Install OPNsense on ZyXEL USG Firewall

Started by k1ngf15h3r, March 18, 2024, 07:12:04 PM

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March 18, 2024, 07:12:04 PM
Hi everyone, I got an older ZyXEL USG40 from a customer and I am trying to install OPNsense on this hardware with the serial installer.

I have an USB RS232 Dongle and a Null Modem Cable. When I try to make a serial connection with putty or screen I only get a blank screen.

Any Ideas how to fix this?


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March 18, 2024, 09:06:42 PM #1
Baudrate is set to 115200


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March 18, 2024, 09:30:38 PM #2
What do the Zyxel docs say about the configuration of the serial console? Bitrate, HW handshake or not, ... shouldn't the system start into a visible self test and then possibly a boot selector? But then you possibly have to hit a key within such and such seconds after power on - every hardware is different and this is a Zyxel USG specific, not an OPNsense question.
Deciso DEC750
People who think they know everything are a great annoyance to those of us who do. (Isaac Asimov)
March 18, 2024, 09:33:28 PM #3
ZyXEL manual says to use bautrate about 115200 and only hit enter to login.

I know it is a ZyXEL topic but hopefully someone already installed OPNsense on this hardware [emoji6]


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March 18, 2024, 09:46:37 PM #4 Last Edit: March 18, 2024, 10:04:27 PM by Patrick M. Hausen
Do they mention anything about a pre boot setup, boot selector or some such? The "enter to login" probably refers to their software booted and running.
Deciso DEC750
People who think they know everything are a great annoyance to those of us who do. (Isaac Asimov)
March 18, 2024, 09:50:26 PM #5
Did not find anything about this. But also when the system is booted and accessible through web interface I can not get any output over serial with minicom, putty, screen and so on. Seems to be a big problem what I found on the net. Maybe wrong hardware for this project


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March 19, 2024, 02:28:55 PM #6
What processor does it have and is there a release for that CPU? I just watched a USG 50 teardown, that guy couldn't get serial to work either, but it had a MIPS processor inside.
March 19, 2024, 06:29:37 PM #7
Until now I could not find any cpu information. Will try to open the device tomorrow. But I think there is a general problem with this devices. Two usg40 and one usgflex100 are unable to give serial access. Tested same client serial access with an hp switch and a tplink switch without any problems


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