Description of Issue

Due to an incorrect partition of the flash storage device, the FortiGate 80C may fail to boot-up. The
flash disk capacity should be 7640MB in size, devices that report a flash disk size of 7636MB have a
hidden partition (4MB) which may prevent the FortiGate from booting up if it attempts to locate the
operating system image in this partition.

The FortiGate models that may be affected by this issue are as follows:

FG-80C (PN: P05403-05-xx or higher)
FG-80CM (PN: P05446-05-xx or higher)
FW-80CM (PN: P05405-06-xx or higher)

To identify the part number (PN) of a specific unit, either;
1) Check the label on the bottom of the unit
or
2) Use the get system status command from the CLI

The part number of a device can be identified using the following CLI command:

FGT80C3900000000 # get system status
*************
Serial-Number: FGT80C3900000000
*************
System Part-Number: P05403-05

If your FortiGate is within the affected part number range you can verify the flash disk size to know if
it is correct or if there is a hidden partition that may cause the device to fail to boot-up. Upon boot-
up the flash size may be reported

Boot up, boot device capacity: 4MB --- Incorrect, the device will not boot
Boot up, boot device capacity: 7636MB --- Incorrect
Boot up, boot device capacity: 7640MB --- Correct









Resolution
This issue can be corrected and prevented from occurring by re-formatting the flash file system and
removing the hidden partition. This operation will take approximately 10 minutes to perform,
FortiGate console access and a local TFTP server are required, the basic procedure is similar to
loading an HQIP test image, during the operation the device will be out of service.
Following are the detailed steps and procedures required to perform the re-formatting, the main
components required for these upgrade steps are:
Console access to the FortiGate
TFTP server connected to port internal1 of the FG80C
Disk format image
Desired FortiOS image

Instruction Steps
Ensure configuration back-ups are taken before any format procedures are started.
1) Download the required format images
Depending upon the hardware model type the following format images will be required:
FortiGate FG80C - FGT_80C-FORMAT.3.0.0.1001.out
FortiGate FG80CM - FGT_80CM-FORMAT.3.0.0.1012.out
FortiWiFi FW80CM - FWF_80CM-FORMAT.3.0.0.1001.out

The images may be downloaded from:
ftp://ftp-temp:r3triev3@support.fortinet.com/CustomerCare/FGT_80C-FORMAT.3.0.0.1001.out
ftp://ftp-temp:r3triev3@support.fortinet.com/CustomerCare/FGT_80CM-FORMAT.3.0.0.1012.out
ftp://ftp-temp:r3triev3@support.fortinet.com/CustomerCare/FWF_80CM-FORMAT.3.0.0.1001.out

2) Set-up a TFTP server for image upload
A suggested TFTP server is available from solar winds, others may also work correctly:
http://www.solarwinds.net/Tools/Free_tools/TFTP_Server/download.htm
a) Save the image to the TFTP root folder, example as follows:
C:\TFTP-Root\ FGT_80C-FORMAT.3.0.0.1001.out
b) Save the desired FortiOS image to the root folder, example as follows:
C:\TFTP-Root\ FGT_80C-v400-build0656-FORTINET.out

Any external USB drive must be removed from the USB port, otherwise the open-card program may
fail to function properly!

For more information on how to setup ftp server and terminal client, please check following KB
article:



http://kb.fortinet.com/kb/microsites/microsite.do?cmd=displayKC&docType=kc&externalId=10338&
sliceId=1&docTypeID=DT_KCARTICLE_1_1

3) Load pre-format image
a) When the download completes, the console displays a message similar to:
Save as Default firmware/Run image without saving:[D/B/R]
b) Press R.
c) The system will start and open card mode selection menu will appear:
Opencard Mode Selection Menu:
[1] Pre-Format
[2] F1-Format
[3] GetInfo

d) Enter selection 1 for pre-format
e) Upon completion Preformat succeeded will be displayed

Below is a sample console output for the pre-format image loading when following the above steps:

FortiGate-80C (16:50-09.27.2011)
Ver:04000009
Serial number: FGT80C3910000000
RAM activation
Total RAM: 1024MB
Enabling cache...Done.
Scanning PCI bus...Done.
Allocating PCI resources...Done.
Enabling PCI resources...Done.
Zeroing IRQ settings...Done.
Verifying PIRQ tables...Done.
Disabling local APIC...Done.
Boot up, boot device capacity: 7636MB.
Press any key to display configuration menu...
..
[G]: Get firmware image from TFTP server.
[F]: Format boot device.
[B]: Boot with backup firmware and set as default.
[I]: Configuration and information.
[Q]: Quit menu and continue to boot with default firmware.
[H]: Display this list of options.

Enter Selection [G]:

Enter G,F,B,I,Q,or H: G

Please connect TFTP server to Ethernet port "1".

Enter TFTP server address [192.168.1.168]:
Enter local address [192.168.1.188]:
Enter firmware image file name [image.out]: FGT_80C-FORMAT.3.0.0.1001.out
MAC:00090F4660A2############
Total 13588979 bytes data downloaded.
Verifying the integrity of the firmware image.

Total 65536kB unzipped.
Save as Default firmware/Backup firmware/Run image without saving:[D/B/R]? R
................................................................
Reading boot image 3954827 bytes.
Initializing firewall...




System is started.

Opencard Mode Selection Menu:
[1] Pre-Format
[2] F1-Format
[3] GetInfo
Enter selection [1, 2, or 3]: 1
ISP started, please wait...
Preformat succeeded!

4) Load and format F1 image
Power OFF the unit, wait for five (5) seconds and power ON again, reload the format image as in step
3 and choose "R" to run the image for next step F1-format as detailed below.
a) The system will start and open card mode selection menu will appear:
Opencard Mode Selection Menu:
[1] Pre-Format
[2] F1-Format
[3] GetInfo

b) Enter selection 2 for F1-format

c) Upon completion F1 format succeeded will be displayed
Below is a sample console output for the F1 format image loading when following the above steps:

FortiGate-80C (16:50-09.27.2011)
Ver:04000009
Serial number: FG80C3910000000
Technical Service Bulletin
RAM activation
Total RAM: 1024MB
Enabling cache...Done.
Scanning PCI bus...Done.
Allocating PCI resources...Done.
Enabling PCI resources...Done.
Zeroing IRQ settings...Done.
Verifying PIRQ tables...Done.
Disabling local APIC...Done.
Boot up, boot device capacity: 7000MB.
Press any key to display configuration menu...
..
[G]: Get firmware image from TFTP server.
[F]: Format boot device.
[B]: Boot with backup firmware and set as default.
[I]: Configuration and information.
[Q]: Quit menu and continue to boot with default firmware.
[H]: Display this list of options.

Enter Selection [G]:

Enter G,F,B,I,Q,or H: G

Please connect TFTP server to Ethernet port "1".

Enter TFTP server address [192.168.1.168]:
Enter local address [192.168.1.188]:
Enter firmware image file name [image.out]: FGT_80C-FORMAT.3.0.0.1001.out
MAC:00090F4660A2############



Total 13588979 bytes data downloaded.
Verifying the integrity of the firmware image.

Total 65536kB unzipped.
Save as Default firmware/Backup firmware/Run image without saving:[D/B/R]? R
................................................................
Reading boot image 3954827 bytes.
Initializing firewall...

System is started.

Opencard Mode Selection Menu:
[1] Pre-Format
[2] F1-Format
[3] GetInfo
Enter selection [1, 2, or 3]: 2
Platform: FG80C
F1 format succeeded.


-------------------- Device Information --------------------
Unit: sector
SDK version=v04.00.01
Date=2013.01.09 Time=17:00
SN=0700319140FFFF00 Manufacture Name=FORTINET
VID=13FE Product Name=80C_G2_FWV071610
PID=3100 Inquiry Product Name=80C_G2_FWV071610
Inquiry Version=1610 TSB-130313-1 Fortinet 8
Technical Service Bulletin
Inquiry Manufacturer=FORTINET
F/W Version=07.16.10 FirmwareType=0xFF01
CDROMSize=0 PublicSize=14336000
SecureSize=0
Normal HiddenSize=0 IsExisted Firmware code=1
IsExisted PWS Private=0 IsLogin Private=0
iController_ID=2233 iMode=3
--------------------------------------------------------
total capacity:14336000 sectors, 7000 MB
All done.
Congratulations! Opencard process succeeded. The device is ready to use now.

Opencard Mode Selection Menu:
[1] Pre-Format
[2] F1-Format
[3] GetInfo
Enter selection [1, 2, or 3]:
5) Load desired FortiOS image (4.0MR3 patch 12 in this example)
a) After the F1 format completes,power OFF the unit, wait for five (5) seconds and power ON again.
b) During boot-up sequence press any key to display configuration menu.
c) Using the TFTP upload procedure in step 3) load FortiOS 4.0MR3 patch 12 image to the FortiGate
flash.

If all the above steps have been completed without error the FortiGate FG80C has been successfully
re-formated to prevent the potential boot failure issue from occurring. For further assistance please
contact your local Fortinet technical support center.