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I've experienced this same issue in several locations on several version of firmware since 02/02/2022.

I have yet to find a fix, ZenArmor is install across all devices. I'll run a diagnostic test here: I'll uninstall ZenArmor on 2 firewalls, reinstall on 2 firewalls, and leave it on 2 firewall and I'll let you know if the crashes stop.

All firewalls are identical hardware. This ZenArmor fix looks promising :)

Thanks so much,
Maybe a stupid question, but how can I apply this?

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[21-Apr-2022 07:03:47 America/Los_Angeles] Exception: Error at /usr/local/opnsense/mvc/app/controllers/OPNsense/Base/ApiControllerBase.php:87 - array_multisort(): Array sizes are inconsistent (errno=2) in /usr/local/opnsense/mvc/app/controllers/OPNsense/Base/ApiControllerBase.php:155
Stack trace:
#0 [internal function]: OPNsense\Base\ApiControllerBase->APIErrorHandler(2, 'array_multisort...', '/usr/local/opns...', 87, Array)
#1 /usr/local/opnsense/mvc/app/controllers/OPNsense/Base/ApiControllerBase.php(87): array_multisort(Array, 4, 6, Array)
#2 /usr/local/opnsense/mvc/app/controllers/OPNsense/IPsec/Api/TunnelController.php(253): OPNsense\Base\ApiControllerBase->searchRecordsetBase(Array)
#3 [internal function]: OPNsense\IPsec\Api\TunnelController->searchPhase2Action()
#4 [internal function]: Phalcon\Dispatcher\AbstractDispatcher->callActionMethod(Object(OPNsense\IPsec\Api\TunnelController), 'searchPhase2Act...', Array)
#5 [internal function]: Phalcon\Dispatcher\AbstractDispatcher->dispatch()
#6 /usr/local/opnsense/www/api.php(26): Phalcon\Mvc\Application->handle('/api/ipsec/tunn...')
#7 {main}
[21-Apr-2022 07:03:53 America/Los_Angeles] Exception: Error at /usr/local/opnsense/mvc/app/controllers/OPNsense/Base/ApiControllerBase.php:87 - array_multisort(): Array sizes are inconsistent (errno=2) in /usr/local/opnsense/mvc/app/controllers/OPNsense/Base/ApiControllerBase.php:155
Stack trace:
#0 [internal function]: OPNsense\Base\ApiControllerBase->APIErrorHandler(2, 'array_multisort...', '/usr/local/opns...', 87, Array)
#1 /usr/local/opnsense/mvc/app/controllers/OPNsense/Base/ApiControllerBase.php(87): array_multisort(Array, 4, 6, Array)
#2 /usr/local/opnsense/mvc/app/controllers/OPNsense/IPsec/Api/TunnelController.php(253): OPNsense\Base\ApiControllerBase->searchRecordsetBase(Array)
#3 [internal function]: OPNsense\IPsec\Api\TunnelController->searchPhase2Action()
#4 [internal function]: Phalcon\Dispatcher\AbstractDispatcher->callActionMethod(Object(OPNsense\IPsec\Api\TunnelController), 'searchPhase2Act...', Array)
#5 [internal function]: Phalcon\Dispatcher\AbstractDispatcher->dispatch()
#6 /usr/local/opnsense/www/api.php(26): Phalcon\Mvc\Application->handle('/api/ipsec/tunn...')
#7 {main}

I received this error after creating, then deleting an IPSec tunnel after updating to 22.1, I have since updated again to 22.1.6 in an attempt to fix this error but it has persisted. Has anyone encountered this before? Our existing tunnels still seem to work, yet I get the pop up error above whenever I attempt to make changes, create new tunnels, etc.

I can create phase 1 tunnels without issue, however I am unable to view, or edit any phase 2 tunnels. I can create a phase 2 tunnel but it does not show up on the ipsec page, and in status overview I am unable to see the phase 2 part of the tunnel I just created.

Here is my system info.

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User-Agent Mozilla/5.0 (Windows NT 10.0; Win64; x64) AppleWebKit/537.36 (KHTML, like Gecko) Chrome/99.0.4844.84 Safari/537.36 OPR/85.0.4341.60
FreeBSD 13.0-STABLE stable/22.1-n248071-cafeb6ce414 SMP amd64
OPNsense 22.1.6 42de9d6d9
Plugins os-dyndns-1.27_3 os-openconnect-1.4.2 os-sensei-1.11.1 os-sensei-updater-1.11 os-sunnyvalley-1.2_1 os-zabbix-agent-1.11
Time Thu, 21 Apr 2022 07:09:09 -0700
OpenSSL 1.1.1n  15 Mar 2022
PHP 7.4.28