We looked into this issue thoroughly today and we found out that it is actually not related directly to the HDMI connected or not, as we first thought that if it is not a bootloader it must be something with HDMI interface signaling/detection.
But the issue really lies somewhere else, that is in the power up procedure. We found out that Raspberry Pi CM4 datasheets states that
All pins should not have any power applied to them before the +5V rail is applied.
We come to that when seeing that device boots up successfully w/out HDMI connected, if the PSU is immediately reattached to the barrel jack connector after disconnection (in ms), or sometimes when PSU is first connected to the jack and after that to wall plug.
To get to the point; we are using external power supply for 3V3 rail which is connected to the RPi CM4 module over pull-up resistors on the input/output signals going to/from the CM4 module.
After 5V is applied, it seems that the 3V3 rail rises to quick (1ms) and kind of a latch-up happens.
We modified the hardware enabling the PMIC with 3V3 generated from RPi, that way ensuring 3V3 power rail voltage will always rise later than 5V is supplied. That resulted in all boards boot up without HDMI connected, no matter the version,, CM4 module variant used... It boots, if we are using CM4 Lite with uSD and booting from there, or if we attach the CM4 with eMMC, booting from eMMC.
Modification that works for now: removed the 10k PU from EN pin on PMIC, and connected EN pin to CM4_3V3 rail.
We believe that the reason for that some of the CM4 modules booted - no matter what Luxonis board we used it on (Luxonis carrier board) while some didn't, is that we were/are really on the edge here with this issue.
On the other hand and we are not aware of the exact boot procedure on the CM4 and what causes the latch before boot, so can not explain the real reason behind this.
Nevertheless in the Raspberry PI compute module datasheet is clearly stated that none of the pins, on a CM4 module, should have any power applied to them before the +5V rail is applied. We are also not sure about why connecting the HDMI cable solves this issue, it could be that the CM4 has different boot procedure when HDMI is connected or not.
To close that up, we will update the design and we can also offer sending a reworked unit for now for everyone affected by this issue.
We are sorry for any inconvenience brought in by this issue.
Best regards David,
Luxonis lead EE