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



  • 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>


  • LAYER 8 Netgate

    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.



  • @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.


  • LAYER 8 Netgate

    See if it takes a reinstall.



  • @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



  • He's dead, Jim.


  • LAYER 8 Netgate

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


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