I got it working.  I updated the onboard Angstrom distribution on the 
eMMC and it fixed the problem of loading the uSD card with LinuxCNC.

Windows OS instructions are here - look for "Update board with latest 
software" on this page:
http://beagleboard.org/Getting+Started
Unpacking the image file in Ubuntu 12.04 and then writing the card with 
DD worked fine as well.

I used the Angstrom distribution for the BeagleBone Black  on this page 
dated 2013-09-04.
http://beagleboard.org/latest-images
It took about 45 minutes for it to rewrite the onboard eMMC using the 
created "update card".  I used a 4GB uSD Sandisk Class 4 I had on hand.

Thanks for the help.  :-)

Dave


On 3/13/2014 3:35 PM, Michael Haberler wrote:
> Am 13.03.2014 um 22:19 schrieb Dave Cole <linuxcncro...@gmail.com>:
>
>> I have a total of 4 BBB's. All 4 boards respond in the same way to the
>> uSD card created with the script.
>> These boards were purchased as one lot, last year.
>>
>> The script is pulling files in off the web, so perhaps some of those
>> source files have changed?
> yeah, that is my suspicion too, in particular the uboot boot loader ; I have 
> a hard time imagining we get this far with an electrical issue in the SD slot
>
> anybody want to try replacing uboot or maybe the whole DOS partition from a 
> know-to-work SD? I wouldnt suggest this as a hack for production work, but it 
> might help isolate the issue
>
> -m
>
>> At the moment I'm writing the 12/28/13 image to a uSD card using DD.
>>
>> I think that using the uSD card slot is a better idea even if it is a
>> little fragile.  Why constrain ourselves to 2 GB?
>> The last 8 Gig card I bought was $8.00 or $1.00 per GB.
>>
>> Dave
>>
>>
>> On 3/13/2014 1:42 PM, Charles Steinkuehler wrote:
>>> It may also be the boot loader on a particular version BeagleBone.  I
>>> haven't reproduced the problem here, so I'm not sure exactly what's
>>> going on.
>>>
>>> On 3/13/2014 1:30 PM, Mark Tucker wrote:
>>>> This seems like another good reason to get this to fit on the eMMc to
>>>> avoid killing the card slot.
>>>>
>>>>
>>>> On 13/03/14 18:24, Michael Haberler wrote:
>>>>> Am 13.03.2014 um 17:33 schrieb Charles Steinkuehler 
>>>>> <char...@steinkuehler.net>:
>>>>>
>>>>>> Pinging Michael Haberler:
>>>>>>
>>>>>> Is this the same issue you were seeing?
>>>>>>
>>>>>> It seems like Michael's issue was with the SD card slot on the BBB, the
>>>>>> same SD card worked on a different board.
>>>>> that is exactly what I saw two days ago - same symptom, almost identical 
>>>>> uboot outpput
>>>>>
>>>>> I eventually swapped the BB against a new one, and that booted the same 
>>>>> SD card just fine!
>>>>>
>>>>> the SD card slot seems to be a bit fragile
>>>>>
>>>>> -m
>>>>>
>>>>>> On 3/13/2014 12:16 PM, Dave Cole wrote:
>>>>>>> I tried adding the partition manager and that made no difference.
>>>>>>>
>>>>>>> I hooked up a TTL to USB serial adapter cable to the debug port and
>>>>>>> this is what I saw (see below)
>>>>>>>
>>>>>>> If you have any ideas, let me know, everything is setup here and it is
>>>>>>> easy to alter.
>>>>>>>
>>>>>>> Otherwise I'll download a 4 gig image and write it to a card.
>>>>>>>
>>>>>>> Thanks,  Dave
>>>>>>>
>>>>>>>
>>>>>>> U-Boot SPL 2013.04-rc1-14237-g90639fe-dirty (Apr 13 2013 - 13:57:11)
>>>>>>> musb-hdrc: ConfigData=0xde (UTMI-8, dyn FIFOs, HB-ISO Rx, HB-ISO Tx,
>>>>>>> SoftConn)
>>>>>>> musb-hdrc: MHDRC RTL version 2.0
>>>>>>> musb-hdrc: setup fifo_mode 4
>>>>>>> musb-hdrc: 28/31 max ep, 16384/16384 memory
>>>>>>> USB Peripheral mode controller at 47401000 using PIO, IRQ 0
>>>>>>> musb-hdrc: ConfigData=0xde (UTMI-8, dyn FIFOs, HB-ISO Rx, HB-ISO Tx,
>>>>>>> SoftConn)
>>>>>>> musb-hdrc: MHDRC RTL version 2.0
>>>>>>> musb-hdrc: setup fifo_mode 4
>>>>>>> musb-hdrc: 28/31 max ep, 16384/16384 memory
>>>>>>> USB Host mode controller at 47401800 using PIO, IRQ 0
>>>>>>> OMAP SD/MMC: 0
>>>>>>> mmc_send_cmd : timeout: No status update
>>>>>>> reading u-boot.img
>>>>>>> reading u-boot.img
>>>>>>>
>>>>>>>
>>>>>>> U-Boot 2013.04-rc1-14237-g90639fe-dirty (Apr 13 2013 - 13:57:11)
>>>>>>>
>>>>>>> I2C:   ready
>>>>>>> DRAM:  512 MiB
>>>>>>> WARNING: Caches not enabled
>>>>>>> NAND:  No NAND device found!!!
>>>>>>> 0 MiB
>>>>>>> MMC:   OMAP SD/MMC: 0, OMAP SD/MMC: 1
>>>>>>> *** Warning - readenv() failed, using default environment
>>>>>>>
>>>>>>> musb-hdrc: ConfigData=0xde (UTMI-8, dyn FIFOs, HB-ISO Rx, HB-ISO Tx,
>>>>>>> SoftConn)
>>>>>>> musb-hdrc: MHDRC RTL version 2.0
>>>>>>> musb-hdrc: setup fifo_mode 4
>>>>>>> musb-hdrc: 28/31 max ep, 16384/16384 memory
>>>>>>> USB Peripheral mode controller at 47401000 using PIO, IRQ 0
>>>>>>> musb-hdrc: ConfigData=0xde (UTMI-8, dyn FIFOs, HB-ISO Rx, HB-ISO Tx,
>>>>>>> SoftConn)
>>>>>>> musb-hdrc: MHDRC RTL version 2.0
>>>>>>> musb-hdrc: setup fifo_mode 4
>>>>>>> musb-hdrc: 28/31 max ep, 16384/16384 memory
>>>>>>> USB Host mode controller at 47401800 using PIO, IRQ 0
>>>>>>> Net:   <ethaddr> not set. Validating first E-fuse MAC
>>>>>>> cpsw, usb_ether
>>>>>>> Hit any key to stop autoboot:  1  0
>>>>>>> gpio: pin 53 (gpio 53) value is 1
>>>>>>> mmc0 is current device
>>>>>>> micro SD card found
>>>>>>> mmc0 is current device
>>>>>>> gpio: pin 54 (gpio 54) value is 1
>>>>>>> SD/MMC found on device 0
>>>>>>> reading uEnv.txt
>>>>>>> 1701 bytes read in 3 ms (553.7 KiB/s)
>>>>>>> Loaded environment from uEnv.txt
>>>>>>> Importing environment from mmc ...
>>>>>>> Running uenvcmd ...
>>>>>>> reading zImage
>>>>>>> 3492416 bytes read in 399 ms (8.3 MiB/s)
>>>>>>> reading uInitrd
>>>>>>> ** Unable to read file uInitrd **
>>>>>>> reading /dtbs/am335x-boneblack.dtb
>>>>>>> 24884 bytes read in 10 ms (2.4 MiB/s)
>>>>>>> Wrong Ramdisk Image Format
>>>>>>> Ramdisk image is corrupt or invalid
>>>>>>> gpio: pin 55 (gpio 55) value is 1
>>>>>>> ** File not found /boot/uImage **
>>>>>>> U-Boot#
>>>>>>>
>>>>>>>
>>>>>>> __________________________________
>>>>>>>
>>>>>>>
>>>>>>> On Wednesday, March 12, 2014 3:20:42 PM, Dave Cole wrote:
>>>>>>>> On 3/12/2014 2:00 PM, Charles Steinkuehler wrote:
>>>>>>>>> On 3/12/2014 2:49 PM, Dave Cole wrote:
>>>>>>>>>> But I did notice when running the script that a few errors pop up
>>>>>>>>>> saying
>>>>>>>>>> it can't recognize a file type and it can't write to the root
>>>>>>>>>> directory.
>>>>>>>>>> I have a sudo in the front of the script command line.
>>>>>>>>>> Although the completed card appears to have a root with files in it,
>>>>>>>>>> etc.  Nothing obvious is out of place.
>>>>>>>>>>
>>>>>>>>>> Perhaps I am missing some dependencies on the Linux 12.04 box?
>>>>>>>>>>
>>>>>>>>>> The uSD card creation script runs to completion.
>>>>>>>>>>
>>>>>>>>>> Anything obvious come to mind?   If not, I'll attach a TTL to USB 
>>>>>>>>>> cable
>>>>>>>>>> and see what a terminal window says when it boots.
>>>>>>>>>>
>>>>>>>>>> I have a Linux 10.04 box also that I can try and use to create the
>>>>>>>>>> uSD card.
>>>>>>>>> The script should work on most recent Debian or Ubuntu systems, but
>>>>>>>>> there are some packages required that are not present by default.  If
>>>>>>>>> you can, review the errors when running the script to see if you're
>>>>>>>>> possibly missing something (the partition manager comes to mind).
>>>>>>>>>
>>>>>>>>> Alternately, you can just use the raw image file which you just dd
>>>>>>>>> straight onto the uSD card...no dependencies required.
>>>>>>>>>
>>>>>>>> I'll load partition manager and see if that helps.  If not I'll try
>>>>>>>> and capture the output and look at it.   It flies by on the screen so
>>>>>>>> fast that I can't catch it just by interrupting the script and
>>>>>>>> scrolling up.    I can fall back to the DD solution, but it might be
>>>>>>>> helpful if I can catch these errors.
>>>>>>>>
>>>>>>>> Thanks,  Dave
>>>>>>> ------------------------------------------------------------------------------
>>>>>>> Learn Graph Databases - Download FREE O'Reilly Book
>>>>>>> "Graph Databases" is the definitive new guide to graph databases and 
>>>>>>> their
>>>>>>> applications. Written by three acclaimed leaders in the field,
>>>>>>> this first edition is now available. Download your free book today!
>>>>>>> http://p.sf.net/sfu/13534_NeoTech
>>>>>>> _______________________________________________
>>>>>>> Emc-users mailing list
>>>>>>> Emc-users@lists.sourceforge.net
>>>>>>> https://lists.sourceforge.net/lists/listinfo/emc-users
>>>>>>>
>>>>>> -- 
>>>>>> Charles Steinkuehler
>>>>>> char...@steinkuehler.net
>>>>>>
>>>>>> ------------------------------------------------------------------------------
>>>>>> Learn Graph Databases - Download FREE O'Reilly Book
>>>>>> "Graph Databases" is the definitive new guide to graph databases and 
>>>>>> their
>>>>>> applications. Written by three acclaimed leaders in the field,
>>>>>> this first edition is now available. Download your free book today!
>>>>>> http://p.sf.net/sfu/13534_NeoTech_______________________________________________
>>>>>> Emc-users mailing list
>>>>>> Emc-users@lists.sourceforge.net
>>>>>> https://lists.sourceforge.net/lists/listinfo/emc-users
>>>>> ------------------------------------------------------------------------------
>>>>> Learn Graph Databases - Download FREE O'Reilly Book
>>>>> "Graph Databases" is the definitive new guide to graph databases and their
>>>>> applications. Written by three acclaimed leaders in the field,
>>>>> this first edition is now available. Download your free book today!
>>>>> http://p.sf.net/sfu/13534_NeoTech
>>>>> _______________________________________________
>>>>> Emc-users mailing list
>>>>> Emc-users@lists.sourceforge.net
>>>>> https://lists.sourceforge.net/lists/listinfo/emc-users
>>>>>
>>>>>
>>>> ------------------------------------------------------------------------------
>>>> Learn Graph Databases - Download FREE O'Reilly Book
>>>> "Graph Databases" is the definitive new guide to graph databases and their
>>>> applications. Written by three acclaimed leaders in the field,
>>>> this first edition is now available. Download your free book today!
>>>> http://p.sf.net/sfu/13534_NeoTech
>>>> _______________________________________________
>>>> Emc-users mailing list
>>>> Emc-users@lists.sourceforge.net
>>>> https://lists.sourceforge.net/lists/listinfo/emc-users
>>>>
>>>
>>>
>>> ------------------------------------------------------------------------------
>>> Learn Graph Databases - Download FREE O'Reilly Book
>>> "Graph Databases" is the definitive new guide to graph databases and their
>>> applications. Written by three acclaimed leaders in the field,
>>> this first edition is now available. Download your free book today!
>>> http://p.sf.net/sfu/13534_NeoTech
>>>
>>>
>>> _______________________________________________
>>> Emc-users mailing list
>>> Emc-users@lists.sourceforge.net
>>> https://lists.sourceforge.net/lists/listinfo/emc-users
>> ------------------------------------------------------------------------------
>> Learn Graph Databases - Download FREE O'Reilly Book
>> "Graph Databases" is the definitive new guide to graph databases and their
>> applications. Written by three acclaimed leaders in the field,
>> this first edition is now available. Download your free book today!
>> http://p.sf.net/sfu/13534_NeoTech
>> _______________________________________________
>> Emc-users mailing list
>> Emc-users@lists.sourceforge.net
>> https://lists.sourceforge.net/lists/listinfo/emc-users
>
> ------------------------------------------------------------------------------
> Learn Graph Databases - Download FREE O'Reilly Book
> "Graph Databases" is the definitive new guide to graph databases and their
> applications. Written by three acclaimed leaders in the field,
> this first edition is now available. Download your free book today!
> http://p.sf.net/sfu/13534_NeoTech
> _______________________________________________
> Emc-users mailing list
> Emc-users@lists.sourceforge.net
> https://lists.sourceforge.net/lists/listinfo/emc-users

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