OpenMarine

⚠️ OpenPlotter v4 boot issue when flashing extracted .img

Just a quick note that may save others a lot of time.

Summary
When flashing OpenPlotter v4 with:

official Raspberry Pi OS
Raspberry Pi Imager

The installation can be silently corrupted if the image archive is manually unzipped before flashing.

This was observed on Raspberry Pi 5 with NVMe, but may also affect other Raspberry Pi platforms (Pi 4 / Pi 3) — not tested yet.

What fails

Download OpenPlotter v4 ZIP
Manually extract the .img
Flash the extracted .img using Raspberry Pi Imager
Result: boot reaches fsck / resize, then kernel panic (run-init, /run mount failure)

This looks like:

filesystem or initramfs corruption
Pi 5 incompatibility
NVMe or power issues
…but it is none of those.

What works

Use Raspberry Pi Imager
Select Custom image
Point directly to the ZIP file (do NOT extract it)
Flash to SD or NVMe

➡️ System boots normally.

Notes

NVMe tested OK (SMART clean)
Power supply OK
Happens even on first boot
Removing HATs does not change the behavior
Not a Raspberry Pi 5 compatibility issue

Recommendation

Always flash OpenPlotter images directly from the ZIP file using Raspberry Pi Imager.
Do not extract the .img manually.

Document clearly that OpenPlotter images must be flashed directly from the ZIP archive
Warn users not to extract the .img manually

This may also affect Pi 3 / Pi 4 etc...

Hope this helps others ?

thierry30