Locked up Boron, ignores ~EN pin: how can this happen?

I’m having intermittent issues with a Boron that’s being controlled through the ~EN pin.

It works fine for hours, then at some point will simply stop responding/won’t boot up, even if I toggle ~EN manually.

At that point, it is completely unresponsive, no LED, no reaction to manually hitting the reset button… nothing but physically removing the battery and re-inserting will bring it back to life.

I’ve verified that, while it is in this state:

  • ~RESET is at 3v3
  • ~EN is (left floating) high and
  • the Boron’s 3v3 output actually at 3v3

Which would seem to indicate that the XC8107 is in fact turned on and feeding VSYS to the on-board switching regulator, and the MCU should be running.

Manually shorting ~EN to ground and releasing has no effect.

I am stumped as to what could cause this behaviour and how bringing ~EN to ground can be different from removing the battery, from the system’s perspective.

Any ideas/input appreciated.
Thanks,
PatD

Is there any chance that external wiring could be providing a back feed to the power rail (even Capacitance) while you pull EN Pin to ground ?

Well, the Boron’s 3v3 out pin isn’t actually connected to anything and the only thing still held high (other than the actual power inputs) are 2 DIO pins–and they’re both configured as inputs prior to ~EN going low.

This issue is intermittent and happens on a couple of my test devices, whereas others never seem to experience it (I have a Boron that’s been running for 10 days without issue, and another that can’t seem to get through the night).

The external ~EN manager now has a watchdog that toggles the pin low for 5 seconds and back on every minute when it gets frozen like this… still doesn’t break me out of these occasional lock-ups.

I’ve caught a module in this odd state a few more times and did some more tests.

The situation is still the same: power applied, ~RESET (floating) high and ~EN floating at something like 3.8V, Boron’s 3v3 out is on but no activity from the module.

So I tried manually shorting out each I/O in turn on . No effect. Then I took a little risk and quickly shorted out the 3v3 output. That actually worked.

The Boron’s 3v3 output momentarily shorted seems like it finally forced the nRF52840 to actually reset. Not certain what this means in terms of figuring out how this is happening…

Does it rule out the XC8107 somehow being latched up? Does it rule out everything that’s on the VSYS rail (like the SARA)?

Kind of at a loss in terms of isolating this, and its killing the possibility of putting these in production. Any ideas welcome.

Ping @rickkas7

Additional info about the setup…

I’ve got an ATTiny841 running on an external 3v3 supply, acting as the power/sleep manager (bringing ~EN down) and an I2C slave to the Boron.

At the end of a wake/sense/publish cycle, the Boron requests a shutdown for X seconds from the power manager slave.

Should this call somehow fail, the main loop would just repeat – so if the Boron was staying on, I’d get a bunch of publishes and see the LED do its thing.

The '841 sleeps the Boron by configuring its connection to the ~EN pin as an output and taking it low. It wakes the Boron after time X simply by releasing the pin (goes into high-Z as an input). When ~EN is released, the line sits at some high voltage (~3.8V). When everything is frozen, shorting it ~EN ground manually has no effect.

This '841 power manager also has two watchdog functions.

Post power-up, it expects an interaction from the Boron within 60 seconds. If this fails to happen, power is cycled through the ~EN pin (5 seconds pulled low) and we try again.

Assuming the Boron did power up and interact with the slave within the allotted time, the power manager has a second timer and expects to be asked to shutdown within 10 minutes. Should this fail to happen, this second watchdog is triggered and power is cycled.

The power manager keeps track of how often the watchdog is tripped and reports this to the Boron on request.

When it’s locked up, and I short the Boron 3v3 out to finally get it going again, the normal loop goes through and I get a report through AWS/MQTT.

I can then see the watchdog trip count, and it is indeed proportional to the amount of time the Boron has been locked up.

Put together, these would indicate that:

  • the boron isn’t simply running the whole time: it goes down, or at a minimum halts normal code processing, as the LED and connect/publish activity stops
  • the power manager is running correctly and continuously, keeping track of watchdog triggers, and actually bringing the ~EN pin low for seconds at a time without managing to reboot the nRF52840

Hopefully, this info can rule out the obvious solutions and help isolate what’s actually going on, or at least help you hint me on where to investigate next.

Gracias,
Pat D

I did not see if the Borons are LTE or 2G3G and how are they powered? Could it be that the enable pin is working, but the starting up sometimes fails due to peaks in power need, when Boron and external devices power up?

Any news on this? I’m pretty sure I’m having same problem…