Thank you for the reply. I don't have load balancing enabled, only failover. Do I have to update?

Update: I bought a new ADSL2+ modem (a Netcomm NB6 modem/router, configured in full-bridge mode, i.e. used as a modem only), and substituted it for the Draytek Vigor 2600Plus. What a contrast!  The complete pfSense PPPoE connection and login sequence was successfully completed in under 6 seconds - everything first time.  The "power on" to "internet available" time was less than 45 seconds.  Now that's more like it. :) I think that proves beyond reasonable doubt that there's nothing wrong with the pfSense PPPoE client and that my problems were 100% related to interference from the Draytek's PPPoE pass-through mode.

Still seems like it's overheating or power related since both boxes are doing the same in the exact same location, but works fine else where. Voltage drop or spike maybe not enough for the ups to kick in. Can you raise the tolerances on the ups to kick on battery if there is any power spikes or drops. Some UPS's won't trip on battery until well below 90 volts.

You have 4 packages including one of the most resource intensive ones installed on an embedded box with barely the required memory for pfSense itself.  Enough said.

All of these questions have been answered in more detail if you search the forum. The hardware you have described should be plenty powerful.  Search the forum for more on hardware sizing, try the hardware forum. I would replace your current router and have the pfsense box be your only NAT and firewall.  Will simplify things. Almost any network card will do, but see the HCL on www.pfsense.org and know that Intel cards are the best, and Realtek cards are the worst.

Yes.  However doing that in a virtual host doesn't give you isolation - just take a look at the security advisories that VMWare (and others) issue.  Virtualisation doesn't add security, it adds another very complex piece of software with it's own vulnerabilities to the mix, reducing security.  Better to use multiple real hosts, or one single host with many interfaces.

Ok, Thanks.

IPsec is a VPN.  The "point" you see for having pfSense an IPsec endpoint applies equally to OpenVPN, PPTP and other VPN technologies.

Ok, so I tried 1.2.2 and it didn't work for me. Now, I'm running 1.2.3-RC1 and it finally works. FYI. Thanks, Julian

Thank you, that answer very helpfull

@submicron: Or if you have multiple public IP addresses, you can use 1:1 NAT. Dear submicron, i have public IP from my ISP is 203.xxx.xxx.xxx/29, there is 6 public IP i can use for my server. How can i use this ?? Do you have 1:1 NAT tutorial / example for me..?? regards ??

If the hardware were under a high interrupt load, that could affect ping or even high cpu usage. It would take more information as to what your box is doing during these instances where ping times fluctuate.