Fortigate Failed Firmware Update 5.6.2 to 5.6.3

[cprezalor]

Greetings all,  

We're trying to update our Fortigate D200 from v5.6.2 to v5.6.3.  When we do this, regardless of the method used to send the firmware (USB, web update / via web interface, boot and pull from USB) our fortigate hangs at "Firmware upgrade in progress ..." after it reboots and nothing else happens after that.  We've let it sit as long as 30 minutes and it does not progress past that point.  If we reboot, the system detects that the firmware update failed on the backup partition and proceeds with a normal boot process.

We've had a history of firmware update issues on this device and I wanted to check with the community here to see if anyone else has had similar issues with this update or the D200 in general, and if so, if anyone knew of anything else I should try to resolve the issue.  If there are also any diagnostics I should run that could give me more insight into the condition of the flash, or logs that could show me more details about the issue, that would be appreciated as well.  

Thanks kindly,

Charles Prezalor

[Toshi_Esumi · Accepted solution]

Do you see anything unusual in "diag hard device disk" and "diag sys flash list"? You should see two boot partitions and different versions if you upgraded before.

Then eventually you would end up formatting the boot drive and uploading the image from a TFTP server via boot menu (http://cookbook.fortinet.com/navigating-the-fortigate-bios/). Just make sure you backup the config.

[cprezalor]

Toshi,  

I believe that the TFTP formatting is going to end up being the way to go.  There doesn't appear to be an actual diagnostic for the flash itself.  It might take a little while for me to schedule another downtime window, but I'll try to remember to come back here and update with the results.