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While a pain the ass, are you able to rebuild your configuration from scratch?  P.S. I assume "secure boot" is off in the bios?

I'll check both and get back. I have a feeling that I did try to rebuild config from scratch last time I upgraded, but it's worth doing again since I have the hardware available now.

[The boot issue occurs after I restore my configuration, reboot (in order to apply it), and then reboot again]

All right, I've found myself with another HP Microserver gen8 and some spare time in order to better understand when the failure to boot occurs. It seems that after a clean install I can update, and reboot as many times I want, no issues at all. The boot issue occurs after I restore my configuration, reboot (in order to apply it), and then reboot again. This is how it looks this time around, on 23.1.4. Just to be clear, when I restore my configuration and reboot everything works fine, and the configuration has been restored and works with no issues, until the next reboot, where the system becomes unbootable.

I've been using OPNsense for a couple of years now without issue, running on my HP Microserver Gen8. After a certain version (//edit: I believe this started occurring after some 22.x.x update), I have the issue that OPNsense will consistently not boot. I'm attaching screenshots of where boot fails.

Just to be clear, a fresh install boots fine, I then import my config and reboot and that is fine too, and I'm up and running with my config working fine. At any subsequent point if I reboot, or update and reboot, I'm stuck at the point shown in the below screenshots. I have tried all 4 installation methods both on a sata ssd as well as a usb flash drive or sd card and unfortunately I get the same results.

So now I'm up and running on 23.1 but cannot update or reboot since I won't be able to and I'll have to reinstall from scratch. This has been quite time consuming; I'm very grateful to anyone who can give me any pointers as to why this is happening and how I can solve it!

Apologies if my description is a bit vague, every time this happens I'm rushing to restore connectivity.

@atxx is the gateway stable under 21.x?

I'll try downgrading and get back to you. I've had issues with 22.1.1 on the LAN side after reverting - vlan interfaces appeared as "down" (GUI) and were missing when running ifconfig -a. Any ideas how I can resolve that in order to downgrade to 21.x?

//edit: I ended up starting again from scratch, from 21.7.8. So far so good, I'll report back soon.

//edit2: Everything was stable on 21.7.8 for almost 24h, then I tried mac spoofing (to test something with the ISP) and the WAN interface started constantly flapping, again disrupting everything. Turning it off & restarting didn't resolve the issues. I noticed that the port was negotiating at 100BASE-TX and after cleaning all cable and port contacts with alcohol and compressed air, the interface is stable again and negotiating gbit speeds. I want to upgrade to 22.x just to check that the issue was with the cables/ports at some point.

Continuing from my last post, removing mac spoofing (after coordinating with the ISP), and disabling IPS does not solve the issue. Reverting to 22.1.1 does not solve the issue either. Reminder that my controller is a Broadcom BCM5720. I'm at a loss and not sure what to do as I've spent countless hours trying to solve this after upgrading to 22.1.7_1. My WAN interface keeps flapping every few minutes/hours. Any advice is welcome.

@Grossartig After I posted, I contacted my ISP and gave them my opnsense device's MAC address therefore I turned mac spoofing off. If the issue appears again I'll try turning IPS off and report back.

@tracerrx WAN

I registered in order to note that I'm experiencing this issue on Broadcom BCM5720 (Microserver Gen8) therefore this is probably not Intel specific as speculated.

I updated to 22.1.6 three days ago and my WAN interface started flapping next day.
After a restart it was fine, until two days later (today) when the flapping started happening again.
Issue still present on 22.1.7_1.

IPS is on, mac spoofing is active, and gateway monitor is disabled. ifdown/up doesn't solve the issue, I need to restart the device for this to get resolved; this issue is quite disruptive.

I do feel obliged to say that Opnsense has pretty much been smooth sailing up until now. Thank you for your good work!