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AM3354: Bootup Issue after MLO copy in firmware update

Part Number: AM3354

Hi All,

I am facing an issue in the bootup of my AM3354 board. It uses the ThreadX RTOS.

The board is able to boot up normally without any issues but after performing a Firmware Upgrade via USB which involves MLO copy from USB to on board SD card (FAT32) the board refuses to boot up.

We have validated the USB file copy by checking the MD5 hash and are pretty sure the issue is related to the some "corruption" to the FAT32 file system after this copy operation.

The ROM bootloader prints "CCCCC" on the debug port indicating that the MLO is not found however the SD card contains the valid MLO file in the root directory. 

To recover from this issue, all we do is plug the SD card into Windows PC and run the built in check disk utility, which says that "No problems were found on the device or disk. It is ready to use". After this we plug the card back into the board and it boots up fine

We suspected the MBR (Master Boot Record) might have something to do with this issue but we were able to read the 512 bytes from the SD card before and after the check disk utility ran. Both the MBR's were same except the SD card did not boot before and now after running checkdisk it booted up successfully.

Could there be anything else that we are "corrupting" in the FAT32 file system while copying the MLO that prevents the TI-ROM bootloader from detecting the MLO and booting up ? 

The application running in ThreadX uses the FileX library and is able to read and write normal files on the FAT32 filesystem without any issue.

Any suggestions will be greatly appreciated !!