I found the problem in case anyone else runs into this issue. Our new hardware does not run on battery so the missing voltage on the battery input pin was causing the power_prep initialization to fail. We modified the power_prep.c file to ignore the voltage on the battery input.
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*** 646,652 ****
HW_POWER_DCDC4P2.B.TRG = 0;
HW_POWER_5VCTRL.B.HEADROOM_ADJ = 0x4;
! HW_POWER_DCDC4P2.B.DROPOUT_CTRL = 0xA; //100mV drop before stealing
// charging current
HW_POWER_5VCTRL.B.CHARGE_4P2_ILIMIT = 0x3f;
}
--- 670,676 ----
HW_POWER_DCDC4P2.B.TRG = 0;
HW_POWER_5VCTRL.B.HEADROOM_ADJ = 0x4;
! HW_POWER_DCDC4P2.B.DROPOUT_CTRL = 0x8; //100mV drop before stealing //was0xA
// charging current
HW_POWER_5VCTRL.B.CHARGE_4P2_ILIMIT = 0x3f;
}