SG3100 keeps locking up after latest update
-
I'm even entertaining the idea that the brand new SG-3100 box might have had a defective power supply in it. The first box that was in production for years had a bad internal disk. I replaced the disk, confirmed it was working and swapped that box with a new SG-3100 (that was purchased years ago as a cold spare) and then put both the old SG-3100 and old power supply in a box on the shelf. Later i might disconnect the new power supply and connect the old one but it seems extreme and possibly a waste of time. It's kinda frustrating because it takes about 1-3 weeks before another lockup.
-
Mmm, I would say it's at least statistically unlikely to be a PSU issue. We really don't see many issues with them.
-
@stephenw10 It froze again yesterday morning with relatively low traffic. Still nothing in console or any console ctrl, no errors in syslog. This time i had a script running to send additional system stats to remote syslog.
CPU Temperature: 76 | Load Average: 0.13, 0.20, 0.16 | Memory Usage: 20.00% | MBUF Usage: 1234/1296/2530/10035 | State Table Size: 1215Here is what we've done:
- Swapped SG-3100 unit and power supply after resolving the hard drive issue on the old SG-3100. Re-confirmed power supply was swapped by looking at asset id written on power supply matches asset id on SG-3100
- Eliminated possibility of ground loop by confirming this system doesn't have ground difference between connected building, and re-confirming the electrical architecture related to the network hasn't changed in the 7 years we've been using pfSense (2 years via ESXi, 5 years with SG-3100), our issues started in April 2023
- Doesn't appear to be firmware related considering i'm managing another SG-3100 at a different location with the same firmware and no problems
- I left console connected so I could see output during failure, no output, not even with ctrl+t
- Doesn't appear to be load or heat issue. Normal/Average temperature and loads reported 13 seconds before lockup: CPU Temperature: 76 | Load Average: 0.13, 0.20, 0.16 | Memory Usage: 20.00% | MBUF Usage: 1234/1296/2530/10035 | State Table Size: 1215. We've had much higher loads and temps as high as 83C without issues.
- Removed non-essential packages (only leaving snort)
- No errors in /var/log/system.log
- I "think" we've eliminated the likelihood of the cause being a surge coming from upstream 4 port ISP modem. 2 Netgate boxes are connected to it side by side (SG-3100 for main office with static WAN IP and a SG-1100 for separate facilities with dynamic WAN IP). The SG-1100 hasn't been affected and hasn't had a lockup since it was installed in April. I'm thinking it was a coincidence this was installed the day after the first unexplained SG-3100 lockup.
I'm not sure what else to try or what I might be missing. My assumptions are:
- If the cause is traffic (good, bad, malicious, etc) related from LAN or WAN, no matter how low level, an error would propagate to /var/log/system.log.
- If the cause is heat related, the temp would not rise from normal, past warning, into fatal in under 15 seconds in a room where all other temperatures remain normal. That's why my load checks only run every 15 seconds.
- If the cause is power related, it's not likely to follow a new power supply that was never used. Especially when it's plugged into an APC UPS.
- If the cause is a Ethernet cable gone bad, we would also likely have traffic problems before total failure.
Are my assumptions wrong? Do any ideas jump out as logical next steps?
-
I confess, I did not read the entire thread, just an overlook.
Are you using RAM disks? I have had a similiar issue some months ago when using RAM disks, see here,
but the interval between freezes was about 14 days or so, but not within a few days as yours.
But just as an idea???Regards
-
@FSC830 No, RAM disk is disabled in System > Advanced > Miscellaneous.
-
Mmm, I run ramdisks and am not seeing any issues in 23.05.1.
So to confirm; your seeing this in every version of pfSense since 23.01?
If you reinstall 22.05 do it stop happening?If you run one of those 3100s with 23.05.1 in a different location does it still happen?
Steve
-
@stephenw10 Yes, in every version since 23.01. I've only run the 2 boxes at this location. The other location i'm running a 3100 with the same software without problems. Both locations have very similar configurations and all the same packages installed. I have not tried taking one of the units from the place that has a primary and backup and taking it to another location. I've just been swapping the primary and backup in the same office.
Yesterday i did a fresh install from a support image I had on file to the backup box, from there i upgraded to latest, then restored the configuration and put it back into production but elevated the unit for more airflow. Even though my logs show temp didn't break 76C 12 seconds before last failure, I don't know how accurate the pfSense temp monitor is, or if my assumptions outlined in my last post are correct.
I could swap it with one in my home lab but I'd rather not and do whatever troubleshooting steps (if anymore exists) to confirm the issue is isolated. Using the 2 boxes in the one location instead of moving boxes to different buildings is potentially interrupting workflows somewhere else. The problem definitely seems isolated to this location based on observing the problem with 2 boxes and 2 power supplies in the same building.
-
The biggest thing that makes me think it's something unique to that install/location is that there are a lot of 3100s running 23.05.1 and if this were common to all 23.0X installs we would be flooded with support tickets.
It almost has to be some combination of unusual things in that specific setup. Testing either of those units in a different location would confirm that.One other thing we could try is using the debug kernel. If there is some issue it might throw some additional errors before it stops responding. I wouldn't really expect to see anything else when it stops though as it logs nothing at all currently.
Steve
-
It's been over a month since the last lockup after consistently locking up 2-4 times a month. There was also an un-managed switch that was randomly failing (3 switches downstream of the router and only managing traffic for 2 computers so seemingly unrelated) and it magically stopped failing. I've only been troubleshooting networks for ~9 years and it's not my primary job. I've never seen hardware problems go away on their own while usage remains the same.
The only things that have happened since the last lockup:
- Kicked everyone off wifi networks (even separate guest wifi) for a few days after the last failure. The networks are segregated and firewalled but without high confidence in my log analysis, this seemed like a fair step.
- Publicly made plans in office after getting green light from owner to start locking down network (every device would have to be registered mac and static IP pair before being allowed on network) if problem persisted.
- Re-allowed everyone to use wifi as usual with the knowledge that the network will eventually be locked down (no more personal devices able to easily get on) to help isolate the mysterious problems if they kept occurring.
No changes were made, just made plans for next move. All hardware and general usage has remained unchanged and in over a month, not 1 failure.
Any ideas about how the issues mysteriously went away (or at least haven't happened in ~38 days)?
-
Some general power issue maybe?
-
@stephenw10 Not sure since power hasn't changed to my knowledge. And my hopes would be that power issues at that scale would also affect other equipment. For example the issue with the switch was only going on for about a month where as the router issues date back to before the summer.
My initial hunch was power user or script kiddie based on the environment and employee history. -
@stephenw10
I continue to have similar issues to this poster that seemed to be improved but not eliminated with a replaced power supply. I think there is something more going on. However, with the end of support for the sg-3100 it may time to shift platforms. -
Potentially could be some DoS attack. Something that could make a switch appear to be failing could certainly affect a 3100. Though I'd expect that to requite a volume of traffic that could not go unnoticed.
-
I've been trying to settle on better monitoring tools to make monitoring, keeping history and alerting on condition changes in traffic easier. If you have suggestions i'm all ears. Security Onion is proving to be too much for someone who doesn't have enough time to figure out the appropriate configurations to be sure i'm properly monitoring. ntopng randomly fails. My graylog server for traffic from the firewall never shows any significant changes but that's no confirmation that there isn't a problem.
Snort felt like a bit of a waste considering i would get alerts about issues but couldn't confirm if there really was a problem (erroneous ftp activity alerts when ftp activity itself seems valid). I may go back to focusing on snort or surricata for intrusion detection but still need a good solution for monitoring abnormal network usage.
For power management, everything is on APC UPS. Most of the server equipment is on more sensitive versions of APC (pure sine instead of step). I don't think i'll get access to anything better to help protect against building power issues.
-
Mmm, if it was either power or DoS it would have to be really obscure to not show up there. I'm not sure what else might cause this though.
-
@stephenw10
Indeed - part of the problem with this (assuming I have the same issue as the OP) is that there are no logs indicating anything, even on the console. I do have a security onion installation capturing logs from the sg-3100 and monitoring all traffic on the inside interface and it indicated nothing interesting around the time of the failures. I had another lockup just this week. And, power is solid here with UPS, other devices sharing the same UPS feed that are happy and other power monitoring that showed no changes in voltage or frequency around the failures. -
Potentially it could be some hardware failure common to those devices but if it is it's not something we've seen across more. And the fact it only seemed o happen after upgrading implies ether software or something in hardware the upgrade started hitting. But again I'd expect to see it far more widespread if so. It could be a combination of uncommon config and hardware.
-
@netplumbers do you have (not service) Watchdog enabled or disabled? (https://docs.netgate.com/pfsense/en/latest/config/advanced-misc.html#watchdog) It may be completely unrelated but in the past couple years we’ve had I think 3-4 incidents of client 3100 routers rebooting for no apparent reason. One was twice, and after the second time I turned off the RAM disk to better capture any logs but it hasn’t happened in the year or so after that. Several other 3100s without issue.
-
@SteveITS said in SG3100 keeps locking up after latest update:
https://docs.netgate.com/pfsense/en/latest/config/advanced-misc.html#watchdog
I don't want to hijack this thread but, yes, watchdog is enabled with a 128s timeout. When I experience this lockup, the box reboots sometimes and doesn't others. I was experiencing this with an increasingly high frequency getting to every couple of days before replacing the 3100's power supply under TAC's advise. Now I experience the issue every few months. I think I had 49 days of uptime until it hard locked a few days ago and required a power cycle to return to service. Perhaps if I waited longer the watchdog would have rebooted the box.
-
Mmm, it's an interesting question. If the watchdog is enabled then it should have rebooted itself rather than locked up requiring manual intervention. The fact it didn't implies at the watchdog process is still running. Or that the hardware suffered something so low level that even the watchdog stopped, which seems very unlikely.
