Netgate 6100 - Installation failure after eMMC failure and no console output

KoDa

Hello,

I am experiencing a serious issue with my Netgate 6100. The problem originated from an eMMC failure. Following the official documentation, I installed a compatible M.2 PCIe SSD (which was correctly detected during the installer stage). However, for some reason, the installation process failed repeatedly. I didn't catch the exact error message, but it mentioned something like "Child process exited" and eventually stated that the installation had failed.

During subsequent attempts to reinstall the OS (connecting via the provided USB cable through the console port), I am now seeing only a blank black screen with no output at all.

I have already tried restarting both the device and my computer, thinking it might be a driver issue on my side, but unfortunately, there is still no visible output via the serial/console connection.

Is there any way to recover this device, or am I left with no choice but to replace the hardware?

For context: The device was purchased 3 years ago, and I do not have an active TAC plan.

Thank you in advance for your help

patient0

@KoDa from what client/os are you trying to connect to the 6100? The console would show output at bootup, if connected correctly.

And: did you follow the guide to the point, including wiping of the eMMC?

KoDa

@patient0 said in Netgate 6100 - Installation failure after eMMC failure and no console output:

@KoDa from what client/os are you trying to connect to the 6100? The console would show output at bootup, if connected correctly.

I'm using MacOS.

I tried diffrent methods (console screen -U /dev/cu.usbserial- 115200*).
Also some 3rd party clients like: https://www.decisivetactics.com/products/serial/

Same result - screen is just hangs on:

No change, nothing :(

EDITED:
Just to mention - no matter if I'm booting with or without USB stick with pfSense+ installer.
Also I tried diffrent flash memory with same result.

I've missed your question @patient0 I tried to wipe the eMMC but with no luck, everytime I've got:

mmcsd0: Error indicated: 1 Timeout  
mmcsd0: failed to flush cache  
mmcsd0: Error indicated: 1 Timeout  
mmcsd0: Error indicated: 1 Timeout  
mmcsd0: Error indicated: 1 Timeout  
mmcsd0: Error indicated: 1 Timeout  
mmcsd0: failed to flush cache  
mmcsd0: failed to flush cache  
mmcsd0: failed to flush cache  
mmcsd0: failed to flush cache  
mmcsd0: failed to flush cache

I suppose it's gone.

patient0

@KoDa on Mac you don't need any driver. The device you show there is likely not the full name of the USB serial device, there must be something more after 'cu.usbserial-', some number, like /dev/cu.usbserial-83734. Do you have more than one USB serial device?

And even if you disconnect & connect the power on the 6100, you don't see anything from the device boot?

Btw: if you got multiple serial device you can find the latest added using ls -ltr /dev/cu.usbserial*, the last entry.

KoDa

@patient0 said in Netgate 6100 - Installation failure after eMMC failure and no console output:

@KoDa on Mac you don't need any driver. The device you show there is likely not the full name of the USB serial device, there must be something more after 'cu.usbserial-', some number, like /dev/cu.usbserial-83734. Do you have more than one USB serial device?

And even if you disconnect & connect the power on the 6100, you don't see anything from the device boot?

I just cut the full output but is /dev/cu.usbserial-0277B92D (and I was connecting to it earlier with no issues) and I tried to reboot multiple times.

Regarding the driver - according to docs I had to install this:
https://www.silabs.com/software-and-tools/usb-to-uart-bridge-vcp-drivers?tab=downloads

patient0

@KoDa said in Netgate 6100 - Installation failure after eMMC failure and no console output:

Regarding the driver - according to docs I had to install this:

Oh, I see, Sorry for me ignorance, you are right.

There is a long thread about eMMCs failing in Netgate devices, one got a 6100 with your symptom (no console output after failing eMMC): https://forum.netgate.com/post/1231106. Do any of the LEDs work?

Maybe it's worth contacting Netgate TAC so see what the suggest, even if it's out of warranty.

KoDa

@patient0 said in Netgate 6100 - Installation failure after eMMC failure and no console output:

@KoDa said in Netgate 6100 - Installation failure after eMMC failure and no console output:

Regarding the driver - according to docs I had to install this:

Oh, I see, Sorry for me ignorance, you are right.

There is a long thread about eMMCs failing in Netgate devices, one got a 6100 with your symptom (no console output after failing eMMC): https://forum.netgate.com/post/1231106. Do any of the LEDs work?

Maybe it's worth contacting Netgate TAC so see what the suggest, even if it's out of warranty.

ETH LEDs are blinking when I'm connecting RJ45 and on the back (it's on NetGate rack mount) I see one red LED.

I'm currently digging that case (thank you).
Somehow I have to revive that device.

SteveITS

@KoDa AFAIK TAC will still help “zero to ping”…worth a try.

Have you removed power?

KoDa

This post is deleted!

KoDa

@SteveITS said in Netgate 6100 - Installation failure after eMMC failure and no console output:

@KoDa AFAIK TAC will still help “zero to ping”…worth a try.

Have you removed power?

OK, I'll give a try with TAC. :)
Currently power cord is removed from device.

stephenw10

Mmm, certainly make sure the USB serial device is being detected by MacOS when you connect it and that it's creating a device with the same name. Though I would expect it to just show some error if you connect to a device that is no longer there with the terminal client.

What do the status LEDs on the 6100 do when you connect power?

KoDa

Sorry for the late reply. Here is the current status:

I checked, and unfortunately, there is only a solid orange LED on 6100.
I went through some older forum posts and tried several suggested fixes, such as removing the motherboard battery and performing a power button reset, but nothing has improved the situation
(the orange LED remains, and there is still no output on the console).
I am attaching a few photos showing the state of the small LEDs on the motherboard.

I haven't reached out to TAC yet, but I will do so shortly. However, looking through the archives, it seems to me that desoldering the Kingston chip might be my last resort.

stephenw10

Do both button stick 'click' when you press them? Neither is stuck down?

Yes open a TAC ticket and reference this thread.

KoDa

@stephenw10 said in Netgate 6100 - Installation failure after eMMC failure and no console output:

Do both button stick 'click' when you press them? Neither is stuck down?

Yes, both buttons "click" and seem to be working fine. To be honest, I hadn't really used them before because they are quite hard to reach when the router is mounted in a rack.

However, since the chassis is currently disassembled, I have easy access to them now