SG-4860 1U failing on updates/reboots

opoplawski

I have a SG-4860 1U that has started to give be a lot of trouble. When I updated to 2.4.4 and to 2.4.4p1 each time it failed to boot with different levels of corruption that forced a re-install. Then the other day while running 2.4.4p1 I made some changes to config.xml and did a restore from the new config.xml file. It would not reboot:

FreeBSD/amd64 (inferno.cora.nwra.com) (ttyu1)

Netgate SG-4860 - Serial: 1035150188 - Netgate Device ID: 19aefd13147d34ce60f1

*** Welcome to pfSense 2.4.4-RELEASE-p1 (amd64) on inferno ***

 WAN (wan)       -> igb1       -> v4: 208.187.183.84/28
 LAN (lan)       -> igb0       -> v4: 10.10.0.1/16
 DMZ (opt1)      -> igb2       -> v4: 192.168.183.1/24
 PUB (opt2)      -> igb3       -> v4: 172.16.10.1/24
 OPT3 (opt3)     -> igb4       -> v4: 172.16.11.1/24
 WANCL (opt4)    -> igb5       -> v4: 204.134.157.90/29

 0) Logout (SSH only)                  9) pfTop
 1) Assign Interfaces                 10) Filter Logs
 2) Set interface(s) IP address       11) Restart webConfigurator
 3) Reset webConfigurator password    12) PHP shell + pfSense tools
 4) Reset to factory defaults         13) Update from console
 5) Reboot system                     14) Disable Secure Shell (sshd)
 6) Halt system                       15) Restore recent configuration
 7) Ping host                         16) Restart PHP-FPM
 8) Shell

Enter an option: ovpns3: link state changed to DOWN
Waiting (max 60 seconds) for system process `vnlru' to stop... done
Waiting (max 60 seconds) for system process `bufdaemon' to stop... done
Waiting (max 60 seconds) for system process `syncer' to stop...
Syncing disks, vnodes remaining... 3 0 0 done
All buffers synced.
Uptime: 30d21h42m37s
umass0: detached
uhub1: detached
256r256H[6n
Google, Inc.
Serial Graphics Adapter 01/27/15
SGABIOS $Id: sgabios.S 8 2010-04-22 00:03:40Z nlaredo $ (wenwang@localhost.localdomain) Tue Jan 27 18:10:24 UTC 2015
Term: 172x41
O4 0
ain)

iPXE (http://ipxe.org) 00:14.0 C100 PCI2.10 PnP PMM+7FB7AF80+7FADAF80 C100
Press Ctrl-B to configure iPXE (PCI 00:14.0)...
iPXE (http://ipxe.org) 00:14.1 C200 PCI2.10 PnP PMM 7FB7AF80 7FADAF80 C200
iPXE (http://ipxe.org) 00:14.2 C300 PCI2.10 PnP PMM 7FB7AF80 7FADAF80 C300
iPXE (http://ipxe.org) 00:14.3 C400 PCI2.10 PnP PMM 7FB7AF80 7FADAF80 C400

Press F12 for boot menu.

-\|/-\|/-\|-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/- to pfSensepts=[0x8+0x197280\|/-\|/-\|/-\+0x8+0x197de9|/-\|/-\|/-\|]
/-\|/-\|/-/boot/entropy size=0x1000
Booting...
Google, Inc.
Serial Graphics Adapter 01/27/15
SGABIOS $Id: sgabios.S 8 2010-04-22 00:03:40Z nlaredo $ (wenwang@localhost.localdomain) Tue Jan 27 18:10:24 UTC 2015
Term: 172x41
O4 0
ain)

iPXE (http://ipxe.org) 00:14.0 C100 PCI2.10 PnP PMM+7FB7AF80+7FADAF80 C100
Press Ctrl-B to configure iPXE (PCI 00:14.0)...
iPXE (http://ipxe.org) 00:14.1 C200 PCI2.10 PnP PMM 7FB7AF80 7FADAF80 C200
iPXE (http://ipxe.org) 00:14.2 C300 PCI2.10 PnP PMM 7FB7AF80 7FADAF80 C300
iPXE (http://ipxe.org) 00:14.3 C400 PCI2.10 PnP PMM 7FB7AF80 7FADAF80 C400

Press F12 for boot menu.

-\|/-\|/-\|-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/- to pfSensepts=[0x8+0x197280\|/-\|/-\|/-\+0x8+0x197de9|/-\|/-\|/-\|]
/-\|/-\|/-/boot/entropy size=0x1000
Booting...
Google, Inc.
Serial Graphics Adapter 01/27/15
SGABIOS $Id: sgabios.S 8 2010-04-22 00:03:40Z nlaredo $ (wenwang@localhost.localdomain) Tue Jan 27 18:10:24 UTC 2015
Term: 172x41
O4 0
ain)

iPXE (http://ipxe.org) 00:14.0 C100 PCI2.10 PnP PMM+7FB7AF80+7FADAF80 C100
Press Ctrl-B to configure iPXE (PCI 00:14.0)...
iPXE (http://ipxe.org) 00:14.1 C200 PCI2.10 PnP PMM 7FB7AF80 7FADAF80 C200
iPXE (http://ipxe.org) 00:14.2 C300 PCI2.10 PnP PMM 7FB7AF80 7FADAF80 C300
iPXE (http://ipxe.org) 00:14.3 C400 PCI2.10 PnP PMM 7FB7AF80 7FADAF80 C400

Press F12 for boot menu.

-\|/-\|/-\|-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\|/-\read 272 from 192 to 0x7cc73a60, error: 0xc|read 258 from 66 to 0x7cc63e60, error: 0xc/read 260 from 128 to 0x7cc6ba60, error: 0xcread 1 from 128 to 0x7cc6ba60, error: 0xcread 1 from 128 to 0x7cc6ba60, error: 0xccan't open '/boot/shortcuts.4th': no such file or directory

read 1 from 128 to 0x7cc6ba60, error: 0xcread 1 from 128 to 0x7cc6ba60, error: 0xcread 1 from 128 to 0x7cc6ba60, error: 0xcread 1 from 128 to 0x7cc6ba60, error: 0xcread 1 from 128 to 0x7cc6ba60, error: 0xcread 1 from 128 to 0x7cc6ba60, error: 0xcread 1 from 128 to 0x7cc6ba60, error: 0xcread 1 from 128 to 0x7cc6ba60, error: 0xcread 1 from 128 to 0x7cc6ba60, error: 0xccan't load 'kernel'

Type '?' for a list of commands, 'help' for more detailed help.
OK

Unfortunately I do not have console transcripts from the other boot failures. Any idea what might be going on? I haven't been able to find any other indications of hardware issues.

chrismacmahon

I would attempt a re-install; we can get you the image at go.netgate.com. Looking at that I am wondering if the on-board storage is starting to fail.

opoplawski

Yes, I've reinstalled successfully each time - but that is getting tiresome :).

Is there any way to replace/upgrade the onboard storage?

chrismacmahon

Yes, we have a document for that:

https://www.netgate.com/docs/pfsense/solutions/sg-4860-1u/msata-installation.html