RoboRio 2.0 Unrecoverable error

[BigMac001]

My team's roborio started to show the unrecoverable error. I have tried to reflash the micro-sd card 3 times. Once with Raspberry Pi imager and twice with balena etcher. I have tried to connect to the roborio though usb and it will not show up at all in the reimaging tool.  I also tried to load into the roborio at "172.22.11.2:1250" and it would not connect and would keep tried to load but never was able to connect. I have tried to boot into safe mode and about 5-10 seconds after I let go of the reset button the status starts to flash unrecoverable error. It is not the Micro-sd card that came with the roborio but it is still a industrial grade one, the only difference I notice is it has 8 gb of capacity instead of 4gb.  The only odd thing that happened before the unrecoverable error was that I tried to power two cameras though the USB ports and then I wasn't able to regain power/connectivity from either of the ports even when I used one camera that was working before. 

[BigMac001]

Also tried to put in a different micro-sd card and still got the same error. This was the micro-SD card that came with the roborio.

[BoKnows]

I want to sanity check some things to make sure we're both thinking the same things.

First, can you take the white sticker off the SD card that came with the device?  That just makes it harder to seat the SD card correctly.

Next, let's look at what that error is telling us.  The unrecoverable error here is it isn't finding a file system that makes sense when it's booting.  This has a few things I can think of being the issue when looking at the rest of your description.  The last resort would be "the SD card reader is damaged and cannot seat and/or read SD cards."  If that's the case, we'd need to talk about a replacement.  Before we do that, we'd want to check a couple of things.

1. Let's verify the seating of the SD cards in the roboRIO 2.0
2. Let's verify the imaging you're doing is correct

If those two aren't true, everything else you describe makes sense.  I wouldn't expect it to show in the imaging tool while flashing continuously.  I wouldn't expect it to boot up correctly if either of those weren't correct.  The first is something you can verify mechanically just by seating the cards and making sure they're staying in place.  If that's the case, let's take a closer look at the image.  I want to check this as a replacement wouldn't fix anything here if this is the problem.  We could ship you out a new device and you'd have the same problem when it arrives.

Here's the detailed instructions for imaging the roboRIO 2.0: https://docs.wpilib.org/en/stable/docs/software/roborio-info/roborio2-imaging.html

I want to highlight this bit: Supported image files are named FRC_roboRIO2_YEAR_VERSION.img.zip. You can locate them by clicking the SD button in the roboRIO Imaging tool and then navigating to the SD Images folder. It is generally best to use the latest version of the image.

The ".img.zip" seems to be something that's causing some issues.  If you use the version without the .img, I'd expect to see the flashing status LED.  Can you verify which of the images you're using here?

[BigMac001]

There is no sticker on either of micro-sd cards. I used the exact file that you said both zipped and unzipped. Here is a screen shot while I was imaging to confirm that I am doing correctly. I have previously successfully flashed to the micro-sd card. The mirco-sd card appears to be seating correctly. 

[BoKnows]

If there's no sticker, it would appear someone already beat us to removing it =). 

I'd leave it in the zipped format (for future folks reading this).

It sounds like there's damage to the SD Card reader.  I sent you a message to talk about the best path forward.