[U-Boot] 'usb start' works very unstable

[Sergei Trofimovich <slyfox@inbox.ru>]

I have 250GB USB-HDD attached to sheevaplug and using u-boot

    U-Boot 2010.03-00176-g42f7128 (Aug 06 2010 - 22:24:34)
    Marvell-Sheevaplug

It's a tip of 'u-boot-marvell/testing' branch.
I'm currently booting linux kernel from NAND
and using ext4 rootfs placed on this USB HDD.
Everything works mostly fine here (in-NAND
kernel and usb survive multiple reboots).

The problem is faulty usb detection in u-boot prompt.

After some reboots (one reboot is usually enough)
u-boot can't find attached USB storages:

    # reboot linux kernel and stop at u-boot prompt
    Marvell>> usb start
    (Re)start USB...
    USB:   Register 10011 NbrPorts 1
    USB EHCI 1.00
    scanning bus for devices... 2 USB Device(s) found
           scanning bus for storage devices... error in inquiry
    0 Storage Device(s) found
    Marvell>> usb start
    (Re)start USB...
    USB:   Register 10011 NbrPorts 1
    USB EHCI 1.00
    scanning bus for devices... 2 USB Device(s) found
           scanning bus for storage devices... 0 Storage Device(s) found
#ok, usb is dead? let's see if linux kernel will find it
    Marvell>> nand read 0x01000000 0x00100000 0x00400000

    NAND read: device 0 offset 0x100000, size 0x400000
     4194304 bytes read: OK
    Marvell>> setenv boot
      bootdelay bootargs bootcmd
    Marvell>> setenv bootargs console=ttyS0,115200 root=/dev/sda3 rw rootwait #points to usb hdd!
    Marvell>> bootm 0x01000000
    ## Booting kernel from Legacy Image at 01000000 ...
       Image Name:   Linux-2.6.35
       Image Type:   ARM Linux Kernel Image (uncompressed)
       Data Size:    2192340 Bytes =  2.1 MB
       Load Address: 00008000
       Entry Point:  00008000
       Verifying Checksum ... OK
       Loading Kernel Image ... OK
    OK

    Starting kernel ...
<skip>
    [   22.867424] Waiting for root device /dev/sda3...
    [   23.015860] scsi0 : usb-storage 1-1:1.0
    [   26.054268] scsi 0:0:0:0: Direct-Access     StoreJet  Transcend            PQ: 0 ANSI: 2 CCS
    [   28.774083] sd 0:0:0:0: [sda] 488397168 512-byte logical blocks: (250 GB/232 GiB)
    [   28.782324] sd 0:0:0:0: [sda] Write Protect is off
    [   28.787167] sd 0:0:0:0: [sda] Assuming drive cache: write through
    [   28.794693] sd 0:0:0:0: [sda] Assuming drive cache: write through
    [   28.800822]  sda: sda1 sda2 sda3 sda4
    [   28.909571] sd 0:0:0:0: [sda] Assuming drive cache: write through
    [   28.915736] sd 0:0:0:0: [sda] Attached SCSI disk
    [   28.944594] EXT3-fs (sda3): error: couldn't mount because of unsupported optional features (240)
    [   28.953954] EXT2-fs (sda3): error: couldn't mount because of unsupported optional features (240)
    [   28.992562] EXT4-fs (sda3): mounted filesystem with ordered data mode. Opts: (null)
    [   29.000323] VFS: Mounted root (ext4 filesystem) on device 8:3.
    [   29.006227] Freeing init memory: 112K
    INIT: version 2.87 booting

And it finds it! *phew*
It usually takes ~4 seconds to wait for root.

When I power off/power on sheevaplug I am able
to load something directly from USB:
    Marvell>> usb start
    (Re)start USB...
    USB:   Register 10011 NbrPorts 1
    USB EHCI 1.00
    scanning bus for devices... 2 USB Device(s) found
           scanning bus for storage devices... 1 Storage Device(s) found
    Marvell>> usb storage
      Device 0: Vendor: StoreJet Rev:  Prod:  Transcend
                Type: Hard Disk
                Capacity: 28759.9 MB = 28.0 GB (488397168 x 512)

Heh, capacity is reported incorrectly, but it works am I'm able
to load kernel from there.

    Marvell>> ext2ls usb 0:2 /
    <DIR>       1024 .
    <DIR>       1024 ..
    <DIR>      12288 lost+found
    <SYM>          1 boot
                   0 .keep
             4466528 vmlinuz-2.6.35
              904705 System.map-2.6.35
               49205 config-2.6.35
             4466528 vmlinuz-2.6.35.old
              904705 System.map-2.6.35.old
               49205 config-2.6.35.old
             2192404 uImage-2.6.35
              331132 u-boot.kwb-20100806

    Marvell>> ext2load usb 0:2 0x01000000 /uImage-2.6.35
    Loading file "/uImage-2.6.35" from usb device 0:2 (usbda2)
    2192404 bytes read
    Marvell>> bootm 0x01000000
    ## Booting kernel from Legacy Image at 01000000 ...
       Image Name:   Linux-2.6.35
       Image Type:   ARM Linux Kernel Image (uncompressed)
       Data Size:    2192340 Bytes =  2.1 MB
       Load Address: 00008000
       Entry Point:  00008000
       Verifying Checksum ... OK
       Loading Kernel Image ... OK
    OK

    Starting kernel ...

and up to the shell#

If I reboot u-boot can't find usb storages (but the in-NAND kernel will boot):
    [  249.433555] Restarting system.

    U-Boot 2010.03-00176-g42f7128 (Aug 06 2010 - 22:24:34)
    Marvell-Sheevaplug
...
    Hit any key to stop autoboot:  0 
    Marvell>> usb start
    (Re)start USB...
    USB:   Register 10011 NbrPorts 1
    USB EHCI 1.00
    scanning bus for devices... 2 USB Device(s) found
           scanning bus for storage devices... error in inquiry
    0 Storage Device(s) found

All these things are almost 100% reproducible.

Vendor-shipped (Marvell's) u-boot has exactly the same disease:
 ** MARVELL BOARD: SHEEVA PLUG LE 
U-Boot 1.1.4 (Mar 19 2009 - 16:06:59) Marvell version: 3.4.16

-- 

  Sergei
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