: ${{ vars.MEMFAULT_PROJECT_SLUG }}
           APP_BUNDLEID: ${{ vars.APP_BUNDLEID }}
+          MCUBOOT_BUNDLEID: ${{ vars.MCUBOOT_BUNDLEID }}
 
       - name: Generate and Push Power Badge
         if: ${{ always() && matrix.device == 'ppk_thingy91x' }}

app/Kconfig.sysbuild

@@ -11,6 +11,9 @@ endchoice
 config SECURE_BOOT_APPCORE
 	default y if BOARD_NRF9151DK_NRF9151_NS
 
+config SECURE_BOOT_SIGNING_KEY_FILE
+	default "$(ZEPHYR_NRF_MODULE_DIR)/boards/nordic/thingy91x/nsib_signing_key.pem" if BOARD_NRF9151DK_NRF9151_NS
+
 config WIFI_NRF70
 	default y if BOARD_THINGY91X_NRF9151_NS
 

docs/common/test_and_ci_setup.md

@@ -19,7 +19,7 @@ The CI pipeline is triggered as follows:
 
 - Pull Request: `build.yml`, `sonarcloud.yml`, `compliance.yml`. No target tests are run on PR to avoid instabilities.
 - Push to main: `build-and-target-test.yml`, `sonarcloud.yml`, `doc-sync.yml`. Only "fast" target tests are run. Avoiding excessively time-consuming tests.
-- Nightly: `build-and-target-test.yml`. Full set of target tests. Includes slow tests such as the full modem FOTA test and the power consumption test.
+- Nightly: `build-and-target-test.yml`. Full set of target tests. Includes slow tests such as the full modem FOTA test, application and bootloader (MCUboot) FOTA.
 
 ### Hardware Tests
 

tests/on_target/tests/test_functional/test_fota.py

@@ -27,16 +27,22 @@
 MFW_VERSION = "mfw_nrf91x1_2.0.4"
 
 APP_BUNDLEID = os.getenv("APP_BUNDLEID")
+MCUBOOT_BUNDLEID = os.getenv("MCUBOOT_BUNDLEID")
 
 TEST_APP_BIN = {
     "thingy91x": "artifacts/stable_version_jan_2025-update-signed.bin",
     "nrf9151dk": "artifacts/nrf9151dk_mar_2025_update_signed.bin"
 }
 
 DEVICE_MSG_TIMEOUT = 60 * 5
-APP_FOTA_TIMEOUT = 60 * 10
+APP_FOTA_TIMEOUT = 60 * 15
+BOOTLOADER_FOTA_TIMEOUT = 60 * 20
 FULL_MFW_FOTA_TIMEOUT = 60 * 30
 
+BOOTLOADER_VERSION_BASELINE = "2"
+BOOTLOADER_VERSION_UPDATED = "3"
+BOOTLOADER_FIRMWARE_VERSION_LOG = "Firmware version 3"
+
 def await_nrfcloud(func, expected, field, timeout):
     start = time.time()
     logger.info(f"Awaiting {field} == {expected} in nrfcloud shadow...")
@@ -61,6 +67,41 @@ def get_modemversion(dut_fota):
     shadow = dut_fota.fota.get_device(dut_fota.device_id)
     return shadow["state"]["reported"]["device"]["deviceInfo"]["modemFirmware"]
 
+def get_bootloaderversion(dut_fota):
+    shadow = dut_fota.fota.get_device(dut_fota.device_id)
+    return shadow["state"]["reported"]["device"]["deviceInfo"]["bootloaderVersion"]
+
+def await_bootloader_version(dut_fota, expected, timeout=DEVICE_MSG_TIMEOUT):
+    start = time.time()
+    logger.info(f"Awaiting bootloaderVersion == {expected} in nrfcloud shadow...")
+    while True:
+        time.sleep(5)
+        if time.time() - start > timeout:
+            raise RuntimeError(
+                f"Timeout awaiting bootloaderVersion == {expected}")
+        try:
+            version = get_bootloaderversion(dut_fota)
+        except (KeyError, TypeError) as e:
+            logger.warning(f"bootloaderVersion not in shadow yet: {e}")
+            continue
+        except Exception as e:
+            logger.warning(f"Exception getting bootloaderVersion: {e}")
+            continue
+        logger.debug(f"Reported bootloaderVersion: {version}")
+        if version == expected:
+            return
+
+def trigger_fota_poll(dut_fota, max_attempts=3):
+    for i in range(max_attempts):
+        try:
+            time.sleep(10)
+            dut_fota.uart.write("att_button press 1\r\n")
+            dut_fota.uart.wait_for_str("nrf_cloud_fota_poll: Starting FOTA download", timeout=30)
+            return
+        except AssertionError:
+            continue
+    raise AssertionError(f"Fota update not available after {max_attempts} attempts")
+
 def perform_disconnect_reconnect(dut_fota, expected_percentage):
     """Helper function to perform a disconnect/reconnect sequence and verify resumption at expected percentage"""
     patterns_lte_offline = ["network: lte_lc_evt_handler: PDN connection network detached"]
@@ -170,17 +211,7 @@ def _run_fota(bundle_id="", fota_type="app", fotatimeout=APP_FOTA_TIMEOUT, new_v
             pytest.skip(f"FOTA create_job REST API error: {e}")
         logger.info(f"Created FOTA Job (ID: {dut_fota.data['job_id']})")
 
-        # Sleep a bit and trigger fota poll
-        for i in range(3):
-            try:
-                time.sleep(10)
-                dut_fota.uart.write("att_button press 1\r\n")
-                dut_fota.uart.wait_for_str("nrf_cloud_fota_poll: Starting FOTA download", timeout=30)
-                break
-            except AssertionError:
-                continue
-        else:
-            raise AssertionError(f"Fota update not available after {i} attempts")
+        trigger_fota_poll(dut_fota)
 
         if reschedule:
             run_fota_reschedule(dut_fota, fota_type)
@@ -284,6 +315,77 @@ def test_app_fota(run_fota_fixture):
         bundle_id=APP_BUNDLEID,
     )
 
+@pytest.mark.slow
+def test_bootloader_fota(dut_fota, hex_file):
+    '''
+    Test MCUboot bootloader (B1) FOTA on Thingy:91 X.
+
+    Verifies deviceInfo.bootloaderVersion in the nRF Cloud shadow (baseline v2,
+    v3 after FOTA) and B0 UART "Firmware version 3" after the swap reboot.
+
+    The finally block re-flashes baseline merged.hex to restore the DUT.
+    '''
+    if os.getenv("DUT_DEVICE_TYPE") != "thingy91x":
+        pytest.skip("Bootloader FOTA test runs on thingy91x only")
+    if not MCUBOOT_BUNDLEID:
+        pytest.skip("MCUBOOT_BUNDLEID environment variable not set")
+
+    try:
+        flash_device(os.path.abspath(hex_file))
+        dut_fota.uart.xfactoryreset()
+        dut_fota.uart.flush()
+        reset_device()
+
+        dut_fota.uart.wait_for_str_with_retries(
+            "Connected to Cloud", max_retries=3, timeout=240, reset_func=reset_device)
+
+        await_bootloader_version(dut_fota, BOOTLOADER_VERSION_BASELINE)
+
+        try:
+            dut_fota.data["job_id"] = dut_fota.fota.create_fota_job(
+                dut_fota.device_id, MCUBOOT_BUNDLEID)
+            dut_fota.data["bundle_id"] = MCUBOOT_BUNDLEID
+        except NRFCloudFOTAError as e:
+            pytest.skip(f"FOTA create_job REST API error: {e}")
+        logger.info(f"Created bootloader FOTA job (ID: {dut_fota.data['job_id']})")
+
+        trigger_fota_poll(dut_fota)
+
+        dut_fota.uart.wait_for_str("fota_download: B1 update, selected", timeout=120)
+        dut_fota.uart.wait_for_str("Download complete", timeout=BOOTLOADER_FOTA_TIMEOUT)
+        post_download_pos = dut_fota.uart.get_size()
+
+        # B1 FOTA: reboot, MCUboot test-swap, then B0 boots slot 1 with new fw_info.
+        dut_fota.uart.wait_for_str(
+            BOOTLOADER_FIRMWARE_VERSION_LOG,
+            timeout=BOOTLOADER_FOTA_TIMEOUT,
+            start_pos=post_download_pos,
+            error_msg="Expected B0 fw_info v3 after download",
+        )
+
+        await_nrfcloud(
+            functools.partial(dut_fota.fota.get_fota_status, dut_fota.data["job_id"]),
+            "IN_PROGRESS",
+            "FOTA status",
+            BOOTLOADER_FOTA_TIMEOUT,
+        )
+        await_nrfcloud(
+            functools.partial(dut_fota.fota.get_fota_status, dut_fota.data["job_id"]),
+            "COMPLETED",
+            "FOTA status",
+            BOOTLOADER_FOTA_TIMEOUT,
+        )
+        if not dut_fota.fota.get_fota_completed_executions(dut_fota.data["job_id"]) > 0:
+            raise AssertionError("Bootloader FOTA job completed but no devices succeeded")
+
+        dut_fota.uart.wait_for_str_with_retries(
+            "Connected to Cloud", max_retries=5, timeout=300, reset_func=reset_device)
+
+        await_bootloader_version(dut_fota, BOOTLOADER_VERSION_UPDATED,
+                                 timeout=BOOTLOADER_FOTA_TIMEOUT)
+    finally:
+        flash_device(os.path.abspath(hex_file))
+
 def test_delta_mfw_fota(run_fota_fixture):
     '''
     Test delta modem FOTA on nrf9151