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Up and running with the new hardware, and no crashes in over 48 hours  ;D  Plus, the CPU temps have barely crested 50 C and the unit doesn't feel hot to the touch (like the FW4B did).

Everyone raves about Protectli, but after my experience I feel like their hardware may not be all it's cracked up to be. For about the same price point, I think the Zotac is a higher quality machine.

Thanks again for everyone's assistance! Hopefully this thread will help out someone else in the future.

After about two days with pfSense, the crashes continue :-[. Sometimes I'll get a kernel panic, and sometimes it just randomly reboots itself without any error logging. So at this point I can confidently say that it's the hardware. Lame!

if you have the same problem with pfsense the power supply might be the problem. It might be sensitive to "noise" on the grid. I would suggest a "online" UPS since that will output nice and clean power if working properly.

Thanks for the tip! I will check that out.

In case anyone is curious, my replacement will be a Zotac C1329 nano. It has some bells and whistles that I don't really need, and it only has 2 ethernet jacks, but otherwise it looks like a promising piece of hardware.

I'll report back on this thread once I get it up and running (it will arrive tomorrow).

I really appreciate everyone's insight and suggestions. Unfortunately, after about 8 days of uptime, the crashing has resurfaced with a vengeance and it's time to throw in the towel :(

Originally thinking that it was a hardware issue, here's a summary of everything I tried:

• three different brand-new drives; Transcend, then Dogfish, and now Kingston
• two different memory sticks: Patriot and now PNY
• replaced the entire FW4B unit itself, thanks to Protectli's great customer service
• added a USB-powered fan to cool the unit's heat sinks
• switching to an electrical outlet which I confirmed had a good ground
• powerd off and on
• many, many permutations of opnsense's settings

Unfortunately, I can't spend the rest of my life debugging this issue, so I've currently "gone to the dark side" and am testing out pfSense right now. At lease this will give me a good indication of if it's software or hardware. I'm bummed because

• I was never able to fully diagnose and resolve this issue and
• there are some features of opnsense that I like a lot better - especially the UI

I'll report back if I find that pfSense exhibits the same problem. Thanks again.

Quick update: I'm cautiously optimistic that enabling powerd has resolved the issue for me.

Since I turned on powerd (System > Settings > Miscellaneous) about 3 days ago, I haven't had a crash. And that's in my un-airconditioned house during the current heat wave here in Southern California.

Weirdly, the CPU core temps are now up to the mid 60s (Celsius), which is still very safely within their max temp of 90. I originally enabled powerd thinking that maybe it would cool down the system by reducing CPU freq and voltage.

So while the cause(es) of the crashing are still unknown, I'm hopeful that maybe I stumbled upon a solution? Will report back with further updates.

Thanks! I'm also suspicious of a hardware problem.

1. Overheating.  Is there sufficient space around it for cooling?  Nothing on top?  Is the heatsink up?  Try aiming a fan of some sort at the unit, see if that makes a difference.

There's plenty of air space around the unit, though maybe this weekend I'll rig up a fan to blow onto it directly. My dashboard shows that the CPUs are idling around 50 deg C (at the most).

2. Bad RAM.  Download memtest86 and write it to a USB drive then let it run for a couple of hours.  Any reported RAM faults is cause to swap the RAM out.

I agree that the RAM could be to blame. Yesterday I picked up a new 8 GB stick (different brand) and installed it. No issues as of yet, but I think running memtest is a wise idea and I'll do that this weekend.

I'll report back with any updates. Thanks again for weighing in! If anyone else has any suggestions - please feel free to share.

Hello!

Almost once a day, my OPNsense 21.1.4 installation crashes and becomes 100% unresponsive. I have to pull the power plug and reboot to get it working again. I'm new to OPNsense and FreeBSD, so I'm a little bit clueless as to how to chase down the problem. Help?

This is running on a Protectli FW4B. From my latest crash report:

   
• system information
• dmesg.boot
• /var/crash/info.0
• /var/crash/textdump.tar.0
• config.xml

My goal is, of course, to stop these crashes and get this thing to just run smoothly. Appreciate any ideas, suggestions, or guidance. Thanks