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sync: auto-sync from HOWARD-HOME at 2026-06-02 14:20:08

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Author: Howard Enos
Machine: HOWARD-HOME
Timestamp: 2026-06-02 14:20:08
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Howard Enos
2026-06-02 14:20:17 -07:00
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## User
- **User:** Howard Enos (howard)
- **Machine:** Howard-Home
- **Role:** tech
# Lone Star Electrical — Unraid Server USB Replacement & Re-registration (2026-06-02)
## Session Summary
The Lone Star Electrical Unraid server was failing to boot, halting at `bzfirmware checksum error - press ENTER key to reboot...`. The boot console showed Unraid verifying its boot files against stored SHA256 sums; `bzimage`, `bzroot`, `bzroot-gui`, and `bzmodules` all passed, but `bzfirmware` failed its checksum, so the OS never mounted and the box looped on reboot. The flash drive (label UNRAID, `/dev/sda1`, Generic 8GB) was detected and `fsck.fat` ran clean (758 files, no FAT errors), isolating the fault to the corrupt `bzfirmware` file content rather than the filesystem.
This was first triaged earlier in the day on another machine. The initial fix — replacing the corrupt `bzfirmware` file on the existing USB — did not hold: after rebooting, the same checksum error recurred. The recurrence confirmed the original diagnosis that the 8GB generic USB flash drive itself was failing (the #1 wear item on Unraid), not a one-off file corruption.
Howard migrated the server to a new USB flash drive. He used the official **Unraid USB Creator** to write **Unraid 7.1.4** to the new stick (which handles FAT32 format, the `UNRAID` volume label, the `bz*` OS files, and installing the syslinux bootloader / boot flag in one step). He then copied the **`config/` folder from the old flash drive** onto the new stick to preserve the array configuration (`super.dat` disk assignments, shares, network settings, and the existing license `.key`).
Because a new USB has a new GUID, the existing license key would not validate against it. Howard completed the license **re-registration / key transfer** to bind the license to the new flash GUID. The server is now booting off the new stick. Mike is having a Claude session run a check on the server to verify health/array state. This log is being saved so a Syncro ticket can be created and notes updated.
## Key Decisions
- Replaced the entire USB flash drive rather than re-replacing the `bzfirmware` file again — the recurrence after a file-level fix confirmed the stick was failing, so a fresh stick was the correct remediation.
- Used the Unraid USB Creator (vs. manual file copy + `make_bootable`) to guarantee a properly bootable stick with correct label/bootloader.
- Preserved the old `config/` folder verbatim on the new stick to retain disk assignments and avoid reconfiguring the array; only the OS files were fresh (from 7.1.4).
- Completed the license key transfer to the new GUID rather than running indefinitely in Trial mode.
## Problems Encountered
- **Recurring `bzfirmware` checksum error on boot.** Initial fix (replacing the `bzfirmware` file on the old USB) failed — error returned after reboot. Root cause: failing USB flash drive. Resolved by migrating to a new USB stick written with the Unraid USB Creator (7.1.4) + copied `config/`.
- **New USB = new GUID, old license invalid.** The copied `.key` would not validate against the new flash GUID. Resolved by completing the Unraid license key transfer/re-registration to the new stick.
## Configuration Changes
- New Unraid boot USB flash drive created for the Lone Star Unraid server (Unraid **7.1.4** via USB Creator).
- Old `config/` folder (super.dat / shares / network / `.key`) copied from the failing stick onto the new stick.
- Unraid license re-registered / transferred to the new flash GUID.
## Credentials & Secrets
- **No Lone Star Unraid credential is vaulted.** Vault search returned only ACG's own Unraid boxes: `infrastructure/jupiter-unraid-primary.sops.yaml` (Jupiter, 172.16.3.20) and `infrastructure/uranus-unraid.sops.yaml` (Uranus, 172.16.3.21) — neither is the Lonestar server.
- Unraid login is always user `root`; the root password is stored in `config/shadow` on the flash, so the original Lonestar root password carried over with the copied `config/` folder.
- **TODO:** capture the Lonestar Unraid root password and create a vault entry for this server (hostname, IP, Unraid 7.1.4, license type). Not yet vaulted.
## Infrastructure & Servers
- **Lone Star Electrical Unraid server** — exact hostname / LAN IP / license type not yet documented (verify and add to vault + wiki).
- Boot device (failed): label UNRAID, `/dev/sda1`, Generic Flash Disk 8GB (8.05 GB / 7.50 GiB).
- Now running: Unraid **7.1.4** on a new USB flash drive.
- Client: Lone Star Electrical Systems LLC — Syncro customer ID `33809612`. Google Workspace shop (`lonestarelectrical.net`), ManageEngine MDM. Primary contact: Robin Eneix (robine@lonestarelectrical.net).
## Commands & Outputs
- Boot failure (verbatim from console): `Verifying bzfirmware checksum ...` → `bzfirmware checksum error - press ENTER key to reboot...`; preceding `umount: /: not mounted`.
- `fsck.fat 4.2 (2021-01-31)`: `/dev/sda1: 758 files, 231850/1961984 clusters` (clean — filesystem healthy, file content corrupt).
## Pending / Incomplete Tasks
- **Create Syncro ticket** for Lone Star Electrical documenting the Unraid USB failure + replacement + re-registration (this is the explicit reason for saving).
- **Mike's Claude session is running a health check on the server** — capture results (array start state, disk assignments, parity validity, registration status) and fold into the ticket/notes.
- **Verify array integrity before/after start:** confirm all disks landed in correct slots from the copied `super.dat`; ensure no unwanted parity rebuild was triggered.
- **Vault the Lonestar Unraid credentials** (root password) and **document the server in the wiki** (hostname, IP, Unraid 7.1.4, license type).
- Keep the old failing USB stick as a temporary backup until the new stick is confirmed stable; then retire it.
## Reference Information
- Unraid downloads / USB Creator: https://unraid.net
- License transfer/registration: webGUI → Tools → Registration → Replace Key (self-service transfer limited to once per 12 months; LimeTech support for dead-stick reissue).
- Files on a bootable Unraid stick: `bzimage`, `bzroot`, `bzroot-gui`, `bzmodules`, `bzfirmware` (+ matching `.sha256`), `syslinux/`, `make_bootable*`. The `config/` folder holds array/license state and must be preserved across migrations.
- Lonestar wiki: `wiki/clients/lonestar-electrical.md`. Syncro customer: `33809612`.