Something might be interfering with controller startup.
Try to remove all installed URCaps, if this doesn’t help, then backup programs, calibration, and reflash USB stick with system image.
This type of problem is almost always caused by incompatible/misbehaving URcaps, corrupt SD card image, too many threads, or some external system causing too many messages to be posted into the log file (usually a URcap or mis-configured safety IO).