Preparing flash for 6602

[Q-Ant]

Hi we have several 6602 switches that are starting to fail after reboot. The issue is mostly caused by the flash cards. If it is replaced with a card from another switch everything is OK, so nothing on the switch is damaged only the card is corupted.

What we are trying to do is to prepare a new flash card and replace the old one. We bought new card and copied all files but the switch can not boot from it. We tried making images from functional card and restoring them to the new card. We also tried cloning from one to another with multiple applications. No success, the switch does not even try to boot from this flash.

What is the correct procedure for preparing the CF card to be bootable for 6602 switches? What are we missing?

[Q-Ant]

This is the current situation: we've managed to replace the CF cards but only with the card of the same size, meaning if you have a 64MB CF card you must use a 64MB original. The same for 128MB. We didn't manage to put AOS on any other size of the CF card yet, which is a hassle because 64/128MB cards are very expensive and hard to get.

[KCler]

hello q-ant...

...i am currently dealing with the same story... 6602 device wont boot anymore after power cycle.

just says;

usrRoot(): COLD Boot. sectors...
usrRoot(): Booting miniboot from flash boot sectors...

on and on.... have tried several cfs; 32MB (which was in) other ones.... even that the flash doesn't seem to be broken. did you make any progress meanwhile ?... i'm out of ideas... it is even the same situation when there is no card inserted...

thanks for any hints guys

[Q-Ant]

on and on.... have tried several cfs; 32MB (which was in) other ones.... even that the flash doesn't seem to be broken. did you make any progress meanwhile ?... i'm out of ideas... it is even the same situation when there is no card inserted...

When you use a flash card from another valid unit will the switch boot?

If it won't boot with a valid card from another unit then the switch is damaged (we had this issues once or twice), send it for repair.

If it boots with a card from another unit then you are not preparing the new CF the right way. You can not just copy and paste the files, you need to create the image from existing valid card and copy it to new card. We used "dd" under Linux.

[KCler]

sorry double post

[KCler]

hello q-ant; it did boot with a card from a working 6602. (and vice versa) so there is definitely smth wrong with the cf (smth logically i guess)

the dd clone you mentioned will be my next try. unfortunately i've no spare 6602, my spare is now working there
...so i have to wait for the right time to extract the image. I'll tell you if it worked out...

did you clone the card on bigger ones ? (like on a 64 / 128 MB with keeping the partition size) ....does this work ? of course you know the problem getting 32MB cards

greetz

[Q-Ant]

hello q-ant; it did boot with a card from a working 6602. (and vice versa) so there is definitely smth wrong with the cf (smth logically i guess)

You can copy the flash contents from working device and just try to copy them on the problematic card (you may want/need to format the card before). It is very unlikely that this is help as it will resolve only issues with damaged files. If the card itself is damaged then this obviously won't be of any help. It is only 5 minutes of work so you should try it.

did you clone the card on bigger ones ? (like on a 64 / 128 MB with keeping the partition size) ....does this work ? of course you know the problem getting 32MB cards
greetz

No, we were not able to successfuly clone a 32MB to a 64MB although we used the same partition and everything. It should work but it doesn't and nobody had an explanation.

We were only successful in copying 32MB->32MB and 64MB->64MB. No other combinations worked. (we tried 32->128, 64->128 and also 32->64, none of it worked).