Kernel oops or hard freeze when streaming video on Zero W (and Pi 3B+)

[balboah]

This is a summary from troubleshooting on https://www.raspberrypi.org/forums/viewtopic.php?f=28&t=213423&p=1315106

When trying to stream video on Zero W with the noir v2 camera module, I get many variants of kernel oopses and freezes. For example:

[  273.802531] random: crng init done
[  379.898672] ------------[ cut here ]------------
[  379.901131] kernel BUG at Returning to usermode but unexpected PSR bits set?:5!
[  379.903359] Internal error: Oops - BUG: 0 [#1] ARM
[  379.905866] Modules linked in: cmac bnep hci_uart btbcm serdev bluetooth ecdh_generic brcmfmac brcmutil cfg80211 snd_bcm2835(C) snd_pcm rfkill snd_timer snd uio_pdrv_genirq uio fixed ip_tables x_tables ipv6
[  379.913291] CPU: 0 PID: 826 Comm: modprobe Tainted: G         C      4.14.34+ #1110
[  379.917705] Hardware name: BCM2835
[  379.920005] task: d6a0e120 task.stack: d5662000
[  379.922689] PC is at no_work_pending+0x30/0x34
[  379.925152] LR is at 0xbea4f970
[  379.927229] pc : [<c000fe54>]    lr : [<bea4f970>]    psr: 20000013
[  379.929588] sp : d5663fa8  ip : d5663fa8  fp : 00000000
[  379.932763] r10: 00000000  r9 : d5662000  r8 : c000ff64
[  379.935421] r7 : 000000d9  r6 : 00d321d8  r5 : 00000020  r4 : 00000078
[  379.938231] r3 : c0939414  r2 : d5663fe4  r1 : b6e6f198  r0 : 00000000
[  379.940929] Flags: nzCv  IRQs on  FIQs on  Mode SVC_32  ISA ARM  Segment user
[  379.943654] Control: 00c5387d  Table: 15664008  DAC: 00000055
[  379.946464] Process modprobe (pid: 826, stack limit = 0xd5662188)
[  379.948699] Stack: (0xd5663fa8 to 0xd5664000)
[  379.951177] 3fa0:                   00d321b8 00000020 00000000 00d321d8 00008000 00000000
[  379.956042] 3fc0: 00d321b8 00000020 00d321d8 000000d9 00000002 0002b990 0003f030 bea4fb10
[  379.960686] 3fe0: 0003efa8 bea4f970 b6e6f198 b6e6f0b8 60000010 00000000 00000000 00000000
[  379.966304] Code: e9527fff e1a00000 e28dd048 e1b0f00e (e7f001f2)
[  379.969043] ---[ end trace ee6907230b405e54 ]---

[  185.473451] random: crng init done
[  289.843386] Unable to handle kernel paging request at virtual address a259878c
[  289.845896] pgd = d3d98000
[  289.847720] [a259878c] *pgd=00000000
[  289.849367] Internal error: Oops: 5 [#1] ARM
[  289.851559] Modules linked in: cmac bnep hci_uart btbcm serdev bluetooth ecdh_generic brcmfmac brcmutil cfg80211 snd_bcm2835(C) rfkill snd_pcm snd_timer snd uio_pdrv_genirq fixed uio ip_tables x_tables ipv6
[  289.858880] CPU: 0 PID: 566 Comm: VCHIQ completio Tainted: G         C      4.14.34+ #1110
[  289.864663] Hardware name: BCM2835
[  289.867276] task: d3d24560 task.stack: d3d94000
[  289.869315] PC is at alloc_contig_range+0x254/0x344
[  289.871577] LR is at drain_all_pages+0x9c/0x148
[  289.873676] pc : [<c01005f8>]    lr : [<c00fcddc>]    psr: 60000013
[  289.876103] sp : d3d95b80  ip : 00000000  fp : d3d95c14
[  289.878873] r10: 00000005  r9 : 00017521  r8 : d3d95ba0
[  289.881112] r7 : c0108314  r6 : c0646614  r5 : d3d95b58  r4 : d3d95b6c
[  289.883087] r3 : a2598780  r2 : 00000000  r1 : d7c8a500  r0 : 00000000
[  289.885885] Flags: nZCv  IRQs on  FIQs on  Mode SVC_32  ISA ARM  Segment user
[  289.888657] Control: 00c5387d  Table: 13d98008  DAC: 00000055
[  289.891100] Process VCHIQ completio (pid: 566, stack limit = 0xd3d94188)
[  289.894036] Stack: (0xd3d95b80 to 0xd3d96000)
[  289.897008] 5b80: 00000002 00000006 fffffff0 00017800 00017400 00000004 00000000 00000000
[  289.902505] 5ba0: d3d95ba0 d3d95ba0 c09be368 00000000 00000001 00000001 00000000 00000000
[  289.907371] 5bc0: 00000000 00017520 014080c0 ffffffff 00000000 00000000 00000000 00000002
[  289.913045] 5be0: 00000001 00000000 00000001 00017520 00000120 c0a46a88 fffffff0 00000001
[  289.918027] 5c00: 00000001 00000800 d3d95c64 d3d95c18 c0155648 c01003b0 00000000 00000000
[  289.924077] 5c20: 00000000 00000001 00000000 014080c0 00000000 c0a46a98 00000000 00000001
[  289.931001] 5c40: d3d95ce8 00000001 00000247 00001000 00000000 d3d95d94 d3d95c74 d3d95c68
[  289.936747] 5c60: c04078d0 c0155554 d3d95c9c d3d95c78 c0019d84 c0407898 d3d95ce8 c0518d68
[  289.943030] 5c80: d7162e10 00000001 00000000 d53ab780 d3d95ccc d3d95ca0 c0019e5c c0019d50
[  289.949379] 5ca0: c0518d68 00000001 00000000 014080c0 ffffffff 014080c0 d7162e10 ffffffff
[  289.956599] 5cc0: d3d95d34 d3d95cd0 c001a01c c0019e18 d3d95d04 d3d95ce0 c004c940 c00409d4
[  289.964323] 5ce0: d515fd40 00000000 00000000 d7162e10 00001000 014080c0 00000247 c0518d68
[  289.970769] 5d00: d3d24501 00000000 00000000 00000000 00000000 00000bb0 0000e2f8 00000198
[  289.977483] 5d20: d7162e10 00000006 d3d95d5c d3d95d38 c001a248 c0019e70 00000247 00000000
[  289.983707] 5d40: 00000000 c0518d68 0000000f c001a1fc d3d95dd4 d3d95d60 c0518d68 c001a208
[  289.991248] 5d60: 00000000 00000200 00000200 c0517a80 00000000 d6b44f10 d3d24560 d3d95d88
[  289.998981] 5d80: 0044bbb0 00000001 00000001 0000e2f8 d3d95dd4 ffffffff c0517a8c c0026478
[  290.005268] 5da0: c0648df0 c0645a34 c0944318 d6b44e00 00000000 0044bbb0 00000000 0000e2f8
[  290.012067] 5dc0: 00000072 00000006 d3d95e44 d3d95dd8 c05110ac c0518c84 00000001 c064767c
[  290.018587] 5de0: d3d95e04 d3d95df0 c064767c 00000020 d6b44efc 00000000 d6b44f10 d6b44f88
[  290.025889] 5e00: c0a54928 d6b44edc d3d95e2c 20000113 20000113 c09b3f50 b6cb6ce4 c014c406
[  290.033451] 5e20: c09b3f50 b6cb6ce4 00000001 d6b44e00 d7580194 d50fd000 d3d95f0c d3d95e48
[  290.039559] 5e40: c0515db8 c0510de0 b63085c0 00000000 00000001 d3d95e60 c0048748 c00484c0
[  290.046525] 5e60: d7122478 d50fd824 b6cb6d84 c014c407 d7580194 00000040 0000012c d6b44e00
[  290.053050] 5e80: c0065900 00000007 ffffffff d3d95e98 b63085c0 00000000 d3d95ec4 d695a268
[  290.060107] 5ea0: 0000b009 0044bbb0 0000e2f8 b63085c0 00000000 d3d95ec0 c004c360 c0638a0c
[  290.069844] 5ec0: c004c95c c00409d4 00000000 d5215340 00000001 d3d24560 d3d95f1c d3d95ee8
[  290.076552] 5ee0: c0046aec b6cb6ce4 d730bd88 d522ca00 00000004 00000004 d3d94000 00000000
[  290.082991] 5f00: d3d95f7c d3d95f10 c016c858 c0515870 d3d95f74 d3d95f20 c06455ac c0046a9c
[  290.090363] 5f20: 00000004 c01770c4 80000013 ffffffff 7a12d780 c01774c4 d5231a80 b6e79538
[  290.098061] 5f40: b6cb6ce4 0044bbb0 c014c406 00000004 d3d95f6c d522ca01 b6cb6ce4 d522ca00
[  290.104406] 5f60: c014c406 00000004 d3d94000 00000000 d3d95fa4 d3d95f80 c016cf54 c016c7c8
[  290.111185] 5f80: 0000b009 b6e79538 b6cb6ce4 0044bbb0 00000036 c000ff64 00000000 d3d95fa8
[  290.117580] 5fa0: c000fdc0 c016cf1c b6e79538 b6cb6ce4 00000004 c014c406 b6cb6ce4 0000b009
[  290.125019] 5fc0: b6e79538 b6cb6ce4 0044bbb0 00000036 b63085c0 b6cb6d84 b6e792b4 b6e68f3c
[  290.132671] 5fe0: b6e79240 b6cb6cd4 b6e66f44 b6d8180c 80000010 00000004 00000000 00000000
[  290.138902] [<c01005f8>] (alloc_contig_range) from [<c0155648>] (cma_alloc+0x100/0x24c)
[  290.145834] [<c0155648>] (cma_alloc) from [<c04078d0>] (dma_alloc_from_contiguous+0x44/0x4c)
[  290.152461] [<c04078d0>] (dma_alloc_from_contiguous) from [<c0019d84>] (__alloc_from_contiguous+0x40/0xc8)
[  290.160121] [<c0019d84>] (__alloc_from_contiguous) from [<c0019e5c>] (cma_allocator_alloc+0x50/0x58)
[  290.167665] [<c0019e5c>] (cma_allocator_alloc) from [<c001a01c>] (__dma_alloc+0x1b8/0x350)
[  290.173780] [<c001a01c>] (__dma_alloc) from [<c001a248>] (arm_dma_alloc+0x4c/0x58)
[  290.180857] [<c001a248>] (arm_dma_alloc) from [<c0518d68>] (vchiq_prepare_bulk_data+0xf0/0x6bc)
[  290.187955] [<c0518d68>] (vchiq_prepare_bulk_data) from [<c05110ac>] (vchiq_bulk_transfer+0x2d8/0x554)
[  290.195634] [<c05110ac>] (vchiq_bulk_transfer) from [<c0515db8>] (vchiq_ioctl+0x554/0x1958)
[  290.202681] [<c0515db8>] (vchiq_ioctl) from [<c016c858>] (do_vfs_ioctl+0x9c/0x754)
[  290.209238] [<c016c858>] (do_vfs_ioctl) from [<c016cf54>] (SyS_ioctl+0x44/0x6c)
[  290.213236] [<c016cf54>] (SyS_ioctl) from [<c000fdc0>] (ret_fast_syscall+0x0/0x28)
[  290.219884] Code: e5931000 e0603008 e0833183 e0813103 (e593300c)
[  290.223715] ---[ end trace ee6907230b405e54 ]---

It can easily be reproduced by these steps:

1. Reset to the 2018-04-18-raspbian-stretch-lite.img and enable the headless SSH and /boot/wpa_supplicant.conf
2. raspi-config -> enable camera module -> reboot
3. (terminal 1)$ raspivid -t 0 -w 1280 -h 720 -o /dev/null
4. (terminal 2)$ ssh pi@the-zero-ip
5. Repeat step 4 until crash (will happen within 5 minutes)

The issue still exists when testing after updating with rpi-update.

I have also had freezes on Pi 3B+ with the same camera, but have not been able to create a proper reproduce or catched any kernel messages. It might be more related to #2387

[lategoodbye]

Could you please try http://downloads.raspberrypi.org/raspbian_lite/images/raspbian_lite-2018-03-14/ with the Zero W?

[balboah]

@lategoodbye

When leaving a watch ssh pi@192.168.1.201 date in my terminal
after the pi had been running raspivid -t 0 -w 1280 -h 720 -o /dev/null for maybe 15 minutes, I got:

dmesg:

[ 1473.345882] systemd: 33 output lines suppressed due to ratelimiting
[ 1551.070104] systemd-journald[108]: Failed to send WATCHDOG=1 notification message: Connection refused

journald:

sshd[857]: Accepted publickey for pi from 192.168.1.14 port 54892 ssh2: RSA SHA256:xxx
sshd[857]: pam_unix(sshd:session): session opened for user pi by (uid=0)
systemd[1]: [35B blob data]
systemd[1]: :0, function (null)(). Aborting.
systemd[1]: Caught <ABRT>, dumped core as pid 861.
kernel: systemd: 33 output lines suppressed due to ratelimiting
systemd[1]: Freezing execution.
systemd-logind[251]: Failed to start session scope session-c19.scope: Message recipient disconnected from message bus without replying
sshd[857]: pam_systemd(sshd:session): Failed to create session: Connection timed out
sshd[867]: Received disconnect from 192.168.1.14 port 54892:11: disconnected by user

But it seems I'm unable to provoke a kernel oops!
I guess it's just something fishy with authenticating new logins too fast in this older version.

UPDATE

It seemed harder to trigger but after making and disconnecting ssh connections with a few seconds in between while running raspivid I got a crash on raspbian_lite-2018-03-14 as well:

[  +0.002281] kernel BUG at kernel/smpboot.c:136!
[  +0.001892] Internal error: Oops - BUG: 0 [#1] ARM
[  +0.001585] Modules linked in: cmac bnep hci_uart btbcm bluetooth brcmfmac brcmutil snd_bcm2835 cfg80211 snd_pcm snd_timer rfkill snd bcm2835_gpiomem uio_pdrv_genirq uio fixed ip_tables x_tables ipv6
[  +0.006210] CPU: 0 PID: 3 Comm: ksoftirqd/0 Not tainted 4.9.80+ #1098
[  +0.002335] Hardware name: BCM2835
[  +0.001928] task: d70a9b40 task.stack: d7100000
[  +0.002436] PC is at smpboot_thread_fn+0x11c/0x178
[  +0.002669] LR is at run_ksoftirqd+0x3c/0x58
[  +0.002489] pc : [<c0042be0>]    lr : [<c0025fa0>]    psr: 60000013
              sp : d7101f40  ip : d7101f30  fp : d7101f64
[  +0.004868] r10: 00000000  r9 : 00000002  r8 : c08c3efc
[  +0.001919] r7 : 00000001  r6 : 00000000  r5 : d7100000  r4 : d70049c0
[  +0.001901] r3 : d7100000  r2 : 00000000  r1 : d70a9b40  r0 : d7100001
[  +0.002381] Flags: nZCv  IRQs on  FIQs on  Mode SVC_32  ISA ARM  Segment user
[  +0.002522] Control: 00c5387d  Table: 1509c008  DAC: 00000055
[  +0.002044] Process ksoftirqd/0 (pid: 3, stack limit = 0xd7100188)
[  +0.001944] Stack: (0xd7101f40 to 0xd7102000)
[  +0.002947] 1f40: 00000000 d70049e0 d70049c0 c0042ac4 00000000 00000000 d7101fac d7101f68
[  +0.005194] 1f60: c003ea54 c0042ad0 00000000 00000001 00000000 d70049c0 00000000 d7101f7c
[  +0.006899] 1f80: d7101f7c 00000000 d7101f88 d7101f88 d70049e0 c003e95c 00000000 00000000
[  +0.005113] 1fa0: 00000000 d7101fb0 c000fed4 c003e968 00000000 00000000 00000000 00000000
[  +0.004385] 1fc0: 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000
[  +0.005620] 1fe0: 00000000 00000000 00000000 00000000 00000013 00000000 00000000 00000000
[  +0.005546] [<c0042be0>] (smpboot_thread_fn) from [<c003ea54>] (kthread+0xf8/0x114)
[  +0.006337] [<c003ea54>] (kthread) from [<c000fed4>] (ret_from_fork+0x14/0x20)
[  +0.003535] Code: e5983010 e5940000 e12fff33 eaffffc4 (e7f001f2)
[  +0.103600] NOHZ: local_softirq_pending 242
[  +0.004190] NOHZ: local_softirq_pending 242
[  +0.011112] ---[ end trace f7cd89d2fa4b04cf ]---
[  +0.006461] NOHZ: local_softirq_pending 242
[  +1.040051] NOHZ: local_softirq_pending 40
[  +2.079984] NOHZ: local_softirq_pending 40
[  +1.039995] NOHZ: local_softirq_pending 40
[  +0.018528] NOHZ: local_softirq_pending 40
[  +0.010858] NOHZ: local_softirq_pending 40

And another (before any hard freeze or reboot):

[ 1766.489466] Unable to handle kernel NULL pointer dereference at virtual address 00000001
[ 1766.496737] pgd = d4524000
[ 1766.500537] [00000001] *pgd=14523831, *pte=00000000, *ppte=00000000
[ 1766.504369] Internal error: Oops: 17 [#2] ARM
[ 1766.507683] Modules linked in: cmac bnep hci_uart btbcm bluetooth brcmfmac brcmutil snd_bcm2835 cfg80211 snd_pcm snd_timer rfkill snd bcm2835_gpiomem uio_pdrv_genirq uio fixed ip_tables x_tables ipv6
[ 1766.516789] CPU: 0 PID: 1822 Comm: sshd Tainted: G      D         4.9.80+ #1098
[ 1766.519532] Hardware name: BCM2835
[ 1766.521996] task: d45e28e0 task.stack: d51e8000
[ 1766.524782] PC is at ret_fast_syscall+0x0/0x1c
[ 1766.527541] LR is at __f_unlock_pos+0x1c/0x20
[ 1766.530035] pc : [<c000fe40>]    lr : [<c0162f64>]    psr: 60000013
               sp : d51e9fa8  ip : d51e9f60  fp : 00000000
[ 1766.535295] r10: 00000000  r9 : d51e8000  r8 : c000ffc4
[ 1766.538023] r7 : 0000008c  r6 : b6fc1000  r5 : 00000000  r4 : 00000000
[ 1766.540395] r3 : 00000000  r2 : 00000001  r1 : 00000000  r0 : 00000000
[ 1766.542901] Flags: nZCv  IRQs on  FIQs on  Mode SVC_32  ISA ARM  Segment user
[ 1766.545469] Control: 00c5387d  Table: 14524008  DAC: 00000055
[ 1766.548381] Process sshd (pid: 1822, stack limit = 0xd51e8188)
[ 1766.551480] Stack: (0xd51e9fa8 to 0xd51ea000)
[ 1766.554274] 9fa0:                   00000000 00000000 00000006 00000000 000002e2 be805d58
[ 1766.560909] 9fc0: 00000000 00000000 b6fc1000 0000008c 0000000a be805f00 00000000 00000000
[ 1766.568064] 9fe0: 00000000 be805d58 b6a84d74 b6aedbe8 80000010 00000006 00000000 00000000
[ 1766.575277] Code: d3a00001 e89da800 00000000 00000000 (e5ad0008)
[ 1766.579137] ---[ end trace f7cd89d2fa4b04d0 ]---

And another (this time ssh stops working but ping replies)

Unable to handle kernel NULL pointer dereference at virtual address 00000008
[  +0.008241] pgd = d4424000
[  +0.004025] [00000008] *pgd=145c7831, *pte=00000000, *ppte=00000000
[  +0.004500] Internal error: Oops: 17 [#3] ARM
[  +0.003847] Modules linked in: cmac bnep hci_uart btbcm bluetooth brcmfmac brcmutil snd_bcm2835 cfg80211 snd_pcm snd_timer rfkill snd bcm2835_gpiomem uio_pdrv_genirq uio fixed ip_tables x_tables ipv6
[  +0.011834] CPU: 0 PID: 1941 Comm: modprobe Tainted: G      D         4.9.80+ #1098
[  +0.008252] Hardware name: BCM2835
[  +0.004382] task: d69edf60 task.stack: d462c000
[  +0.004458] PC is at __vma_adjust+0x18/0x644
[  +0.003961] LR is at down_write+0x1c/0x50
[  +0.003729] pc : [<c011cb68>]    lr : [<c05e15bc>]    psr: 60000013
              sp : d462de34  ip : d462de50  fp : d462de4c
[  +0.007947] r10: d50892c0  r9 : d5093f78  r8 : d5089228
[  +0.004195] r7 : d6e48164  r6 : d6e48178  r5 : d50892c0  r4 : d6870820
[  +0.003990] r3 : d5089228  r2 : ffff0001  r1 : 00000000  r0 : 00000000
[  +0.003854] Flags: nZCv  IRQs on  FIQs on  Mode SVC_32  ISA ARM  Segment user
[  +0.004033] Control: 00c5387d  Table: 14424008  DAC: 00000055
[  +0.003645] Process modprobe (pid: 1941, stack limit = 0xd462c188)
[  +0.003479] Stack: (0xd462de34 to 0xd462e000)
[  +0.003240] de20:                                              d6870820 d462de74 c05e15bc
[  +0.006929] de40: d462de64 d462de50 c05e15bc c05dfd34 d5089228 d6870820 d462de8c d462de68
[  +0.007166] de60: c011cad8 c05e15ac d5089228 b6d99000 d5089220 d6870820 d5093f78 00000075
[  +0.007300] de80: d462def4 d462de90 c011f42c c011caa4 d5089220 00000000 d6b34a00 00000000
[  +0.007776] dea0: 00000000 0013f000 00000000 00000000 0000013f d50892c0 d6b34a00 00000075
[  +0.007966] dec0: 00000000 b6d99000 d462def4 0013f000 00000075 00000005 d6b34a00 d6870820
[  +0.008631] dee0: b6d99000 0000013f d462df34 d462def8 c011fa3c c011f100 00000000 00000000
[  +0.008825] df00: 5aa855df 2ad97987 0000076f d6870854 00000005 0013e540 d6b34a00 00000000
[  +0.009310] df20: d462c000 00000000 d462df74 d462df38 c01076dc c011f718 00000002 00000000
[  +0.009775] df40: 00000000 d462df4c 00000005 00000000 00000000 00000002 00000005 0013e540
[  +0.010438] df60: 00000000 d6b34a00 d462dfa4 d462df78 c011d6f0 c0107658 00000002 00000000
[  +0.011373] df80: befaf8ec 00000000 00000000 befaf8ec 000000c0 c000ffc4 00000000 d462dfa8
[  +0.010882] dfa0: c000fe40 c011d65c 00000000 00000000 00000000 0013e540 00000005 00000802
[  +0.011535] dfc0: 00000000 00000000 befaf8ec 000000c0 b6f1c558 befaf7ac 0013e540 befaf72c
[  +0.011882] dfe0: 00000000 befaf51c b6ef40bc b6f086bc 60000010 00000000 00000000 00000000
[  +0.011645] Code: e24cb004 e24dd034 e52de004 e8bd4000 (e5906008)
[  +0.006647] ---[ end trace f7cd89d2fa4b04d1 ]---

[amovitz]

I'm having this issue when streaming video for long periods of time, even if the CPU average usage is below 30%. The 3B+ hard locks some time between 30 minutes to a few hours, consistently. Using the exact same SD card image, it works perfectly stable for over a week on a 3B. It will usually not let the hardware or software watchdog kick it after the hard lock occurs. I've been seeing this behavior since I got the 3B+ on day one.

[JamesH65]

@amovitz What version of kernel are you running? Does rpi-update fix the issue.

[amovitz]

It should be noted, the Pi camera module is not being used on my system. It has been tested with every version of the kernel available - rpi-update has not fixed the problem.

This particular test lasted approximately 45 minutes before hard locking this morning.

Linux Pi-2 4.14.42-v7+ #1114 SMP Mon May 21 16:39:21 BST 2018 armv7l armv7l armv7l GNU/Linux

[JamesH65]

If you drop the max CPU frequency to 1200, does that help?

[amovitz]

I have set arm_freq=1200 and will let it run. I'll report back.

$ sudo cat /sys/devices/system/cpu/cpu0/cpufreq/cpuinfo_min_freq
600000
$ sudo cat /sys/devices/system/cpu/cpu0/cpufreq/cpuinfo_max_freq
1200000
$ sudo cat /sys/devices/system/cpu/cpu0/cpufreq/cpuinfo_cur_freq
1200000

[balboah]

@amovitz I have that same problem on 3B+ as well without any camera attached, from start it has frozen within a day or maximum 2 days. The recent crash logs are from my Zero W though. I never managed to get a dump from the 3B+, so maybe or maybe not two different issues. And these two rPi's are my first experience, not great :P

[JamesH65]

Almost certainly different problems, the SoC on the Zero and 3B+, along with the different wireless chips means they are sufficiently dissimilar. Unless (!) there is something in your environment that is triggering the fault. We've sold a lot of Pi's which run for years without issue, so this is unusual. First check is power supply, is it sufficient?

[amovitz]

The power supply I'm using is the branded one. we've tried many different power supplies and it will even hard lock when no applications are running.

We don't use any Zeros, so I couldn't tell you if the same happened for some reason. We have extensively tested with the 3B, running for months at a time, and never had an issue until we put the SD card into a 3B+ (and upgraded the boot for it). Same image works perfectly well on a 3B, but the 3B+ will constantly lock up.

So far, it's been a little over 6 hours, and it hasn't locked with the lowered CPU Freq, but we'll see within 24 hours if it's more stable.

From our testing, it feels like it is an issue with either the upgraded SoC or another chip on the board which has changed that the Kernel is not handling properly or that the Broadcom firmware is not interfacing properly with the new chip.

[balboah]

@JamesH65 yeah I would have expected more people to react if it was common, I must have hit the jackpot with 2 out of 2. My power is the raspberry branded ones which I'm assuming has the correct rating.

The thing both have in common is that the SDCard brand is Sandisk class 10 and that it is written to by dd on mac.

Zero W

The installed image is not customized in any way except for configuring WiFI, camera module via raspi-config and SSH access.

3B+

This one runs Kubernetes master which averages on 20% cpu.
I also tried a more recent version with rpi-update without luck. Have not yet tried the frequencey limit. I no longer have a camera or camera module active on this one, which still freeze

[amovitz]

About 1 hour and 15 minutes after my last post (Total Uptime: 07:35:46), it hard locked.

[JamesH65]

Hmm, if it had kept running at 1200 I would have thought it was one of the test escapes (i.e. an SoC that passed test but shouldn't have). But I believe they work at 1200. So confused, and not sure what to suggest. Might be worth RMA'ing for a replacement.

[balboah]

@amovitz and when it freeze it become burning hot right. sounds very much the same as my 3B+