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Fixing a RV042

Discussion in 'Cisco Small Business Routers and VPN Solutions' started by Sfor, Aug 1, 2011.

  1. Sfor

    Sfor Network Guru Member

    I do have two damaged RV042 units. One does blink with the DIAG led constantly, the other does not.

    I did replace the elecrolytic capacitors, so the problem must be comming from somewhere else.

    - both devices do respond to ping on LAN side to 192.168.1.1.
    - It is possible to connect through HTTP. But, device just wants to download a firmware through here. In any case the procedure does nothing. After uploading firmware, device resets, and there is no apparent change in how it works.
    - It is possible to telnet to the device boot loader.

    Is it possible to test the device somehow? For example: Why, the system does not boot, or Is the flash working correctly?
     
  2. Toxic

    Toxic Administrator Staff Member

    There is a TFTP recovery utility for the RV042 when the Flash gets corrupted.

    can only find the v3 utility on Ciscos website though, will ask a few cisco contacts...
     
  3. Toxic

    Toxic Administrator Staff Member

  4. Toxic

    Toxic Administrator Staff Member

  5. Sfor

    Sfor Network Guru Member

    The TFTP utility changed nothing. After a successful firmware upgrade, the both routers failed to boot.

    It is possible to boot both routers using telnet. At the SME boot prompt after running command "boot -s 2" routers are loading the firmware. The standard WEB management pannels are available, then. But they refuse to boot by themselves when reseted, rebooted or power cycled. So, no change. I was able to confirm the 1.3.7.2 firmware was flashed, however.
     
  6. Toxic

    Toxic Administrator Staff Member

    the only thing i can suggest if they are still under warranty (5 year warranty afaik with RV042's) is to RMA them.
     
  7. Sfor

    Sfor Network Guru Member

    Too late for that, I did replace the capacitors, I'm afraid.

    Also, I was unaware, it is possible to force boot the devices through telnet. So, I did factory reset, before retrieving the config data. It took me quite a while to enter all static DHCP entries, tunnel settings and such.
     
  8. Toxic

    Toxic Administrator Staff Member

    so are you able to access the router at all once rebooted? do ports enable? take it your webgui though doesn't load?
     
  9. Sfor

    Sfor Network Guru Member

    Yes. I can access the router through HTTP (only firmware upgrade screen), telnet (SME boot prompt) and TFTP. The LAN ports are working.

    Also, on the RV042-EU box there is a sticker with "2-Year limited Warranty" on it. Funny thing is, both damaged routers were made at 03/2008. So, I doubt the 5 year warranty would apply to my case.
     
  10. Toxic

    Toxic Administrator Staff Member

    could you do a screen shot of the HTTP firmware upgrade page.

    Thanks.
     
  11. Sfor

    Sfor Network Guru Member

    Here is the screenshot.
     

    Attached Files:

  12. Toxic

    Toxic Administrator Staff Member

    Thanks for that,
     
  13. Sfor

    Sfor Network Guru Member

    I just received another RV042 unit manufactured 06/2006. It seemed to work fine, but a loud coil hissing noise was present. It was obvious two larger capacitors are broken, after disassembling the unit. The coil hissing stopped, when all 3 electrolytic capacitors were replaced. It's a standard case for RV042 v1.1, I think.
     
  14. Toxic

    Toxic Administrator Staff Member

    ok try this..

     
  15. Sfor

    Sfor Network Guru Member

    The recommended way of using the TFTP utility does not work as expected in both cases.

    Router 1:
    The Diag LED flashes by itself when the router is powered on. There is no difference, if the power is applied with reset switch pressed.

    Router2:
    The Diag LED does not flash at all. It could be broken.

    Both devices seem to be damaged in some way. Most probably, some of the board components have to be replaced. The question is, what chips are damaged. Is there a way to test the RAM, Flash or other components?
     
  16. Toxic

    Toxic Administrator Staff Member

    are you able to telnet onto the rv042 units at all?
     
  17. Sfor

    Sfor Network Guru Member

    Yes, I am able to telnet to them. I can also force the firmware to boot with "boot -s 2" using telnet. By my understanding, both units are stuck at PME Boot loader for some reason. Resets to the defaults, or firmware flashes do not change a thing. It looks like the router always boots the way it would do, if a reset switch is pressed when power is applied.

    SME Boot loader does seem to provide DHCP in 192.168.1.1 255.255.255.0 subnet, telnet, and HTTP server (with just firmware upgrade page).
     
  18. Sfor

    Sfor Network Guru Member

    I've got yet another damaged RV042. But, this time the situation is quite different.

    The first thing I did after obtaining the device was to check the electrolytic capacitors. They were visibly broken, so I did replace all three. However, this time, the hissing noice did not disappeared completely. Also, the coil near the capacitors was clearly exposed to some unusual heat. The router was working perfectly for a few days, then suddenly all the LAN ports refused to work. In the same time both the WAN ports are working correctly.
     
  19. Sfor

    Sfor Network Guru Member

    Since the damaged RV042 devices are piling up I've decided to post the help output from SME boot.

    Code:
    SME boot> help
    ps                    Print main-task tasks
    rg_conf_print        rg_conf_print <root> - Print OpenRG configuration starting from <root> - use /
                          for the whole configuration
    rg_conf_set          rg_conf_set <path> <value> - Set rg_conf path to a value
    rg_conf_set_obscure  rg_conf_set_obscure <path> <value> - Set rg_conf path to an obscured value
    rg_conf_del          rg_conf_del <path> - Del subtree path from rg_conf
    rg_conf_ram_set      rg_conf_ram_set <path> <value> - Set rg_conf_ram path to a value
    rg_conf_ram_print    rg_conf_ram_print <root> - Print OpenRG dynamic configuration starting from
                          <root> - use / for the whole configuration
    reconf                reconf <flash_delay 1(=NOW) to 4> - Reconfigure the system according to the
                          current rg_conf
    entity_close          entity_close <entity ptr> - Close an entity
    host                  host <name> - Resolve host by name
    flash_commit          Save configuration to flash
    restore_default      restore_defaults [-d] - Restore default configuration (use -d to avoid
                          rebooting after)
    reboot                Reboot the system
    log_lev_on            log_lev_on <severity> - redirect rg_error output from severity equal or higher
                          to <sevrerity> to the current cli
    log_lev_off          Stop rg_error redirection to the current cli
    cat                  Print file contents on console
    shell                Spawn busybox shell in foreground
    flash_layout          Prints the flash layout and content
    flash_erase          flash_erase [-d] <section> - erases a given section in the flash
    flash_dump            flash_dump [-s <section> | -r <address>] [-l <length>] [-1|2|4] - dumps the
                          flash content
    bset                  Configure bootloader
    ifconfig              Configure network interface
    route                Print route table
    ping                  Test network connectivity
    boot                  boot -g {-s <section> | -r <address>} - Boot the system (-g boot with kgdb)
    load                  load -u <url> {-s <section> | -r <address>} - Load and burn image
    ver                  ver - Display version information
    help                  Print this menu
    etask_list_dump      Dump back trace of all etasks
    lock                  lock mtd region <addr, len>
    unlock                unlock mtd region <addr, len>
    Returned 0
    
    I'm trying to find a way of testing the RAM and Flash chips, in order to determine if some smd chips do need replacement.

    ----------------------------
    Apparently the SME boot prompt comes from RGloader v 1.1.6 a part of Open RG.

    According to my research in order to interrupt the Open RG boot it is necesary to keep the ESC key pressed during the system boot. The RGLoader does not load the system image in such a case. ESC key is the hardware reset button in RV042, I think.

    I do not know how to use the the RGLoader CLI to troubleshoot the RV042. It is certainly possible to dump the flash contents to the conslole, download and burn flash images from tftp, check and change the Open RG configuration. I just do not have the experience necesary to do anything useful with it, yet.
     
  20. Sfor

    Sfor Network Guru Member

    The flash data are organized in five sections:
    Code:
    Section 00 Type BOOT      Range 0x00000000-0x000F0000 MaxSize 0x000F0000
        No more information.
    
    Section 01 Type BOOTCONF  Range 0x000F0000-0x00100000 MaxSize 0x0000FEEC
        Size 0x000003E5 Name 'rg_conf'
        Checksum 0x0001F3D2 Counter 0x00002D4B Start Offset 0x00000000
    
    Section 02 Type IMAGE      Range 0x00100000-0x00640000 MaxSize 0x0053FEEC
        Size 0x0052FD00 Name 'Downloaded at: Wed Jan  1 00:03:16 2003' Version '1.3.12.19-tm'
        Checksum 0x2A4FE102 Counter 0x000031E8 Start Offset 0x00000000
    
    Section 03 Type CONF      Range 0x00640000-0x007C0000 MaxSize 0x0017FEEC
        Size 0x00003215 Name 'rg_conf'
        Checksum 0x001984C2 Counter 0x0000329A Start Offset 0x00000000
    
    Section 04 Type FACTORY    Range 0x007C0000-0x007E0000 MaxSize 0x0001FEEC
        Size 0x00000162 Name 'Image downloaded from: tftp://192.168.1.100/RV042/rg_factory3'
        Checksum 0x00006B1B Counter 0x0000000B Start Offset 0x00000000
    I was able to dump the configuration related sections to the terminal, convert them to binary files, then download them to other routers through TFTP. However I could not do the same with large sections. Apparently there is a limit to the flash_dump command data size. When I tried to dump the entire IMAGE section, the router hanged.

    Perhaps, it could be possible to test the flash memory for errors, somehow.
     
  21. Sfor

    Sfor Network Guru Member

    I was able to compare flash contents, finaly. The trick was, the bigger the data chunk, the longer it takes to start dumping. Also, the device refuses to dump blocks above 2MB, for some reason. Anyways, the flash images were exactly the same. The only differences were related to time marks and checksums in the section headers.

    I was also able to connect through the COM port and see the boot log.
    Code:
    Uncompressing Linux.................................. done, booting the kernel.
    Press ESC to enter BOOT MENU mode.
    Version 1.1.6
    Booting an active image in 3 seconds
    http open success!
    open DHCP Server for dev ixp0
    Boot aborted
    There is no indication why the boot process was aborted. But, the "Boot aborted" entry happens before the 3 second time limit. So, it seems to be some sort of an interruption equal to pressing the Reset switch, or ESC key.

    I started to play around with bset command. Finally after "bset timeout 0" the router started to boot main image automaticaly.

    So, I was able to revive two RV042 devices that way. However I do not know if they will work correctly, from now on. One of them does not blink the Diag LED at all. The other does not stop blinking, after booting the main image. So, they do not work exactly the same way as they should to.
     
  22. Sfor

    Sfor Network Guru Member

    Well, I had enough time to test the both revived devices. They are working stable without any apparent issues. The only concern is small amount of errors reported in the port related counters. Still, I can not say for sure it is the router's fault. So, except the DIAG LED strange behavior, both devices are working fine.
     
  23. Sfor

    Sfor Network Guru Member

    Recently, I had an opportunity to retest the router with a constantly blinking LED. What I found is a shortcircuit fault in the reset button circuit. The button itself was fine, so the problem is somewhere else. In any case the device still works correctly, with exception for the blinking Diag LED.
     

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