Failed OS installation using SDcard - Wrong image format for "source" command

Good day Toradex!

We are now having an issue where we are unable to install OS if we are using SDcard. The situation is per described below.

  1. First, we consolidated our custom image with TEZI into one USB stick. Then we run the command run distro_bootcmd, the installation was successful.
  2. We have prepared a bundle of one Application and OS, and both files is packed into .ipk format.
  3. Then, these .ipk files will be extracted using opkg and OS.ipk is extracted to SDcard. (the content inside OS.ipk and custom image used in step 1 is exactly the same).
  4. The unit is rebooted and uboot is up, however the uboot somehow unable to find any OS image in the SDcard.

The SDcard is in ext4 format and it is in a good health.

We are using Toradex Apalis iMX6 Quad 2GB IT V1.1D board.

The error message:

Industrial temperature grade DDR3 timings.
Trying to boot from MMC1
U-Boot 2019.07-3.0.4+g26d926eda0 (Nov 25 2022 - 14:44:49 +0000)
CPU:   Freescale i.MX6Q rev1.6 at 792MHz
CPU:   Industrial temperature grade (-40C to 105C) at 49C
Reset cause: WDOG
DRAM:  2 GiB
PMIC:  device id: 0x10, revision id: 0x21, programmed
Loading Environment from MMC... OK
In:    serial
Out:   serial
Err:   serial
Model: Toradex Apalis iMX6 Quad 2GB IT V1.1D, Serial# 11000465
Net:   using PHY at 7
Autoboot in 0 seconds
Booting TEZI Partition...
** Unrecognized filesystem type **
# # Executing script at 17000000
Wrong image format for "source" command
Apalis iMX6 #

Can you help to advise us what are the possible cause and what can we do to fix it?

Your response in this matter is highly appreciated.