Dell PowerEdge R620 hang at 36%
I tried to install pfsense 2.0, 2.0.3, 2.1-beta but the installation always stops at 36% in step
/usr/local/bin/cpdup -vvv -l -o /usr/mnt/usr
Recommendations from http://forum.pfsense.org/index.php?topic=31907.0 did not work
Just to share my experience, I disabled network cards and all PCI slots from BIOS and got everything installed smoothly, then enabled everything back after first boot from local hard drive.
Are you using the 32-bit or 64-bit version of pfsense for your install? In case you are using the 32-bit version, give the 64-bit version a try to see if you can get any further. In case you are using the 64-bit version, I'm not sure why the R620 is hanging.
Disable all power management and set the system to only present a single CPU core. After the install is done you can put things back. If that doesn't work, do the install in a desktop and then move the drive over.
I had similar issues on Dell machines and ended up having to disable PCI slots during install, then re-enable them and pfsense will detect NICs and all is well.