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AM625: Sometimes u-boot.img is not loaded from eMMC (after reboot from Linux)

Part Number: AM625


Tool/software:

Hello,

Using u-boot 2023.04 and kernel 6.1.82 we had it running very stable for a long time (on a custom board). However, we now sometimes have a boot issue.

After a Linux reboot (we finalize writing data to eMMC, then umount partitions and the soc reset. Coming out of reset, pmic, power rails are ok but loading u-boot.img fails.

We boot using eMMC hw boot partition 0. tiboot3.bin and tispl.bin are loaded, but tispl.bin fails to load u-boot.img (all three are in the same partition). The console shows it:

U-Boot SPL 2023.04-ti-gf9b966c67473 (Mar 19 2024 - 20:31:40 +0000)
SYSFW ABI: 3.1 (firmware rev 0x0009 '9.2.7--v09.02.07 (Kool Koala)')
SPL initial stack usage: 13392 bytes
Trying to boot from MMC1
Authentication passed
Authentication passed
Authentication passed
Authentication passed
Authentication passed
Starting ATF on ARM64 core...
 
NOTICE:  BL31: v2.10.0(release):v2.10.0-367-g00f1ec6b87-dirty
NOTICE:  BL31: Built : 16:09:05, Feb  9 2024
 
U-Boot SPL 2023.04-ti-gf9b966c67473 (Mar 19 2024 - 20:31:40 +0000)
SYSFW ABI: 3.1 (firmware rev 0x0009 '9.2.7--v09.02.07 (Kool Koala)')
SPL initial stack usage: 1888 bytes
MMC: no card present
** Bad device specification mmc 1 **
Couldn't find partition mmc 1:1
Error: could not access storage.
Trying to boot from MMC1
Card did not respond to voltage select! : -110
spl: mmc init failed with error: -95
SPL: failed to boot from all boot devices
### ERROR ### Please RESET the board ###


We use fixed voltage 3v3 for the eMMC flash. Device part is Kingston EMMC16G-WW28-01E10.
As part of board production, the warm boot mode is enabled.

It does not help to assert the eMMC reset pin, the boot still fails at this point.

NOTE: A full power cycle of the board (soc, eMMC..) is required in order to boot up successfully again. The board must be able to boot up in warm reset mode.

How can we diagnose/fix this?

Thanks for help.
Lars Horvath