You need to add common folder to your SD as well as in each preset.
As nosloppy noted, don’t use “Mass Storage” unless you have no way to remove SD card. Use an external SD reader AND be sure you are Ejecting the SD before removing from the computer.
It’s not a OS issue. I’m a installer and have installed over 100 proffies
I “think” it’s primarily a hardware (board or SD) issue but since some are reporting no issue on OS5 I feel like there’s something on the software side that either triggers or contributes but need to narrow down the “what” and eliminate as many variables as possible.
I think SD speed could be related in someway as I’ve seen a lot more users using poor performing SD cards so running ‘sdtest’ will help us see if there is a relationship between the card performance and this issue.
I have been using OS6.7 from release date and have installed roughly 10 Sabers with this that have had no issues. Now I have just installed 2 Sabers both have this issue. One is a very basic install and this config is running fine on my Saber the other is crystal chamber with Bluetooth and oled. I have already used this config twice before without any issues but this new board has that issue 
I have taken out the sd card from a fully working Saber and used this in that board and uploaded the same config to it too but it made no difference still having the same issue
OK, I now disabled mass storage, added common and common/tracks folder and preset. In 5.9 all fine. Using excat that config in 6.7 - Issue. I also now disabled the fett props file - still Issue in 6.7.
Ok now I’m not so sure as I’ve just tried os5.7 and it’s working fine 
So upload that OS5 config in OS6 and test. Then run ‘sdtest’ and post results.
Then we’ll add defines one at a time to isolate the cause.
Post the config that works in OS5 but has issue in OS6 and run ‘sdtest’ and post results.
Switched to OS6 with the 5 config - I dont get to the sdtest - USB goes off/on too often. Last serial output I got was:
16:36:03.569 → No sdcard found.
16:36:03.569 → blade= 0
16:36:03.569 → WS2811 Blade with 144 leds.
16:36:03.569 → WS2811 Blade with 1 leds.
16:36:03.569 → WS2811 Blade with 2 leds.
16:36:03.569 → Simple Blade
16:36:03.569 → Failed to mount SD card.
16:36:03.569 → Failed to open: presets.ini
16:36:03.569 → Failed to open: presets.tmp
16:36:03.569 → Failed to mount SD card.
16:36:03.569 → Scanning sound font: hand done
16:36:04.589 → Failed to mount SD card.
16:36:04.589 → Activating polyphonic font.
Update: This is after 6.7 flash - and 1st reboot:
16:45:46.495 → No sdcard found.
16:45:46.495 → Failed to mount SD card.
16:45:46.495 → Failed to mount SD card.
16:45:46.495 → blade= 0
16:45:46.495 → WS2811 Blade with 144 leds.
16:45:46.495 → WS2811 Blade with 1 leds.
16:45:46.495 → WS2811 Blade with 2 leds.
16:45:46.495 → Simple Blade
16:45:47.470 → Failed to mount SD card.
16:45:48.493 → Failed to mount SD card.
16:45:49.466 → Failed to mount SD card.
16:45:49.466 → Failed to open: presets.ini
16:45:49.466 → Failed to open: presets.tmp
16:45:50.480 → Failed to mount SD card.
16:45:51.499 → Failed to mount SD card.
16:45:51.499 → Style RAM = 1460
16:45:51.499 → Style RAM = 52
16:45:51.499 → Style RAM = 36
16:45:51.499 → Style RAM = 60
16:45:51.499 → Style RAM = 8
16:45:52.517 → Failed to mount SD card.
16:45:52.517 → Scanning sound font: hand NOT FOUND!
16:45:52.517 → Scanning sound font: common NOT FOUND!
16:45:53.532 → Failed to mount SD card.
16:45:54.706 → Failed to mount SD card.
16:45:54.706 → Activating polyphonic font.
16:45:55.521 → Failed to mount SD card.
16:45:56.544 → Failed to mount SD card.
And here I am up with an sdtest:
16:48:01.623 → Failed to mount SD card.
16:48:01.623 → Amplifier off.
16:48:01.623 → Motion chip … Failed to mount SD card.
16:48:02.591 → Time to open files: Average time: 0.00 us
16:48:02.591 →
16:48:02.591 →
16:48:02.591 →
16:48:02.591 →
16:48:02.591 →
16:48:02.591 →
16:48:02.591 →
16:48:02.591 →
16:48:02.591 →
16:48:02.591 →
16:48:02.591 →
16:48:02.591 → x100us 1 2 3 4 5
16:48:02.591 → 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
16:48:02.591 → Time to read blocks: Average speed: 0.00 kb/s, 0.00 simultaneous audio streams.
16:48:02.591 →
16:48:02.591 →
16:48:02.638 →
16:48:02.638 →
16:48:02.638 →
16:48:02.638 →
16:48:02.638 →
16:48:02.638 →
16:48:02.638 →
16:48:02.638 →
16:48:02.638 →
16:48:02.638 → x100us 1 2 3 4 5
16:48:02.638 → 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
16:48:02.638 → 105 found.
16:48:02.683 → Display initialized.
16:48:04.020 → Battery voltage: 3.77
16:48:18.734 → Failed to mount SD card.
16:48:18.734 → Time to open files: Average time: 0.00 us
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 → x100us 1 2 3 4 5
16:48:18.734 → 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
16:48:18.734 → Time to read blocks: Average speed: 0.00 kb/s, 0.00 simultaneous audio streams.
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 →
16:48:18.734 → x100us 1 2 3 4 5
16:48:18.734 → 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
16:48:24.039 → Battery voltage: 3.77
16:48:44.063 → Battery voltage: 3.77
Go back to OS5 and run ‘sdtest’ then.
I skip all the playing sounds lines - this is the result
16:53:32.348 → Playing hand/boot/boot5.wav
16:53:32.440 → 6
16:53:32.440 → Playing hand/boot/boot6.wav
16:53:32.578 → 6
16:53:32.671 → Playing hand/boot/boot.wav
16:53:32.764 → 66
16:53:32.901 → Time to open files: Average time: 5085.43 us
16:53:32.901 → .
16:53:32.901 → :
16:53:32.901 → :
16:53:32.901 → :
16:53:32.901 → . :
16:53:32.901 → : :
16:53:32.901 → : :
16:53:32.901 → : : :
16:53:32.901 → : :: :
16:53:32.901 → :: :: … :
16:53:32.901 → .: ::: ::: .::. .:
16:53:32.901 → x100us 1 2 3 4 5
16:53:32.901 → 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
16:53:32.901 → Time to read blocks: Average speed: 615.13 kb/s, 6.97 simultaneous audio streams.
16:53:32.901 → .
16:53:32.901 → :
16:53:32.901 → :
16:53:32.901 → :
16:53:32.901 → :
16:53:32.901 → .:
16:53:32.901 → ::
16:53:32.901 → ::
16:53:32.901 → ::
16:53:32.901 → :::
16:53:32.901 → … :::… …
16:53:32.901 → x100us 1 2 3 4 5
16:53:32.901 → 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
16:53:32.901 → Battery voltage: 3.77
16:53:32.901 → Unmounting SD Card.
16:53:52.920 → Battery voltage: 3.77
16:54:12.897 → Battery voltage: 3.77
16:54:32.924 → Battery voltage: 3.77
16:54:52.943 → Battery voltage: 3.77
16:55:12.941 → Battery voltage: 3.77
Ok, that’s pretty slow. Do you have other SD cards you can test?
OK, now with a sandisk ultra sdhc 16GB, class 10:
first on 5.9:
17:07:46.636 → Playing hand/boot/boot.wav
17:07:46.682 → EE
17:07:46.728 → Time to open files: Average time: 1948.17 us
17:07:46.728 →
17:07:46.728 → :
17:07:46.728 → :
17:07:46.728 → :
17:07:46.728 → :
17:07:46.728 → :
17:07:46.728 → : :
17:07:46.728 → : : :
17:07:46.728 → :: :: :
17:07:46.728 → . :: :: : :
17:07:46.728 → : :: : .:::: : .:: :
17:07:46.728 → x100us 1 2 3 4 5
17:07:46.728 → 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
17:07:46.728 → Time to read blocks: Average speed: 1266.12 kb/s, 14.36 simultaneous audio streams.
17:07:46.728 → .
17:07:46.728 → :
17:07:46.728 → :
17:07:46.728 → :
17:07:46.728 → :
17:07:46.728 → :
17:07:46.728 → :
17:07:46.728 → :
17:07:46.728 → :
17:07:46.728 → ::
17:07:46.728 → ::… …
17:07:46.728 → x100us 1 2 3 4 5
17:07:46.728 → 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
17:07:46.728 → Battery voltage: 3.77
17:07:46.775 → Unmounting SD Card.
17:08:06.768 → Battery voltage: 3.77
Much better, try that on OS6 and if no errors run ‘sdtest’ again.
At the 8th (!!!) boot try on OS6 - this came out (All other tries were nothing, or no sd-card)
17:15:24.279 → Playing hand/boot/boot.wav
17:15:24.325 → DD
17:15:24.371 → Time to open files: Average time: 3392.22 us
17:15:24.371 → .
17:15:24.371 → :
17:15:24.371 → :
17:15:24.371 → . :
17:15:24.371 → : :
17:15:24.371 → : :
17:15:24.371 → : :
17:15:24.371 → : . :
17:15:24.371 → : : . :
17:15:24.371 → : ::. : :
17:15:24.371 → : . .:… .:::. :. .:. … :
17:15:24.371 → x100us 1 2 3 4 5
17:15:24.371 → 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
17:15:24.371 → Time to read blocks: Average speed: 1197.23 kb/s, 13.57 simultaneous audio streams.
17:15:24.371 → .
17:15:24.371 → :
17:15:24.371 → :
17:15:24.371 → :
17:15:24.371 → :
17:15:24.371 → :
17:15:24.371 → :
17:15:24.371 → :
17:15:24.371 → :
17:15:24.371 → ::
17:15:24.371 → ::… …
17:15:24.371 → x100us 1 2 3 4 5
17:15:24.371 → 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0
17:15:24.371 → Battery voltage: 3.77
17:15:24.418 → Unmounting SD Card.
So it couldn’t read the exact same SD for 7 tries on OS6 but when it did those were results? Can you post the config that caused.
Exactly. Same sd-card. Same config. 8 “reset” tries. Currently testing, I use the following (without error messages WHEN booted). For now it doesn’t matter, if I use “plain” OS5 or this test OS6 config.
My last try was with: #ifdef CONFIG_TOP#include "proffieboard_v2_config.h"#define CONFIG_STARTUP - Pastebin.com