Here's what the tail of boot messages from serial console says:

speaker0: <PC speaker> at port 0x61 on isa0
unknown: <PNP0c01> can't assign resources (memory)
unknown: <PNP0c02> can't assign resources (memory)
unknown: <PNP0501> can't assign resources (port)
unknown: <PNP0401> can't assign resources (port)
unknown: <PNP0501> can't assign resources (port)
ugen0: American Power Conversion Back-UPS CS 650 FW:817.v2.I USB FW:v2, rev 
1.10/0.06, addr 2
Timecounter "TSC" frequency 1002277921 Hz quality 800
Timecounters tick every 1.000 msec
Fast IPsec: Initialized Security Association Processing.
ad0: FAILURE - SETFEATURES SET TRANSFER MODE status=51<READY,DSC,ERROR> 
error=4<ABORTED>
ad0: 244MB <TOSHIBA THNCF256MMA 3.10> at ata0-master BIOSPIO
GEOM_LABEL: Label for provider ad0a is ufs/pfSense.
GEOM_LABEL: Label for provider ad0d is ufs/pfSenseCfg.
Trying to mount root from ufs:/dev/ufs/pfSense
WARNING: / was not properly dismounted
init died (signal 6, exit 0)
panic: Going nowhere without my init!
Uptime: 1s
Cannot dump. No dump device defined.
Automatic reboot in 15 seconds - press a key on the console to abort


----- Forwarded message from Eugen Leitl <[EMAIL PROTECTED]> -----

From: Eugen Leitl <[EMAIL PROTECTED]>
Date: Mon, 27 Aug 2007 12:27:40 +0200
To: [EMAIL PROTECTED]
Subject: Re: [pfSense Support] i just can't succeed in upgrading anymore...
User-Agent: Mutt/1.5.13 (2006-08-11)

On Sun, Aug 26, 2007 at 05:27:18PM -0400, Vivek Khera wrote:
> I don't know if my fingers are emitting some radiation that makes it  
> fail, but the last three upgrades I've attempted have all ended in  
> disaster, requiring a re-flash and restore on my WRAP boxes.

I don't think it's you. I've just tried a remote upgrade from 1.2-RC1
embedded on a mini-ITX to 1.2-RC2, and it probably didn't succeed (haven't 
powercycled the system yet -- so one of my firewalls is now h0sered).

Interim:

# df -k
Filesystem          1K-blocks   Used Avail Capacity  Mounted on
/dev/ufs/pfSense       113755 113260 -8605   108%    /
devfs                       1      1     0   100%    /dev
/dev/md0                39406   1472 34782     4%    /tmp
/dev/md1                19566   5006 12996    28%    /var
/dev/ufs/pfSenseCfg      1871    473  1249    27%    /cf
devfs                       1      1     0   100%    /var/dhcpd/dev

# df -k
elf_load_section: truncated ELF file
ELF interpreter /libexec/ld-elf.so.1 not found
Abort

# top was showing 

# top

last pid: 86040;  load averages:  2.69,  1.29,  0.53                            
                       up 2+22:38:39  12:08:03
39 processes:  3 running, 34 sleeping, 2 zombie
CPU states:  0.0% user, 34.0% nice, 66.0% system,  0.0% interrupt,  0.0% idle
Mem: 70M Active, 88M Inact, 79M Wired, 360K Cache, 58M Buf, 241M Free
Swap: 

  PID USERNAME  THR PRI NICE   SIZE    RES STATE    TIME   WCPU COMMAND
  617 root        1  -8   20  2288K  1724K piperd   2:41 16.89% sh
  416 root        1   4    0  3700K  2816K kqread   1:27  0.00% lighttpd
  533 root        1  96    0  2876K  2288K select   0:36  0.00% racoon
35288 root        1   4    0 20416K 17716K accept   0:35  0.00% php
  424 root        1   4    0 23068K 21080K accept   0:24  0.00% php
29977 root        1   4    0 20736K 18528K accept   0:06  0.00% php
 3640 root        1 116   20  3064K  2560K select   0:04  0.00% sshd
 7828 root        1 -58    0  3712K  1720K bpf      0:03  0.00% tcpdump
  229 root        1  96    0  1440K  1068K select   0:02  0.00% syslogd
 1246 root        1   8   20  1272K   720K nanslp   0:02  0.00% 
check_reload_status
35708 root        1   4    0 20480K 17800K accept   0:02  0.00% php
 4675 _ntp        1  96    0  1340K  1052K select   0:02  0.00% ntpd
  718 root        1   8    0  1384K  1032K nanslp   0:01  0.00% cron
 4639 dhcpd       1  96    0  2216K  1828K select   0:01  0.00% dhcpd
47807 root        1  96    0  2432K  1636K RUN      0:01  0.00% top
 4677 root        1  96    0  1376K  1048K select   0:00  0.00% ntpd
  749 root        1   8    0  1268K   732K nanslp   0:00  0.00% minicron
46674 root        1 116   20  5748K  2764K RUN      0:00  0.00% sshd
  343 root        1  -8    0  1268K   660K piperd   0:00  0.00% sshlockout_pf
  438 root        1   8    0 14200K  4712K wait     0:00  0.00% php
46796 root        1  20    0  4652K  3636K pause    0:00  0.00% tcsh
  437 root        1   8    0 14200K  4712K wait     0:00  0.00% php
  425 root        1   8    0 14200K  4712K wait     0:00  0.00% php
  417 root        1   8    0 14200K  4712K wait     0:00  0.00% php
  757 root        1   8    0  1712K  1352K wait     0:00  0.00% login
  758 root        1   8    0  1712K  1352K wait     0:00  0.00% login
46691 root        1   8    0  1720K  1180K wait     0:00  0.00% sh
46692 root        1   8    0  1728K  1188K wait     0:00  0.00% sh
  760 root        1   5    0  1724K  1140K ttyin    0:00  0.00% sh
  764 root        1   5    0  1724K  1140K ttyin    0:00  0.00% sh
  762 root        1   8    0  1720K  1136K wait     0:00  0.00% sh
  759 root        1   8    0  1720K  1136K wait     0:00  0.00% sh
  128 root        1  96    0   504K   352K select   0:00  0.00% devd
 4614 nobody      1 102    0  1448K  1100K select   0:00  0.00% dnsmasq
 7829 root        1  -8    0  1272K   708K piperd   0:00  0.00% logger

-- notice that bsdtar seems to have already crashed here, it was
running in the top before:

46641 root        1  -8    0  1744K  1356K biowr    0:04  0.00% bsdtar

Looks like it's running out of flash space. Just powercycled the box, 
hasn't come up so far. Oh well, I have still the other firewall
running.

We definitely need to get away from fixed partition size on the
embedded. A way to grow the filesystem would seem to be required,
or at least images which can handle larger flash cards (1 GByte CF
is a dime a dozen these days). It's too bad there's no vanilla CF
which can take a real r/w filesystem.
 
> My prior upgrade brought my personal firewall up to the July 29  
> snapshot.  This was an upgrade from an early-june snapshot.  This one  
> I upgraded by uploading the firmware upgrade file, then running the  
> rc.firmware upgrade script.  It ran out of disk space and destroyed  
> some key files so it was basically bricked ;-(  I flashed the  
> firmware to the July 29 snapshot and went on my business...
> 
> Then last night I decided to upgrade this box to RC2.  The web-based  
> upgrade seemed to do nothing -- the browser kept timing out or  
> getting network disconnects.  It was strange.  So I uploaded the  
> firmware to the /tmp MFS partition.  About 80% into the upload, the  
> console showed a kmem_malloc panic and rebooted.  So then I uploaded  
> the firmware to the /root directory.  I ran the command line upgrade  
> from the main menu, but after a while started getting disk full  
> errors again.  Since I was still up and running, I tried to move the  
> firmware file to /tmp and re-run it, but after the move when I did an  
> "ls -l" the system again rebooted on kmem_malloc panic.   
> Unfortunately it scrolled off the history buffer of my console window  
> so I don't have the exact message.  Once again, I had to flash the  
> firmware and restore.
> 
> 
> Last week I upgraded another WRAP which was a late June snapshot to  
> bring it to the RC2.  The web-based upgrade seemed to do nothing.  I  
> got the "this is not signed" warning, clicked upgrade, and then a few  
> minutes later it rebooted with no changes to the system (still  
> reported old version.)  So then I tried the manual route of uploading  
> the file and running the rc.firmware script.  Again, it gave disk  
> full errors, and destroyed the system (the elf loader was corrupted,  
> so there was no recovering...)
> 
> Anyhow, I know others have successfully upgraded embedded versions,  
> but I have not been able to do so for at least the last 4 upgrades  
> I've attempted.
> 
> Has anyone else experienced similar troubles upgrading embedded pfsense?
> 
> 
> ---------------------------------------------------------------------
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-- 
Eugen* Leitl <a href="http://leitl.org";>leitl</a> http://leitl.org
______________________________________________________________
ICBM: 48.07100, 11.36820 http://www.ativel.com http://postbiota.org
8B29F6BE: 099D 78BA 2FD3 B014 B08A  7779 75B0 2443 8B29 F6BE

----- End forwarded message -----
-- 
Eugen* Leitl <a href="http://leitl.org";>leitl</a> http://leitl.org
______________________________________________________________
ICBM: 48.07100, 11.36820 http://www.ativel.com http://postbiota.org
8B29F6BE: 099D 78BA 2FD3 B014 B08A  7779 75B0 2443 8B29 F6BE

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