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(SOLVED) Missing key file error suddenly, USB stick corrupted?

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Hello. This morning I'm seeing this error on my second unRAID server:

"Missing key file. Your license key file is corrupted or missing. The key file should be located in the /config directory on your USB Flash boot device. If you do not have a backup copy of your license key file you may attempt to recover your key. If this was an expired Trial installation, you may purchase a license key."

I was organizing some cables behind the computer, so it is possible that I bumped the unRAID USB stick. I can create a new one if needed.

The Dashboard tab is blank when I click on it. And I clicked on the Apps tab and got this error:

Fatal Boot Device Error

This usually means your Boot Device is corrupted or has dropped offline. The rest of the Unraid GUI will also be affected. Post a new thread in the Unraid forums if this error continues.

I was able to download a Flash backup from unRAID Connect dated yesterday.

What are the next steps? Thanks. Diagnostics attached.

Screenshot 2025-09-14 at 7.37.16 AM.png

USBstick.png

tower2-diagnostics-20250914-0626.zip

Edited by stor44
Added SOLVED to title.

Solved by stor44

  • stor44 changed the title to (SOLVED) Missing key file error suddenly, USB stick corrupted?
  • Author
  • Solution

UPDATE: I was able to solve the problem. I used the unRAID USB Creator app on macOS to create a new USB stick using the zipped backup from my old stick, as per these instuctions:

No image preview

Changing the flash device | Unraid Docs

The USB flash device is critical to your Unraid server as it stores the operating system, configuration files, and license. If this device fails or becomes unreliable, prompt replacement is essential

I shutdown my unRAID server, swapped the failed USB stick with this new one and booted it up. I set the password, then confirmed the drive assignments were still correct and started the array.

Seems back to normal now.

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