opnsense / opnsense/src

Excessive wear on flash devices on dell server r640

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Dominant language
C
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Description

Important notices

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Describe the bug

I'm running a few clusters of OPNsense firewalls on dell r640 servers.
While the installation is stable, I've had some hardware failures triggered by the upgrade process. Once the server reboots, it is unable to start due to a hardware failure.
After contacting dell support and having a replacement part shipped, they've pointed a reported bug on the mfi driver that seems to be present at least since 12.1.
Bug reported upstream here: https://bugs.freebsd.org/bugzilla/show_bug.cgi?id=248352

To Reproduce

We've been able to verify this behavior when upgrading majors. (major version 24 to major version 25, major version 25 to major version 26)

Expected behavior

Upgrades not failing due to early hardware failure.

Describe alternatives you considered

Is it possible to make this patch available to users impacted by this corner case?

Environment

Software version used and hardware type if relevant, e.g.:

OPNsense 26.1.2 (amd64).
Intel(R) Xeon(R) Bronze 3206R CPU @ 1.90GHz (8 cores, 8 threads)
Broadcom BCM57416 NetXtreme-E 10GBase-T Ethernet
dell servers running latest firmware available

Contributor guide

Open the contributing guide

First steps

  1. Read the whole issue, then the project's contributing guide.
  2. Comment on the issue to say you are picking it up — it saves two people doing the same work.
  3. Fork the repository and make your change on a branch.
  4. Open a pull request that references the issue number.

Research direction

Start with upstream FreeBSD bug 248352 and the mfi driver involved in Dell R640 upgrades. Confirm how the reported patch relates to OPNsense and define done as making the fix available without upgrade-triggered hardware failure.

Written by the indexing model from the issue text.

Assessment

Tech stack
c
Domain
operating-systems
Issue type
Bug
Difficulty
4/5
Estimated time
3-5 days
Activity status
Stale
Clarity
Needs clarification
Newbie friendliness
25/100

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