FW crash when opening a file from SD card
When I try to open certain files on an SD card, the usual message "Checking file" appears but without any progress bar. After a second or two I hear a beep and firmware reboots and shows:
FW crash detected! You can continue printing. Debug data available for analysis. contact support to submit details.
Only some gcode files trigger the problem, most files are printed fine. When a file triggers the crash, it triggers it every time I try to print it. The content of the file looks fine to me, it even has a terminating G codes. File size is reasonable, less than 2 MB. Usually, changing print settings in slicer (e.g., changing to a finer layer height preset, now using PrusaSlicer 2.9.0) and generating a new file produces a non-crashing file, sometimes it does not.
I tried opening the file in notepad and deleting most lines, hoping that I can produce a non-crashing file and later I could isolate a line triggers the crash but I got inconsistent results; as if the crashing would depend on file system layout. Formatting the SD card (using Windows) almost always "fixes" the problem, but today it did not (and I have only file in one folder, long names). Copying the file to desktop, changing the name to 8.3 name and copying to the card did not fix it today but I believe it did before. I always use button in slicer or in Explorer to unmout the card safely. I have two sd cards, different brands, both manifest the problem, occasionally.
I connected to the printer via USB serial, issued D21 command and the printer produced a dump in Intel HEX format, see attachment: fw-crash-2025-03-09
How can I help getting this fixed? (I can do some AVR coding, although I do not look forward to bootstraping the FW compilation.)