Hello,
today I've tried to install the special build of pfSense based on FreeBSD 6.3, 
because the 'Full install' version showed several wireless improvement on an 
old atx computer with an Atheros wifi pci card.
I have to say I'm using ALIX with pfSense-1.2rc4 since February 2008 
successfully. When I bought this box I had to update its BIOS to v.0.99 and it 
works great.
Once reflashed with new firmware, the Alix box is able to boot, but it enters 
in an endless question loop, because it seems to be some problem regarding 
network interfaces as you can see:

[---CUT---]

Creating symlinks......done.
Launching PHP init system... done.
Initializing.................. done.
Starting device manager (devd)...done.
Loading configuration......done.

Network interface mismatch -- Running interface assignment option.

Valid interfaces are:

vr0     XX:XX:XX:XX:XX:XX
vr1     XX:XX:XX:XX:XX:XX
vr2     XX:XX:XX:XX:XX:XX
ath0    XX:XX:XX:XX:XX:XX

Do you want to set up VLANs first?
If you are not going to use VLANs, or only for optional interfaces, you should 
say no here and use the webConfigurator to configure VLANs later, if required.

Do you want to set up VLANs now [y|n]?

[---CUT---]

I answer no by pressing 'n' and I hit enter, but it always asks the same 
question. I'm forced to switch off power and reflash the old CF's content.

What does "Network interface mismatch -- Running interface assignment option" 
exactly mean?
Alix box has "VIA VT6105M Rhine III" with three 10/100 ethernet ports as 
onboard network card.
I've also tried to install latest snapshots, including 
'pfSense-20080709-1940.img.gz', but the same problem happens anyway.
I'm used to do CF dump when I'm going to install new builds, so that I easily 
restored the old content (pfSense 1.2rc4) and now the Alix board is working 
well again.
As far as you know, is there any known problem with latest builds?
Are you able to install and correctly use latest snapshot (pfSense 1.2.1) on an 
Alix board?

To troubleshoot I've saved system messages during booting and compared them:

[pfSense 1.2rc4 (it is old but working well)]
vr0: <VIA VT6105M Rhine III 10/100BaseTX> port 0x1000-0x10ff mem 
0xe0000000-0xe00000ff irq 10 at device 9.0 on pci0
vr0: Ethernet address: 00:0d:b9:13:4a:6c
vr1: <VIA VT6105M Rhine III 10/100BaseTX> port 0x1400-0x14ff mem 
0xe0040000-0xe00400ff irq 11 at device 10.0 on pci0
vr1: Ethernet address: 00:0d:b9:13:4a:6d
vr2: <VIA VT6105M Rhine III 10/100BaseTX> port 0x1800-0x18ff mem 
0xe0080000-0xe00800ff irq 12 at device 11.0 on pci0
vr2: Ethernet address: 00:0d:b9:13:4a:6e


[pfSense 1.2.1]
vr0: <VIA VT6105M Rhine III 10/100BaseTX> port 0x1000-0x10ff mem 
0xe0000000-0xe00000ff irq 10 at device 9.0 on pci0
vr0: Quirks: 0x2
vr0: using obsoleted if_watchdog interface
vr0: Ethernet address: 00:0d:b9:13:4a:6c
vr0: [ITHREAD]
vr1: <VIA VT6105M Rhine III 10/100BaseTX> port 0x1400-0x14ff mem 
0xe0040000-0xe00400ff irq 11 at device 10.0 on pci0
vr1: Quirks: 0x2
vr1: using obsoleted if_watchdog interface
vr1: Ethernet address: 00:0d:b9:13:4a:6d
vr1: [ITHREAD]
vr2: <VIA VT6105M Rhine III 10/100BaseTX> port 0x1800-0x18ff mem 
0xe0080000-0xe00800ff irq 12 at device 11.0 on pci0
vr2: Quirks: 0x2
vr2: using obsoleted if_watchdog interface
vr2: Ethernet address: 00:0d:b9:13:4a:6e
vr2: [ITHREAD]

Something seems to go wrong, but I don't know what 
'quirks','ITHREAD','obsoleted if_watchdog' mean.
Have you got the chance to try latest embedded snapshots on your ALIX hardware?

Hope to be useful

Regards


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