Over the weekend I attempted to upgrade from 6.10.3 to 6.12.6 and it went terribly.  The server would hard freeze anywhere between 30 seconds to 3 minutes after boot.  Trying safe mode did the same thing, although it did seem the server would stay online until I tried logging into the web interface.  It took numerous attempts but I was able to get one diagnostic file while on 6.12.6.  I've rolled back to 6.10.3 using a flash backup taken before the upgrade, although I had to use the manual copy files over+makeboot.bat process as the server didn't see the USB drive as bootable when using USB Creator tool.  The server has been up for about 5 days now and last night I got the warning the USB Flash drive is corrupted or missing.  So far all my docker containers and VM's appear to be running, but I can't access any file shares.  I also had similar issues when trying to upgrade to 6.11.X over a year ago, hence why I'm still on the older 6.10.  Attached are diagnostics from today (6.10.3) and the upgrade attempt (6.12.3)

 

Server is a bit older

   SuperMicro X11SSH-F

   i3-7100

   LSI SAS 2008 card

   Mix of drives connected to MB and SAS card

   Norco 4220 case  (old as hell)

diagnostics-6.10.3-20231207-1536.zip diagnostics-6.12.6-20231201-1803.zip

When you upgraded to 6.12.6 did you try saving the /config folder from the boot USB. Re-flashing the boot USB with 6.12.4 via the usb creator tool. Then copying back the /config folder?

I upgraded using the Update OS option after running the update assistant.  I only had 3 warnings on plugins that were no longer supported on 6.12.x.

Dec  3 23:04:16 Serenity kernel: sd 0:0:0:0: [sda] tag#0 UNKNOWN(0x2003) Result: hostbyte=0x07 driverbyte=DRIVER_OK cmd_age=1s
Dec  3 23:04:16 Serenity kernel: sd 0:0:0:0: [sda] tag#0 CDB: opcode=0x28 28 00 00 78 07 80 00 00 08 00
Dec  3 23:04:16 Serenity kernel: usb 1-9: USB disconnect, device number 3
Dec  3 23:04:16 Serenity kernel: blk_update_request: I/O error, dev sda, sector 7866240 op 0x0:(READ) flags 0x80700 phys_seg 1 prio class 0
Dec  3 23:04:16 Serenity kernel: blk_update_request: I/O error, dev sda, sector 7866240 op 0x0:(READ) flags 0x0 phys_seg 1 prio class 0
Dec  3 23:04:16 Serenity kernel: Buffer I/O error on dev sda, logical block 983280, async page read
Dec  3 23:04:16 Serenity emhttpd: error: get_key_info, 529: No such file or directory (2): opendir: /boot/config
Dec  3 23:04:16 Serenity emhttpd: Unregistered - missing key file (ENOKEYFILE2)
Dec  3 23:04:16 Serenity kernel: FAT-fs (sda1): Directory bread(block 16384) failed
Dec  3 23:04:16 Serenity kernel: FAT-fs (sda1): Directory bread(block 16385) failed

 

Flash drive dropped offline, try a different USB port, ideally USB 2.0, if it keeps happening replace it.

 

I've restored to a new flash drive and activated it, everything seems OK so far, albeit still on 6.10.3