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NPU load crash on Strix Halo: Inference.Service.Agent.exe fault in onnxruntime_vitis_ai_custom_ops.dll (0xc0000005) #832

Description

@kenrick3577

Summary

On AMD Strix Halo (Ryzen AI Max+ 395), Foundry Local can run GPU models successfully, but NPU model load consistently fails and crashes Inference.Service.Agent.exe.

Environment

  • OS: Windows 11 host (WSL2 Ubuntu 24.04 used only as operator shell)
  • Hardware: AMD Ryzen AI Max+ 395 / Radeon 8060S
  • Foundry Local: Microsoft.FoundryLocal_0.8.119.102_x64__8wekyb3d8bbwe
  • NPU EP: MicrosoftCorporationII.WinML.AMD.NPU.EP.1.8_1.8.62.0_x64__8wekyb3d8bbwe

Reproduction

  1. foundry service status (service running, VitisAI EP listed)
  2. Run:
    foundry model run qwen2.5-0.5b --device NPU --prompt "test" --ttl 120
  3. Failure happens during load request.

Observed behavior

  • CLI stderr includes:
    • Exception: Request to local service failed. Uri:http://127.0.0.1:<port>/openai/load/qwen2.5-0.5b-instruct-vitis-npu:3?ttl=120
    • An error occurred while sending the request.
  • Application log repeatedly records crash:
    • Event ID: 1000
    • Faulting app: Inference.Service.Agent.exe (0.8.119.102)
    • Faulting module: onnxruntime_vitis_ai_custom_ops.dll (1.7.0.0)
    • Exception code: 0xc0000005
    • Fault offset: 0x00000000000246f5

Control test

GPU path works on same machine:
foundry model run qwen2.5-0.5b --device GPU --prompt "test" --ttl 120
Model loads and returns text successfully.

Mitigations tried

  • Service reset/init and smoke retest
  • Tested two NPU model variants (qwen2.5-coder-0.5b, qwen2.5-0.5b)
  • Repaired Foundry package (initially blocked by in-use files 0x80073d02, then repair completed after stopping processes)
  • Retested after repair: same NPU crash signature remains

Why this seems product/runtime related

CPU/GPU paths are healthy on the same system, but NPU path consistently crashes in onnxruntime_vitis_ai_custom_ops.dll during model load.

Artifacts available

I collected full evidence bundle under:
C:\Users\Ken\foundry_fix_round1\

Key files:

  • ISSUE_BUNDLE_20260623.md
  • r2b_01_service_status.txt
  • r2b_02_versions.txt
  • r2b_03_npu_smoke_stdout.txt
  • r2b_03_npu_smoke_stderr.txt
  • r2b_04_events.txt
  • r3_06_gpu_smoke_stdout.txt
  • r3_14_npu_after_repair_stderr.txt
  • r3_15_events_after_repair.txt

If you want, I can upload zipped artifacts from this folder.

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