Hi Mikkel,

I am trying to follow Andrew's post as close as I can. The tree I am 
building from is git://git.denx.de/u-boot.git, the one provided in Andrew's 
post.

RESOLVED:
>
> Upon investigating the u-boot output we found we were facing the same 
> problem reported earlier in this thread by duckhunter: u-boot was detecting 
> spurious data on uart0 and entering the u-boot console on about 1/20 
> power-ups.
>
> Rather than making any hardware mods I decided to reconfigured u-boot to 
> look for a specific key sequence before entering the u-boot console. To do 
> this I firstly downloaded and rebuilt u-boot following instructions here: 
> http://eewiki.net/display/linuxonarm/BeagleBone+Black#BeagleBoneBlack-Bootloader:U-Boot.
>  
> (Testing with the default config produced the same 'failure' rate)
> I then modified '/include/config.h' in the u-boot source files, adding the 
> following:
>
> #define CONFIG_AUTOBOOT_KEYED 1 
> #define CONFIG_AUTOBOOT_DELAY_STR "uboot"
>
> This now forces a user to enter the string 'uboot' before entering the 
> u-boot console, otherwise the device will boot up normally.
>
> Rebuilding with this configuration still gave the same failure rate 
> however. This is when I learned that the boot files on the eMMC flash are 
> still loading before jumping to the files on the sd card I am using. So 
> upon deleting the MLO file on the eMMC flash I had more luck.
>
> We setup a programmable power supply and a script looking at the output of 
> uart0 to detect whether the device had successfully booted or had become 
> stuck in u-boot, and then left it cycling power. We were then able to get 
> many hundreds of consecutive successful boots - we only stopped the test 
> because we decided it would probably never fail.
>
> So in the end it all came down to spurious data on uart0 - along with 
> disabling booting from the eMMC. (we could have simply reconfigured u-boot 
> on the eMMC in the same way, but disabling it drops a few seconds off the 
> boot time).
>
>
> Thanks for all your help Gerald (and duckhunter).
>
> Regards,
> Andrew Glen.
>

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