eviala wrote: ↑
Thu Sep 19, 2019 2:37 pm
"I would be suspicious first of all in the custom hardware you have attached to the Pi0, and perhaps the software that is driving it. Is there any way you can test without it?"
I leave a RPi Zero disconnected from the hardware and it fails with the same problem (faulty reset with dirty bit and hang) than the RPi .
I think the reason to suspect a hardware problem is because you yourself said you know software but not so much hardware.
Memory and SD card corruption can be caused by low voltages, electrically noisy power supplies and overloaded GPIO. The fact that the Pi computers do not have ECC further increases the likelihood of memory errors. At any rate, if the filesystem has what appears to be a significant amount of corruption, the automatic repair algorithm that runs at boot time gets scared, quits and waits for user intervention. This may cause the failure to boot you are experiencing.
While the filesystem format repair algorithm can be set to automatically proceed even if things look grim, it would be better to track down what is causing the problem.
One way I have used to stabilize Pi and other computers in the past had been to lower the clock speed of the processor and memory. In your case I would edit config.txt in the boot partition and set the CPU frequency explicitly to 700. That's an easy change such that if it doesn't make a difference, you can just as easily put things back the way they were.
With power supplies there are two things to check: Whether the correct 5V potential actually appears at the correct places in the Pi Zero and how clean the 5V supply is. The potential can be checked with a cheap multimeter purchased from eBay, Amazon or your favorite discount electronics store. How clean the voltage source is can be checked with a scope or oscilloscope. As scopes are expensive, it's better to have such a device at work or through a friend. If you have a business relationship with the owner of a local electronics store--for example the store which sold you the power supply--you may be able to get them to check the power supply output. Note there are a number of 5V supplies designed to power things other than computers for which electrical noise can be a problem.
Good stress tests are important for identifying such problems. Such tests are difficult to create but can result in new patentable technology if one is lucky.