Firmware Upgrade to 6.1 failed - no WEB If **solved**

[jochen.richert]

Hello
I tried to upgrade my mbpro (red) to 6.0 by rebooting the device 3 or 4 times. This did not work.
Today I saw, there is a 6.1 and I've done a reboot again. The upgrade started, but after a while I did not get a WEB IF, only the landing page and now I have a Bad Gateway message after trying a few things.
/cgi-bin/luci is still running.

I have done the following:
SSH into the device and started the start.sh which always ended with a tar: write error: No space left on device.
Replaced temporarily the original USB stick with a larger one and started start.sh again, the same error.
Low level formatted the original USB stick, started the device again and started start.sh.

root@MeteoBridge:~# df -h
Filesystem Size Used Available Use% Mounted on
rootfs 9.1M 436.0K 8.7M 5% /
/dev/root 5.5M 5.5M 0 100% /rom
tmpfs 30.0M 11.9M 18.1M 40% /tmp
/dev/mtdblock5 9.1M 436.0K 8.7M 5% /overlay
overlayfs:/overlay 9.1M 436.0K 8.7M 5% /
tmpfs 512.0K 0 512.0K 0% /dev
/dev/sda 928.4M 19.5M 844.9M 2% /tmp/mnt

root@MeteoBridge:~# pwd
/root
root@MeteoBridge:~# ./start.sh
HW: Carambola2
MAC: C4:93:00:1E:52:2F
USB stick /dev/sda1 detected
meteobridge pro storage: /dev/sda
Internet available
download application stack
tar: write error: No space left on device
sh: can't open '/home/setup.sh'
root@MeteoBridge:~#

During the script is running, I've done some DF -h on a second SSH session.
You can see, /tmp is growing up to 100% and the script ends with the error message No space left on device.
It seems, that the automatic partitioning process creates a too small tmp partion/mount.

root@MeteoBridge:~# df -h
Filesystem Size Used Available Use% Mounted on
rootfs 9.1M 440.0K 8.7M 5% /
/dev/root 5.5M 5.5M 0 100% /rom
tmpfs 30.0M 19.5M 10.6M 65% /tmp
/dev/mtdblock5 9.1M 440.0K 8.7M 5% /overlay
overlayfs:/overlay 9.1M 440.0K 8.7M 5% /
tmpfs 512.0K 0 512.0K 0% /dev
/dev/sda 928.4M 19.5M 844.9M 2% /tmp/mnt
root@MeteoBridge:~# df -h
Filesystem Size Used Available Use% Mounted on
rootfs 9.1M 440.0K 8.7M 5% /
/dev/root 5.5M 5.5M 0 100% /rom
tmpfs 30.0M 16.0M 14.0M 53% /tmp
/dev/mtdblock5 9.1M 440.0K 8.7M 5% /overlay
overlayfs:/overlay 9.1M 440.0K 8.7M 5% /
tmpfs 512.0K 0 512.0K 0% /dev
/dev/sda 928.4M 19.5M 844.9M 2% /tmp/mnt
root@MeteoBridge:~# df -h
Filesystem Size Used Available Use% Mounted on
rootfs 9.1M 440.0K 8.7M 5% /
/dev/root 5.5M 5.5M 0 100% /rom
tmpfs 30.0M 11.9M 18.1M 40% /tmp
/dev/mtdblock5 9.1M 440.0K 8.7M 5% /overlay
overlayfs:/overlay 9.1M 440.0K 8.7M 5% /
tmpfs 512.0K 0 512.0K 0% /dev
/dev/sda 928.4M 19.5M 844.9M 2% /tmp/mnt
root@MeteoBridge:~# df -h
Filesystem Size Used Available Use% Mounted on
rootfs 9.1M 440.0K 8.7M 5% /
/dev/root 5.5M 5.5M 0 100% /rom
tmpfs 30.0M 30.0M 0 100% /tmp
/dev/mtdblock5 9.1M 440.0K 8.7M 5% /overlay
overlayfs:/overlay 9.1M 440.0K 8.7M 5% /
tmpfs 512.0K 0 512.0K 0% /dev
/dev/sda 928.4M 19.5M 844.9M 2% /tmp/mnt
root@MeteoBridge:~# df -h
Filesystem Size Used Available Use% Mounted on
rootfs 9.1M 440.0K 8.7M 5% /
/dev/root 5.5M 5.5M 0 100% /rom
tmpfs 30.0M 30.0M 0 100% /tmp
/dev/mtdblock5 9.1M 440.0K 8.7M 5% /overlay
overlayfs:/overlay 9.1M 440.0K 8.7M 5% /
tmpfs 512.0K 0 512.0K 0% /dev
/dev/sda 928.4M 19.5M 844.9M 2% /tmp/mnt

Thanks for any ideas, I could try...
Jochen

[admin]

It turns out that latest version is too big to fit into ramdisk during download on startup.
I set back to 6.0 preliminary. I will make the 6.1 feature available again, when root cause is fixed.

Sorry for any inconvenience!

[jochen.richert]

OK, thanks for the info, that's what I thought.
My device is now up and running again on 6.0...

Many thanks
Jochen

[admin]

To give a bit more background what happened: I updated my toolchain (which is necessary from time to time) and that also brought a new version of the archive tool "tar" with it. New "tar" makes use of a newer archive format as default. This is not a big deal, but the firmware on Meteobridge PRO makes use of an older version "tar" (being part of busy box) and this is not able to handle the new format. As a result extraction of the downloaded application stack failed during boot and by that the Meteobridge cannot start correctly.

I fixed this by giving new "tar" the -Hgnu option when creating the archive. That way the application stack gets "tared" into a more backward compatible format and all skies are blue again.

All this is a reminder to me to do tests on various platforms when anything in build chain has chained and not to assume that "it will be fine" when being tested ok one one platform.

Sorry for the inconvenience this might have caused.

[admin]

After a reboot your systems will no be back to current version 6.1.

[jochen.richert]

No Problem, this could and will ever happend again. When you think, it must work, it willn ot It happened also often to me....

Just done a test, it works Upgraded to 6.1 ....
Many thanks for the quick support and enjoy the weekend

Jochen