openpilot

This occurs when modeld loads the 773 MB big model from a cold page cache while running at realtime priority. The loader inherits modeld's realtime scheduling and starves controlsd/selfdrived during memory reclaim, causing the 6 s init timeout, carControl not alive, blocked DAS_control, and a cruise fault.

Fix by updating to an openpilot build containing [PR #39007](https://github.com/commaai/openpilot/pull/39007), "modeld: set realtime scheduling after model load." When backporting:

1. Load the big model before calling config_realtime_process()/setting realtime scheduling.
2. Keep garbage collection disabled during loading, previously done inside config_realtime_process(), for example with gc.disable().
3. Switch modeld to realtime priority only after the model has finished loading.

This has no measurable model-loading performance impact and prevents controlsd startup from being starved. A second startup after the model is already in the page cache may avoid the fault, but the priority change is the actual fix.

This can occur when the panda's STM32 enters a brown-out/NMI state. The NMI handler stays in an infinite loop instead of resetting, leaving GPIO/relay and CAN bus states in a bad condition. Temporary workaround: unplug and reconnect the comma device; it should boot and work normally afterward. Permanent fix: update openpilot/panda firmware to a build containing PR #38737, "Handle and report NMI/hardfaults," which resets the STM on NMI/hard fault and adds logging. On night-dev, check for updates after the fix is merged; advanced users can flash the test branch. If it repeats, inspect comma power and supply voltage.

This affects nightly builds after PR #38684, where comma ARM64 portable builds only generate the camera warp file for the build device instead of both TICI and MICI resolutions. A comma four/MICI needs selfdrive/modeld/models/dm_warp_1344x760_tinygrad.pkl.

Immediate workaround: reflash or switch the comma four to the known-working release-chestnut build:
- AGNOS: 19.6
- Branch: release-chestnut
- Commit: 053d9c446800df38aca42b69bb99197aefbea77b

Verify the file exists from the openpilot directory:

ls -l selfdrive/modeld/models/dm_warp_1344x760_tinygrad.pkl

For a portable nightly/release build, fix SConscript so comma ARM64 prebuilts include both camera configurations:
- TICI: 1928x1208 from _ar_ox_fisheye
- MICI/comma four: 1344x760 from _os_fisheye

Keep the single-camera optimization only for device-local builds. Rebuild and confirm both files are present before deploying:

ls -l selfdrive/modeld/models/dm_warp_1344x760_tinygrad.pkl \
       selfdrive/modeld/models/dm_warp_1928x1208_tinygrad.pkl

The 2019 Kia Niro PHEV's EPS firmware enforces a minimum steering speed of about 32 MPH (14 m/s); openpilot cannot make the car steer from 0 MPH on that EPS. The forks you used did not declare this limit, so openpilot kept requesting steering and could abruptly reapply it when the actual speed crossed 32 MPH.

Fix: use an upstream openpilot build that includes the official HKG 2019 Kia Niro PHEV support/PR instead of v0.8.5 forks such as hkg_085 or Donfyffe. If you maintain a fork, add the vehicle in selfdrive/car/hyundai/interface.py and set ret.minSteerSpeed = 14.0 for the 2019 Niro PHEV, matching the existing 2019 Hyundai Ioniq handling. This lets openpilot cleanly suppress and re-enable steering across the threshold rather than fighting the EPS.

Until upgraded, do not use the system in stop-and-go traffic or when speed may hover around 32 MPH, and be prepared to steer manually. The missing LKAS fault warning is a separate issue and requires logs from an affected route.

This is a startup-order race. Processes publish their early logs before loggerd/logmessaged has connected the ZeroMQ subscriber, so those initial PUB messages are discarded and cannot be recovered.

Fix:
1. Update openpilot to a version containing both PRs:
- logmessaged: avoid dropping messages
- manager: start loggerd before other processes
2. If backporting manually, edit selfdrive/manager/process_config.py and move loggerd before dmonitoringd, dmonitoringmodeld, modeld, and other processes that emit startup logs.
3. Rebuild and restart the manager, or reboot the device:

cd /data/openpilot
   scons -j$(nproc)
   sudo reboot

./selfdrive/debug/filter_log_message.py "" 0 | grep modeld