Firewall is failing to reboot [UPDATED]

[allenlook]

Been running 25.7.1_1 for a few days and it has been OK, everything working. [Update, now also same problem with 25.7.3_7]

Overnight, the router stopped responding, and WiFi computers could not connect to the Internet or to the router's Web GUI.  DHCP was not working and hard-coded IPs were unsuccessful.

A reboot of the router failed while headless, again.

Attaching a monitor and keyboard allowed the firewall to reboot and everything is working again at the moment.

No indication why it died like that, or why it won't reboot headless now that 25.7+ is installed.

[bamf]

So it's working only when a monitor is attached? Maybe you need an HDMI dummy plug.

[allenlook]

It works fine once booted, and prior to 25.7 it always ran and rebooted while headless.

Since the upgrade to 25.7 I've had to reboot it twice (once as part of the upgrade and again today), and each time it failed to reboot until I connected a monitor and keyboard to it.

[allenlook]

Yesterday, one of my reverse proxy services stopped working.  As part of the troubleshooting I restarted Caddy and Unbound DNS, but that did not help, so I then used the GUI to reboot the firewall, and it did not come back up, again.

Since the problems with reboots mentioned earlier in this thread I have installed a KVM with full-time EDID, thinking the box might not like being headless.

The firewall had the power button illuminated, but nothing would come up on the monitor.  I pressed the button quickly and the light extinguished (usually you have to hold it for a while to get the box to shutdown / power cycle, I thought).  Then I pressed it again and the box booted normally.

Not sure what else to do in troubleshooting this issue, but the box is set to boot on power failure, and it's not been a problem prior to 25.7 series.

[BrandyWine]

Sudden hard reboots, like a forced shutdown from overtemp, is not good for most filesystems.
Is it on ZFS?
If so try scheduling a ZFS scrub on zroot from cron section in gui, or manually run it.

In Lobby what does your mem usage look like?

v..1_1 ? Why not v..3_7 ?

[allenlook]

Thank you for responding.  Memory utilization runs in the low 30% range, and ZFS has been installed from day 1.

Good catch, I am running 25.7.3_7 now (and for about a week), but I was running 1_1 back when I started this thread on 8/22.

Zpool scrub reports 0 errors and 0 blocks repaired.

[BrandyWine]

Start looking at things like dmesg, look for errors.
So the issue you posted on Sept 24th is on OPNsense 25.7.3_7, but you didn't mention that.

If i were to guess, it's a hardware problem. Maybe re-seat your SSD and mem module(s).

[allenlook]

RAM is soldered on, so that's not going to be possible.  Maybe I'll look at the SSD at some point, but if it reboots by button and not by system "restart" command that doesn't feel like a hardware issue to me?