Hello,

Just ran the upgrade from 7.2.5 to 7.3.1 from the UI. After rebooting, no Unraid UI, no mounted volumes or disks, literally nothing but a command prompt. SSH works in but it's a very thin OS. I have syslogs from before and after. Tried it 3 times, and 3 times, the same result. A very minimal OS and no Unraid.

Rolled back to 7.2.5 each time and all is well.

Thanks!

Craig

Please post the diagnostics after upgrading; you can get them from the CLI/SSH

1 hour ago, Craigb said:

A very minimal OS and no Unraid.

What do you mean? Unraid IS the OS. Are you sure you are booting Unraid? Do you get the Unraid boot menu?

I seem to remember it being possible to get to this state if the second stage of the boot process where the flash drive is mounted at /boot does not succeed?

The output from the ‘df’ command after logging in at the prompt would make it clear if this is the case.

Thanks! It is booting to unraid. The boot menu is there on startup and it defaults to booting (loading bzimage, bzmodules, etc.) after a few seconds. I'm able to SSH in with the admin credentials but I see a very light Linux instance. df -h shows no data drives. Not sure how to get the diagnostics file from the CLI.

I've since had to revert back to 7.2.5 for work and everything is there as expected. I do have syslogs from before and after the upgrade as well as a diagnostic zip from before the upgrade if those are of any value.

I must wait until tomorrow morning early to try it again. I'll get the output from a df as well.

7 minutes ago, Craigb said:

Not sure how to get the diagnostics file from the CLI.

The word diagnostics in your post and my post and everywhere it appears in the forum is a link to the documentation explaining how to get diagnostics.

Thanks...

Booting after upgrade, the console shows "Unraid Server OS version: 7.3.1" and the login prompt.

Ran the diagnostic which returned the following and created a zip.

>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>

root@NAS1:/boot# diagnostics

Starting diagnostics collection... sh: line 1: /tmp/servers.conf.txt: No such file or directory

done.

ZIP file '/boot/logs/nas1-diagnostics-20260627-0944.zip' created.

>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>

One final point, the last line in the boot text before the version line is "sh: -c option requires an argument" I don't recall seeing that booting 7.2.5.

nas1-diagnostics-20260627-0944.zip

One more data point, after the upgrade, the server will not power down from a command line command. sudo shurdown shuts down the OS but does not power off the server. The front panel power button does not work. A sudo poweroff command also does not power off the machine.

It's a problem with the flash drive layout; 7.3.x is more strict about that.

To fix it, back up the current flash drive, recreate it with the USB tool and 7.3.1, restore only the config folder from the backup, overwriting existing files.

Thanks. Ran the create tool 3 times with 7.3.1 on 2 different bootable usb drives. Copied the config folder and it's contents from the backup each time. Same result each time. The most recent 7.3.1 diagnostic file is attached.

7.2.5 works well, is stable and reliable. Colleagues are waiting to get on with their work so at this point, I'm giving up on the upgrade, maybe later.

I appreciate the assistance and tips.

nas1-diagnostics-20260627-1430.zip

You have a custom go file which includes things from Unraid v5. Replace with the stock go file

Thanks for the tip on the go file. The next opportunity to try an upgrade will be Monday AM early CET. This Unraid instance, in various forms, has been running since 2009, so that's too surprising.

There's still a problem with the flash drive, is this the OS flash drive?

Sony_Storage_Media_6A0903240007610-0:0 (sdn) 512 7831552 => no partitions

That's correct. The Sony flash drive has been in that server since around 2010. Whilst it seems to be good, my Windows workstation occasionally fails to enumerate it when it's plugged in.

Tried upgrading twice more today, no luck. The Sony is MBR FAT32. Double checked the replacement drive and it was GPT. Changed it to MBR, no difference. Copied over the config folder from the good instance and removed the junk from the go file. No difference.

Whilst I appreciate the feedback, we're now into the work week here, so I'm done. It stays on 7.2.5.

20 minutes ago, Craigb said:

The Sony flash drive has been in that server since around 2010. Whilst it seems to be good, my Windows workstation occasionally fails to enumerate it when it's plugged in.

The occasional failure to enumerate on Windows is worth paying attention to -- that's an early warning signal of a drive approaching end of reliable operation rather than a random quirk.

A Sony flash drive from 2010 has had a good run by any measure.

But 15+ years puts any consumer USB drive well past its expected service life regardless of how it appears to be performing day to day.

Enumeration failures are typically the first visible symptom before more serious read/write reliability issues develop.

Before your next upgrade attempt it might be worth starting fresh with a known good quality drive rather than continuing to troubleshoot around a 15 year old flash drive that's already showing warning signs.

There's a "PSA in Industrial MLC" in the Pre-Sales section covering what's currently available for boot drives if you haven't seen it -- including options that should last considerably longer than the Sony has.

2 hours ago, Craigb said:

Tried upgrading twice more today, no luck.

It will never work with the flash drive being detected without partitions; that should not happen if it was recreated with the USB tool.

Post the output from fdisk -l /dev/sdn

Update.

I've run the the 7.3.1 upgrade several times using three different, new flash drives, both 8 and 32 GB. I used the USB creator tool each time on freshly formatted devices. Tried both GPT and MBR FAT32 formatting before running the creator. No difference.

I've intentionally NOT tried to upgrade or reformat the old flash drive, since as LoLight points out, it is very much past it's sell by date!

fdisk of /dev/sda (the Sony 4 GB flash disk) shows 3 very clearly incorrect partitions.

>>>>>>>>>>>

root@NAS1:~# fdisk -l /dev/sda

Disk /dev/sda: 3.73 GiB, 4009754624 bytes, 7831552 sectors

Disk model: Storage Media

Units: sectors of 1 * 512 = 512 bytes

Sector size (logical/physical): 512 bytes / 512 bytes

I/O size (minimum/optimal): 512 bytes / 512 bytes

Disklabel type: dos

Disk identifier: 0x0009e87d

Device Boot Start End Sectors Size Id Type

/dev/sda1 3223366752 3470046675 246679924 117.6G f4 SpeedStor

/dev/sda2 378192737 710426324 332233588 158.4G 10 OPUS

/dev/sda3 225603442 225603451 10 5K 74 unknown

Partition table entries are not in disk order.

>>>>>>>>>>>>

Absolutely not a clue what those are or where they could've come from... That flash disk has never been used anywhere other than in that server since new. It is FAT32, MBR. I have a clean backup of 7.2.5 just in case...

I've now agreed to a full rebuild of that server with finance. New MB, CPU, memory, etc. It's far past time and I'm pretty sure we've got our money's worth from the current hardware.

Many thanks to all for the feedback!!

It will never wotk with those 3 partitions; you can try Rufus if the USB tool is not working (though not sure why that is)

Get the Unraid zip from https://docs.unraid.net/unraid-os/download_list/

- Open Rufus and change "Boot selection" to "Freedos"

- Set the "Volume label" to UNRAID

- set filesystem to FAT32

- click START

- once done, unpack the Unraid ZIP to the flash drive

If you are booting UEFI nothing else you need to do, if you are booting legacy/CSM, run the make_bootable.bat as administrator first.

Thanks! I'll give this a try.

FWIW, that Sony drive has been in service exactly as it is, for years. Can't explain it, but it works.

Got the 7.3.1 zip and Rufus. I'll get on it later today.

2 hours ago, Craigb said:

FWIW, that Sony drive has been in service exactly as it is, for years. Can't explain it, but it works.

I'll make an attempt at explaining it, but let's get your current upgrade sorted first.

Once everything is stable and the Sony is sent to its well-deserved retirement, let me know and I'll walk through what's likely behind its unusual longevity.

Or show how to achieve similar longevity in the replacement drive.

Don't just go out and buy another one without knowing the details

Edited June 30Jun 30 by Lolight

Thanks LoLight! Will do. All new bits now on order.