Wheezy ran great on E02 for two weeks, now no go, EHCI time out on boot

Hello, my E02 with wheezy was working like a champ for over two weeks. I rebooted the box (Using reboot command). While watching the netconsole, it now errors out:

U-Boot 2011.12 (Feb 20 2012 - 21:21:59)
Pogoplug E02
arm-none-linux-gnueabi-gcc (Sourcery G++ Lite 2009q3-67) 4.4.1
GNU ld (Sourcery G++ Lite 2009q3-67) 2.19.51.20090709
Hit any key to stop autoboot:  0 
(Re)start USB...
USB:   Register 10011 NbrPorts 1
USB EHCI 1.00
scanning bus for devices... 4 USB Device(s) found
       scanning bus for storage devices... 1 Storage Device(s) found
Loading file "/rescueme" from usb device 0:1 (usbda1)
** File not found /rescueme
reading /rescueme.txt

** Unable to read "/rescueme.txt" from usb 0:1 **
Creating 1 MTD partitions on "nand0":
0x000002500000-0x000008000000 : "mtd=3"
UBI: attaching mtd1 to ubi0
UBI: physical eraseblock size:   131072 bytes (128 KiB)
UBI: logical eraseblock size:    129024 bytes
UBI: smallest flash I/O unit:    2048
UBI: sub-page size:              512
UBI: VID header offset:          512 (aligned 512)
UBI: data offset:                2048
UBI: attached mtd1 to ubi0
UBI: MTD device name:            "mtd=3"
UBI: MTD device size:            91 MiB
UBI: number of good PEBs:        728
UBI: number of bad PEBs:         0
UBI: max. allowed volumes:       128
UBI: wear-leveling threshold:    4096
UBI: number of internal volumes: 1
UBI: number of user volumes:     0
UBI: available PEBs:             717
UBI: total number of reserved PEBs: 11
UBI: number of PEBs reserved for bad PEB handling: 7
UBI: max/mean erase counter: 1/1
UBIFS error (pid 0): ubifs_get_sb: cannot open "ubi:rootfs", error -19
Error reading superblock on volume 'ubi:rootfs'!
Loading file "/boot/uImage" from usb device 0:1 (usbda1)
1 bytes read
Found bootable drive on usb 0:1
Loading file "/boot/uImage" from usb device 0:1 (usbda1)
EHCI timed out on TD - token=0x800d8d80
EHCI timed out on TD - token=0x800d8d80
EHCI timed out on TD - token=0x800d8d80
 ** ext2fs_devread read error - block
** Unable to read "/boot/uImage" from usb 0:1 **
Loading file "/boot/uInitrd" from usb device 0:1 (usbda1)
EHCI timed out on TD - token=0x800d8d80
 ** ext2fs_devread read error - block
** Unable to read "/boot/uInitrd" from usb 0:1 **
## Booting kernel from Legacy Image at 00800000 ...
   Image Name:   Linux-3.2.0-4-kirkwood
   Image Type:   ARM Linux Kernel Image (uncompressed)
   Data Size:    1606376 Bytes = 1.5 MiB
   Load Address: 00008000
   Entry Point:  00008000
   Verifying Checksum ... Bad Data CRC
ERROR: can't get kernel image!
stopping USB..

NAND read: device 0 offset 0x100000, size 0x400000
 4194304 bytes read: OK
## Booting kernel from Legacy Image at 00800000 ...
   Image Name:   Linux-3.3.2-kirkwide
   Image Type:   ARM Linux Kernel Image (uncompressed)
   Data Size:    3627768 Bytes = 3.5 MiB
   Load Address: 00008000
   Entry Point:  00008000
   Verifying Checksum ... OK
   Loading Kernel Image ... OK
OK

Starting kernel ...

So looks like an EHCI time out is my issue. I've googled around on it and found this and I've found a few clues:

http://archlinuxarm.org/forum/viewtopic.php?f=18&t=3584

It looks like my thumb drive is bad? I ran e2fsck:

rescue:~# e2fsck -n -f -v /dev/sda1
e2fsck 1.41.12 (17-May-2010)
Pass 1: Checking inodes, blocks, and sizes
Pass 2: Checking directory structure
Pass 3: Checking directory connectivity
Pass 4: Checking reference counts
Pass 5: Checking group summary information

   18491 inodes used (4.09%)
     157 non-contiguous files (0.8%)
      22 non-contiguous directories (0.1%)
         # of inodes with ind/dind/tind blocks: 1134/12/0
  173281 blocks used (9.59%)
       0 bad blocks
       1 large file

   14464 regular files
    2098 directories
      12 character device files
      25 block device files
       1 fifo
      12 links
    1882 symbolic links (1818 fast symbolic links)
       0 sockets
--------
   18494 files

Everything looks good there (right?) So do I just toss the usb stick and move on?

Thanks in advance

Two other details:

printenv

rescue:~# printenv
HISTFILESIZE=1000
INPUTRC=/etc/inputrc
SSH_CLIENT=10.0.1.51 53953 22
MAIL=/var/mail/root
USER=root
HOSTNAME=rescue
HOME=/root
SSH_TTY=/dev/pts/0
PAGER=/bin/more 
PS1=\h:\w\# 
LOGNAME=root
TERM=xterm-color
PATH=/bin:/sbin:/usr/bin:/usr/sbin:/usr/local/bin
DMALLOC_OPTIONS=debug=0x34f47d83,inter=100,log=logfile
HISTSIZE=1000
LS_COLORS=no=00:fi=00:di=01;34:ln=01;36:pi=40;33:so=01;35:do=01;35:bd=40;33;01:cd=40;33;01:or=40;31;01:ex=01;32:*.tar=01;31:*.tgz=01;31:*.arj=01;31:*.taz=01;31:*.lzh=01;31:*.zip=01;31:*.z=01;31:*.Z=01;31:*.gz=01;31:*.bz2=01;31:*.deb=01;31:*.rpm=01;31:*.jar=01;31:*.jpg=01;35:*.jpeg=01;35:*.png=01;35:*.gif=01;35:*.bmp=01;35:*.pbm=01;35:*.pgm=01;35:*.ppm=01;35:*.tga=01;35:*.xbm=01;35:*.xpm=01;35:*.tif=01;35:*.tiff=01;35:*.mpg=01;35:*.mpeg=01;35:*.avi=01;35:*.fli=01;35:*.gl=01;35:*.dl=01;35:*.xcf=01;35:*.xwd=01;35:
SHELL=/bin/sh
PWD=/root
SSH_CONNECTION=10.0.1.51 53953 10.0.1.10 22
EDITOR=/bin/vi

fwprintenv

rescue:~# fw_printenv
ethact=egiga0
bootdelay=3
baudrate=115200
mainlineLinux=yes
console=ttyS0,115200
led_init=green blinking
led_exit=green off
led_error=orange blinking
mtdparts=mtdparts=orion_nand:1M(u-boot),4M(uImage),32M(rootfs),-(data)
mtdids=nand0=orion_nand
partition=nand0,2
stdin=serial
stdout=serial
stderr=serial
rescue_set_bootargs=setenv bootargs console=$console ubi.mtd=2 root=ubi0:rootfs ro rootfstype=ubifs $mtdparts $rescue_custom_params
rescue_bootcmd=if test $rescue_installed -eq 1; then run rescue_set_bootargs; nand read.e 0x800000 0x100000 0x400000; bootm 0x800000; else run pogo_bootcmd; fi
pogo_bootcmd=if fsload uboot-original-mtd0.kwb; then go 0x800200; fi
force_rescue=0
force_rescue_bootcmd=if test $force_rescue -eq 1 || ext2load usb 0:1 0x1700000 /rescueme 1 || fatload usb 0:1 0x1700000 /rescueme.txt 1; then run rescue_bootcmd; fi
ubifs_mtd=3
ubifs_set_bootargs=setenv bootargs console=$console ubi.mtd=$ubifs_mtd root=ubi0:rootfs rootfstype=ubifs $mtdparts $ubifs_custom_params
ubifs_bootcmd=run ubifs_set_bootargs; if ubi part data && ubifsmount rootfs && ubifsload 0x800000 /boot/uImage && ubifsload 0x1100000 /boot/uInitrd; then bootm 0x800000 0x1100000; fi
usb_scan=usb_scan_done=0;for scan in $usb_scan_list; do run usb_scan_$scan; if test $usb_scan_done -eq 0 && ext2load usb $usb 0x800000 /boot/uImage 1; then usb_scan_done=1; echo "Found bootable drive on usb $usb"; setenv usb_device $usb; setenv usb_root /dev/$dev; fi; done
usb_scan_list=1 2 3 4
usb_scan_1=usb=0:1 dev=sda1
usb_scan_2=usb=1:1 dev=sdb1
usb_scan_3=usb=2:1 dev=sdc1
usb_scan_4=usb=3:1 dev=sdd1
usb_init=run usb_scan
usb_device=0:1
usb_root=/dev/sda1
usb_rootfstype=ext2
usb_rootdelay=10
usb_set_bootargs=setenv bootargs console=$console root=$usb_root rootdelay=$usb_rootdelay rootfstype=$usb_rootfstype $mtdparts $usb_custom_params
usb_bootcmd=run usb_init; run usb_set_bootargs; run usb_boot
usb_boot=mw 0x800000 0 1; ext2load usb $usb_device 0x800000 /boot/uImage; if ext2load usb $usb_device 0x1100000 /boot/uInitrd; then bootm 0x800000 0x1100000; else bootm 0x800000; fi
bootcmd=usb start; run force_rescue_bootcmd; run ubifs_bootcmd; run usb_bootcmd; usb stop; run rescue_bootcmd; run pogo_bootcmd; reset
ethaddr=00:25:31:04:AA:18
arcNumber=3542
serverip=10.0.1.51
ipaddr=10.0.1.10
if_netconsole=ping $serverip
start_netconsole=setenv ncip $serverip; setenv bootdelay 10; setenv stdin nc; setenv stdout nc; setenv stderr nc; version;
preboot=run if_netconsole start_netconsole
set_bootargs_rescue=setenv bootargs console=$console ubi.mtd=2 root=ubi0:rootfs ro rootfstype=ubifs $mtdparts
bootcmd_rescue=run set_bootargs_rescue; nand read.e 0x800000 0x100000 0x400000; bootm 0x800000
bootcmd_pogo=run bootcmd_rescue
rescue_installed=1

There was a long thread about various kind of working and non-working USB sticks:
http://forum.doozan.com/read.php?2,1915,page=1

Sandisk is among the most reliable USB sticks.

Also, sometime adding a "usb stop; usb start" once or a few times before scanning would enable an unreliable USB stick to work:

fw_setenv usb_init 'usb stop; usb start; run usb_scan'

Edited 1 time(s). Last edit at 02/08/2013 04:55PM by bodhi.

Hi Bodhi, thank you for the tip. I added it to the set env:

arm-none-linux-gnueabi-gcc (Sourcery G++ Lite 2009q3-67) 4.4.1
GNU ld (Sourcery G++ Lite 2009q3-67) 2.19.51.20090709
Hit any key to stop autoboot:  0 
(Re)start USB...
USB:   Register 10011 NbrPorts 1
USB EHCI 1.00
scanning bus for devices... 4 USB Device(s) found
       scanning bus for storage devices... 1 Storage Device(s) found
Loading file "/rescueme" from usb device 0:1 (usbda1)
** File not found /rescueme
reading /rescueme.txt

** Unable to read "/rescueme.txt" from usb 0:1 **
Creating 1 MTD partitions on "nand0":
0x000002500000-0x000008000000 : "mtd=3"
UBI: attaching mtd1 to ubi0
UBI: physical eraseblock size:   131072 bytes (128 KiB)
UBI: logical eraseblock size:    129024 bytes
UBI: smallest flash I/O unit:    2048
UBI: sub-page size:              512
UBI: VID header offset:          512 (aligned 512)
UBI: data offset:                2048
UBI: attached mtd1 to ubi0
UBI: MTD device name:            "mtd=3"
UBI: MTD device size:            91 MiB
UBI: number of good PEBs:        728
UBI: number of bad PEBs:         0
UBI: max. allowed volumes:       128
UBI: wear-leveling threshold:    4096
UBI: number of internal volumes: 1
UBI: number of user volumes:     0
UBI: available PEBs:             717
UBI: total number of reserved PEBs: 11
UBI: number of PEBs reserved for bad PEB handling: 7
UBI: max/mean erase counter: 1/1
UBIFS error (pid 0): ubifs_get_sb: cannot open "ubi:rootfs", error -19
Error reading superblock on volume 'ubi:rootfs'!
stopping USB..
(Re)start USB...
USB:   Register 10011 NbrPorts 1
USB EHCI 1.00
scanning bus for devices... 4 USB Device(s) found
       scanning bus for storage devices... 1 Storage Device(s) found
Loading file "/boot/uImage" from usb device 0:1 (usbda1)
1 bytes read
Found bootable drive on usb 0:1
Loading file "/boot/uImage" from usb device 0:1 (usbda1)
EHCI timed out on TD - token=0x800d8d80
 ** ext2fs_devread read error - block
** Unable to read "/boot/uImage" from usb 0:1 **
Loading file "/boot/uInitrd" from usb device 0:1 (usbda1)
EHCI timed out on TD - token=0x800d8d80
EHCI timed out on TD - token=0x800d8d80
 ** ext2fs_devread read error - block
** Unable to read "/boot/uInitrd" from usb 0:1 **
## Booting kernel from Legacy Image at 00800000 ...
   Image Name:   Linux-3.2.0-4-kirkwood
   Image Type:   ARM Linux Kernel Image (uncompressed)
   Data Size:    1606376 Bytes = 1.5 MiB
   Load Address: 00008000
   Entry Point:  00008000
   Verifying Checksum ... Bad Data CRC
ERROR: can't get kernel image!
stopping USB..

NAND read: device 0 offset 0x100000, size 0x400000
 4194304 bytes read: OK
## Booting kernel from Legacy Image at 00800000 ...
   Image Name:   Linux-3.3.2-kirkwide
   Image Type:   ARM Linux Kernel Image (uncompressed)
   Data Size:    3627768 Bytes = 3.5 MiB
   Load Address: 00008000
   Entry Point:  00008000
   Verifying Checksum ... OK
   Loading Kernel Image ... OK
OK

Starting kernel ...

Looks like I'm still out of luck... sigh, thanks for the tip about the brand. Are there semi-fast sandisk drives that are reliable?

ubermacin,

I've used many different Sandisk sticks for booting (Ducati, Cruzer, Cruzer Titanium, Fit, Edge, ...) they all are very reliable for cold and warm boot. Ducati is most expensive and fastest. But it does not really bother me to use the slowest Sandisk. It varies from 40 seconds to 90 seconds, from the slowest to the fastest Sandisk stick, booting my Debian system. Nowadays I use Sandisk Cruzer Fit drives because it is very reliable and has a very small footprint (however, it is slower than the other Sandisk models).

Thanks for all the advice bodhi! I'll get a Sandisk so I won't have this issue in the future.