I have the very same issue with my Pinsound not recognizing the USB. I have the high speed USB stick as well. My power supply is dead nuts on @ 5.095 (pinsound reports the same in diagnostics). However... I will say that I believe it has something to do with how the power supply comes up. The reason I say this is because I never had this issue... until i replaced my LM323 with the EZSBC PSU5. If my machine sits off for a bit (capacitance discharges) it will almost never come up on the first try. I'm not sure how pinsound has its power supply designed but I believe there is a sensitivity there on some units.

On my unit you can literally see that the drive access led doesn't come on at cold startup and that's when it (obviously) fails to recognize it. I suspect the difference between the linear transistor vs. switching regulator exacerbates the issue.

Even though I'm running on a different machine ... I'm very interested to see if this problem ever goes away for you... I've my theories ... but they are difficult to verify without really understanding how Pinsound is designed... and I have a sample set of 1.

I'd bet that because unregulated power supply (used to power audio amplifiers) and the 5V logic power supply have different rise times and some Pinsound boards are more sensitive to this than others so the USB controller isn't coming out of reset when it should... or something like that... that's just my guess. When it works you can clearly see the access LED on the USB stick illuminate immediately when the power is first applied. When it doesn't ... the LED is always off.

Been having a heck of a time getting my IJ to consistently come up and recognize the USB card when the machine has been cold for a while. Usually it takes one or two power cycles to work.

Full disclosure my WPC power driver board was rebuilt ... and it now uses the EzSBC modules for both the 12V and 5V supplies. Power supplies are dead nuts on and PinSound diagnostics consistently report 5V as such. My machine has been gone over with a fine toothed comb... no strange behavior ... everything works perfectly. I am running an LEDOCD and GIOCD but this problem existed before those were added.

I had been suspecting all along my faulty power up has something to do with the power supplies... These little switching modules have different behavior (power up rise time / regulation) than the traditional linear devices they replace.

What I did is hack-ish... but I’m OK with it:
I used my Kahr board that I don’t need anymore since I have nice clean power supplies... so am generating the +5V needed for the sound board from the 12V supply. I’ve either sped up or slowed down the rise time of the 5V supply for the PinSound board.

Works perfectly... no more faulty starts.

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I don't have the exact reason why (I've my hypothesis) but I will get to that as soon as I can hook some probes up and examine what is going on with and without what I've done.

I thought the sound went away after you install your own boot.wav? I don't hear it on mine... and it works just fine.

I need to get back to this... I've a temporary solution for the moment. It's going to take some time to get this setup so I can actually see whats happening during power up. It has to be some sort of transient phenomenon with my board set that PinSound is sensitive to.... as there are no other issues otherwise.

Yeah I need to see what the 5 volt rail is doing on my system when it doesn’t start right. I want to compare it to what it does with my 12-5V hack in there. I suspect there is a transient that isn’t bad enough to affect the WPC system but PinSound doesn’t like it. Just need to make time to get back to it.