Juniper EX3400: How to Recover from PoE Firmware Upgrade Failure

Did you know Juniper EX switches have PoE firmware updates to be applied?

Chelsea Lately - Great question. I had no idea.

Well, I didn’t until about a year ago when I did an upgrade and was checking on PoE power. Looking at the controller info from show poe controller, I noticed the following:

Juniper poe firmware available

Huh. Ok. Well, I’ve got a eight unit stack here, and the Juniper EX software upgrade is usually pretty solid, so let’s upgrade it — and it goes off without a hitch.

Fast forward nine months later, and I’m running into strange issues with PoE and Mercury door controllers, particularly model ‘MRE62E’. Basically the Juniper switches won’t provide power to this model, but the older MRE52’s had no problem. Checking out the firmware version using show chassis firmware detail, I noticed that the switch had the older 1.x firmware and not the new 2.x.

PoE firmware 1.6.1.21.1

 

Alrighty then — let’s upgrade this stack. I upgrade the software using the latest JTAC recommended version (staying in 15.x), then upgrade the PoE firmware — no problem. Door controller is now getting power, I see a MAC address. Everything is hunky dory.

Now let’s upgrade this other stack.

No problems on EX software upgrade. Great. Now upgrade PoE firmware…

Ten minutes later, I get the following on the terminal:

Magic Thread Message

Of note, and the thing that made me panic, was that out of nine switches in the stack, only one came back online. Checking the firmware versions, I see the following:

Various PoE firmware versions, some missing, some 0.0.0.0.0, only one 2.x

Okay… F***. Well, let’s reboot the stack; perhaps a reboot is needed*. After reboot, I get the following:

PoE Device Fail on FPC 8. All but FPC 2 are missing.WTF.

Guy shaking head mouthing WTF

In the past when I’ve done a PoE firmware upgrade (between now and when I first learned about it), I had no recourse but to RMA the switch. Well in this case, I don’t have eight spare switches to fill this temporarily while I wait for an RMA! WTF am I going to do?!

Solving the PoE Firmware Upgrade Failure

If you’re in the same situation as I was in, take a deep breath — you’re not dead in the water.

There are two scenarios for a PoE firmware upgrade failure that I’ve encountered, and I have a solution for both:

  • PoE Firmware Failure #1 – After firmware upgrade, you see a mixed result of firmware versions, some being 0.0.0.0.0, some being correct (2.1.1.19.3**), and some missing/blank (see picture above showing mixed/missing versions)
  • PoE Firmware Failure #2 – Perhaps you did as I did and rebooted and the PoE controller shows one with the message ‘DEVICE_FAILED’ (see above)

Solution for PoE Firmware Failure #1

If you encounter this failure, DON’T REBOOT THE STACK. You’ll make your life harder if you do.

Next, Juniper TAC (finally) has a solution — and it requires remote/on-site hands. If you’re going on-site or working with someone remotely, get yourself a cup of coffee (or beverage of choice) and some podcasts lined-up, because you’re going to be doing this awhile (~10 minutes for each switch/fpc).

From their site, the solution is the following (with my own notes):

  1. Power cycle the affected FPC (re-seat the power cord). Do not perform a soft reboot.
  2. After the FPC joins the VC or the standalone device reboots, execute one of the following commands in operational mode:

    OR

    JTAC Note: You need to change the fpc-slot number accordingly. Also, it is recommended that you push the PoE code one by one instead of adding all members in the virtual-chassis setup. (Emphasis mine)
  3. After the above command is executed, the FPC should automatically reboot. If not, reboot from the Command Line Interface.
    Note: Be patient and wait. No, seriously…wait. It takes awhile. If you need to reboot, you’re rebooting the whole unit AFAIK:
  4. After the FPC is online, check the PoE version with the show chassis firmware detail command. The PoE version should be the latest version (2.1.1.19.3) after the above steps are completed.
  5. If the version is correct, the PoE devices should work.
  6. Repeat the above steps to upgrade the PoE versions on other FPCs in the virtual-chassis setup.

The one thing to note that when it’s doing its upgrade is that you can see the progress with show poe controller, but at some point it will hang at 95%, then disappear, then come back, then the process will be complete — in other words…WAIT, unless you want to try out the solution for failure #2. 😆

Solution for PoE Firmware Failure #2

In this scenario, you rebooted the stack and something failed. The following is similar to solution #1, but the failed PoE controller requires to basically upgrade it twice. The steps:

  1. Execute the following command to reload the firmware on the FPC:

    Note: You need to change the fpc-slot number accordingly.
    The PoE controller will disappear when you run show poe controller, then come back and start upgrading like this:
    PoE firmware upgrading
  2. After the firmware upgrade completes, the firmware will likely be incorrect (it always was for me). Power cycle the affected FPC (re-seat the power cord). Do not perform a soft reboot.
  3. After the FPC joins the VC or the standalone device reboots, execute one of the following commands in operational mode:

    JTAC Note: You need to change the fpc-slot number accordingly. Also, it is recommended that you push the PoE code one by one instead of adding all members in the virtual-chassis setup. (Emphasis mine)
  4. After the above command is executed, the FPC should automatically reboot. If not, reboot from the Command Line Interface.
    Note: Be patient and wait. No, seriously…wait. It takes awhile. If you need to reboot, you’re rebooting the whole unit AFAIK:
  5. After the FPC is online, check the PoE version with the show chassis firmware detail command. The PoE version should be the latest version (2.1.1.19.3) after the above steps are completed.
  6. If the version is correct, the PoE devices should look like this:
    Successful PoE firmware upgrade
  7. Repeat the above steps to upgrade the PoE versions on other FPCs in the virtual-chassis setup.

Just like solution #1, one thing to note is that when it’s doing its upgrade you can see the progress with show poe controller, but at some point it will hang at 95%, then disappear, then come back, then the process will be complete — in other words…WAIT! You don’t really want to re-apply this whole process, do you?

Final Thoughts

Here’s the kicker for me: I’ve had this work just fine for stacks and single switches alone, and fail on stacks and single switches alone — I can’t find the common denominator here. Perhaps there’s a hardware build that has this more than others, but I can’t figure it out. The official documentation doesn’t hint on a best practice for this (other than maintenance hours), so I’m uncertain on the best approach.

Here’s some ideas I have to change my PoE firmware upgrade procedure (unsure if this will help):

  • Turning off PoE on all interfaces
  • Upgrading one at a time.
  • Trying an earlier version of the JTAC software, the going to the latest recommended. Example: I had no problems with 15.1X53-D59.4 or 15.1X53-D590, but the sample size for determining that is small (only two stacks attempted).

Time will tell.

Hope this helps! If it doesn’t I’d love to know the different experiences others have.

* I swear I saw a message that a reboot is required, but I can’t confirm this (I didn’t screencap it)

** There is a version 3.4.8.0.26, but that’s on the 18.x software version line, and it requires a whole different set of upgrade procedures. This is outside the scope of this post.

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