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    SG-2220 fails to boot after only 3 months of use

    General pfSense Questions
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    • T
      TechNinja
      last edited by

      The company I am employed at has been using an SG-2220 (OS version 2.3.1 amd64) for a few months.
      Last night (2016-09-30 ~4:00am EST) the box appeared to have kicked the bucket.

      Troubleshooting through the console reveals:

      • The OS (ver 2.3.1 amd64) appears hang when booting.
      • There is a flood of "/etc/rc: <filepath>: Device not configured" lines before the console stops responding
      • The last line that appears before the console stops responding is: "/etc/rc: /bin/rm: Device not configured"
      • Booting in safemode does not fix, or change the last line that appears.

      Other interesting lines in the console output:

      • "Trying to mount root from ufs:/dev/ufsid/5762c4d1ab093e6a [rw]…"
      • "WARNING: / was not properly dismounted"
        "WARNING: Trying to recover filesystem from inconsistency..."
        "Can't stat /dev/ufsid/5762c4d1ab093e6a: No such file or directory" (there are 12 lines of this consecutively, also after this is when the "Device not configured" messages start appearing)

      I have attached both the standard console output as well as the verbose console output in case anyone wants to see.
      I am still relatively new to pfSense (especially debugging the console) and was hoping someone could help point me in the right direction before I say "screw it, RMA the thing"

      Thank you all for any help you might provide.
      2016-09-30_sg-2220_boot_console.txt
      2016-09-30_sg-2220_boot_console_verbose.txt</filepath>

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      • DerelictD
        Derelict LAYER 8 Netgate
        last edited by

        At the logo menu press 2 for single user mode

        At press RETURN for /bin/sh press return

        Run this until it comes back clean: /sbin/fsck -y /

        Run /sbin/reboot

        Gracefully halt the system using Diagnostics > Halt System or ssh/console option 6 whenever possible prior to powering off.

        Chattanooga, Tennessee, USA
        A comprehensive network diagram is worth 10,000 words and 15 conference calls.
        DO NOT set a source address/port in a port forward or firewall rule unless you KNOW you need it!
        Do Not Chat For Help! NO_WAN_EGRESS(TM)

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        • T
          TechNinja
          last edited by

          @Derelict:

          At the logo menu press 2 for single user mode

          At press RETURN for /bin/sh press return

          Run this until it comes back clean: /sbin/fsck -y /

          Run /sbin/reboot

          Gracefully halt the system using Diagnostics > Halt System or ssh/console option 6 whenever possible prior to powering off.

          Alright. I gave it a try. Here's some examples of the output (the entire time it's running, it's spitting out this same message with different sectors):

          THE FOLLOWING DISK SECTORS COULD NOT BE READ: 320, 321, 322, 323, 324, 325, 326, 327, 328, 329, 330, 331, 332, 333, 334, 335, 336, 337, 338, 339, 340, 341, 342, 343, 344, 345, 346, 347, 348, 349, 350, 351, 352, 353, 354, 355, 356, 357, 358, 359, 360, 361, 362, 363, 364, 365, 366, 367, 368, 369, 370, 371, 372, 373, 374, 375, 376, 377, 378, 379, 380, 381, 382, 383,

          CANNOT READ BLK: 40456
          UNEXPECTED SOFT UPDATE INCONSISTENCY

          CONTINUE? yes

          THE FOLLOWING DISK SECTORS COULD NOT BE READ: 40456, 40457, 40458, 40459, 40460, 40461, 40462, 40463,
          fsck_ufs: CANNOT ALLOCATE ROOT INODE

          Trying to run the command after running once results in:

          /sbin/fsck -y /

          Can't stat /dev/ufsid/5762c4d1ab093e6a: No such file or directory
          Can't stat /dev/ufsid/5762c4d1ab093e6a: No such file or directory

          Also after running fsck, any other command results in: "Device not configured"

          I'm pretty convinced the flash storage is fried at this point. I anyone thinks otherwise, please let me know.

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          • DerelictD
            Derelict LAYER 8 Netgate
            last edited by

            See if it takes a reinstall.

            Chattanooga, Tennessee, USA
            A comprehensive network diagram is worth 10,000 words and 15 conference calls.
            DO NOT set a source address/port in a port forward or firewall rule unless you KNOW you need it!
            Do Not Chat For Help! NO_WAN_EGRESS(TM)

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            • T
              TechNinja
              last edited by

              @Derelict:

              See if it takes a reinstall.

              No luck. I downloaded ADI iso from the support portal & put it on a flash drive.
              I'm able to boot from flash drive, but formatting da0 (the internal storage) errors out and then disappears from the list of drives.
              I've tried both the custom & easy options. Either way it always dies at the format. I also tried reimaging the flash drive just in case the image corrupted somehow.

              Here are the failed portions of the logs.

              ================================================================================
                ▒ ,-<<< Executing /sbin/fdisk -I da0'                                    ▒   ▒ | fdisk: can't get disk parameters on /dev/da0                          ▒   ▒ | fdisk: cannot open disk /dev/da0: No such file or directory            ▒   ▒ [Fri Jan 22 01:06:24 2016]                                              ▒   ▒ ->>> Exit status: 1                                                    ▒

              ▒ ,-<<< Executing /sbin/fdisk -v -f /tmp/format.fdisk da0'                ▒   ▒ | fdisk: can't get disk parameters on /dev/da0                          ▒   ▒ | fdisk: cannot open disk /dev/da0: No such file or directory            ▒   ▒ [Fri Jan 22 01:11:54 2016]                                              ▒   ▒ ->>> Exit status: 1                                                    ▒

              ▒ ,-<<< Executing /sbin/fdisk -v -f /tmp/format.fdisk da0'                ▒   ▒ | fdisk: can't get disk parameters on /dev/da0                          ▒   ▒ | fdisk: cannot open disk /dev/da0: No such file or directory            ▒   ▒ [Fri Jan 22 01:11:54 2016]                                              ▒   ▒ ->>> Exit status: 1                                                    ▒
                ▒ [Fri Jan 22 01:12:54 2016]                                              ▒
                ▒ ,-<<< Executing /sbin/fdisk da0'                                        ▒   ▒ | fdisk: can't get disk parameters on /dev/da0                          ▒   ▒ ->>> Exit status: 1                                                    ▒
                ▒ [Fri Jan 22 01:13:39 2016]                                              ▒
                ▒ ,-<<< Executing /usr/bin/yes | /sbin/fdisk -B da0'                      ▒   ▒ | fdisk: can't get disk parameters on /dev/da0                          ▒   ▒ | fdisk: cannot open disk /dev/da0: No such file or directory            ▒   ▒ | yes: stdout: Broken pipe                                              ▒   ▒ ->>> Exit status: 1                                                    ▒

              I notice at right before the format starts, the following errors get spit out:

              (da0:umass-sim0:0:0:0): READ(10). CDB: 28 00 00 71 ff ff 00 00 01 00 Status Error
              (da0:umass-sim0:0:0:0): CAM status: SCSI Status Error
              (da0:umass-sim0:0:0:0): SCSI status: Check Condition
              (da0:umass-sim0:0:0:0): SCSI sense: NOT READY asc:4,ff (Vendor Specific ASCQ)
              (da0:umass-sim0:0:0:0): Retrying command (per sense data)
              (da0:umass-sim0:0:0:0): READ(10). CDB: 28 00 00 71 ff ff 00 00 01 00
              (da0:umass-sim0:0:0:0): CAM status: SCSI Status Error
              (da0:umass-sim0:0:0:0): SCSI status: Check Condition
              (da0:umass-sim0:0:0:0): SCSI sense: NOT READY asc:4,ff (Vendor Specific ASCQ)
              (da0:umass-sim0:0:0:0): Retrying command (per sense data)
              (da0:umass-sim0:0:0:0): READ(10). CDB: 28 00 00 71 ff ff 00 00 01 00
              (da0:umass-sim0:0:0:0): CAM status: SCSI Status Error
              (da0:umass-sim0:0:0:0): SCSI status: Check Condition
              (da0:umass-sim0:0:0:0): SCSI sense: NOT READY asc:4,ff (Vendor Specific ASCQ)
              (da0:umass-sim0:0:0:0): Retrying command (per sense data)
              (da0:umass-sim0:0:0:0): READ(10). CDB: 28 00 00 71 ff ff 00 00 01 00
              (da0:umass-sim0:0:0:0): CAM status: SCSI Status Error
              (da0:umass-sim0:0:0:0): SCSI status: Check Condition
              (da0:umass-sim0:0:0:0): SCSI sense: NOT READY asc:3a,0 (Medium not present)
              (da0:umass-sim0:0:0:0): Error 6, Unretryable error

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              • KOMK
                KOM
                last edited by

                He's dead, Jim.

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                • DerelictD
                  Derelict LAYER 8 Netgate
                  last edited by

                  Looks that way. Register it (www.pfsense.org/activate) and open a ticket. Refer to this thread and RMA should be easy.

                  Chattanooga, Tennessee, USA
                  A comprehensive network diagram is worth 10,000 words and 15 conference calls.
                  DO NOT set a source address/port in a port forward or firewall rule unless you KNOW you need it!
                  Do Not Chat For Help! NO_WAN_EGRESS(TM)

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