Thanks DerekLau.
I believe I was working with bad hardware. Most likely a bad USB cable. All working fine now.
Story in case it's helpful to others...
I found D4 on my FRDM-KL25Z board, right next to the OpenSDA chip, stamped M20AGV.
I used a Windows 8 laptop with a blue USB 3.0 port for this test. I also used a different USB cable. I didn't read anything in your reply about releasing the reset switch. I found the D4 LED before plugging it in, held in RESET, and waited...
Good news: My Windows 8 laptop recoginsed something on the USB bus. It said something like looking for driver. That's the first time I've seen that message, so I'm pleased.
... still connected and holding in the reset button and trying to focus on whether D4 is lit. I didn't see d4 light.
Bad news: I smelled smoke. I disconnected, and touched the OpenSDA chip and found it was hot and glossy black. I tried reconnecting a couple times with and without the RESET held in and now the tri-color LED doesn't light.
Analysis: I changed too many variables at once
Variable 1: I'm thinking my first USB cable may have been a charge only model and not a data cable. Maybe that's why it didn't connect in the first place.
V2: I'm not sure how long I was supposed to hold in RESET or when/if to release.
V3: I have two FRDM-KL25Z boards. I tried my other board. Maybe it has a bug or bad OpenSDA chip?
V4: Now sure if USB3.0 or Windows 8 had anything to do with it..
Trying my other un-fried board now...
Test 1 Setup: un-fried FRDM-KL25Z board, win8, usb2 port, old USB cable(might be power only/no data), leaving the RESET button untouched.
T1 Result: Tri-color lights up. Yay, back to square one.
(checked out the USB cable that lights the tri-color on my USB hub, no data connection. Strange it's stamped Belkin)
using my usb hub to find a known-good data USB cable. Found one.
Test 2 Setup: un-fried FRDM-KL25Z board, win8, usb2 port, known good USB data cable, leaving the RESET button untouched.
T2 result, tri color blinks once?, board goes into intermittent D4 blink, 8 blinks, 1 second pause. Windows 8 discovers new USB device and loads driver. Appears in Windows Device Manager as Portable Devices, FRDM-KL25Z. I also see an E drive named FRDM-KL25Z.
E: drive named FRDM-KL25Z
E:\>dir /b
SERCDC89.INF
SERCDC89.CAT
LASTSTAT.TXT
SDA_INFO.HTM
FSL_WEB.HTM
TOOLS.HTM
I then held in the Reset, plugged in and quickly released.(experience from before was likely bad cheapest eBay cable)
E:drive now named BOOTLOADER
E:\>dir /b
LASTSTAT.TXT
SDA_INFO.HTM
FSL_WEB.HTM
TOOLS.HTM
All good.
I thin tried my fried board with same good cable. It does light the tri-led and go into demo mode, the reset button does restart the demo. The D4 OpenSDA light never goes on.
Strange, when I plugged my working FRDM-KL25Z in, it didn't go into DEMO mode. It just sits with no lights. held in reset and replugged in and it came up as BOOTLOADER drive. Oh well, I think I can work with this. first step is to upgrade firmware.
Thanks,
Ray Metz