PowerStore: Pre upgrade health check (PUHC) to detect if the "new FW zip is wiped out from the stage of FW partition"

Summary: When upgrading to PowerStoreOS version 3.x, If NDU target version includes a new FW zip file, the file is pre-staged into FW partition during the prestage phase. After that, if the second M.2 is re-populated (for example, the M.2 replacement, layout known issue), the prestaged .zip file will be lost and causes NDU to fail at the step of upgrading firmware. The off_release_new_firmware_zip_existence_check Pre-Upgrade Health Check (PUHC) detects this issue and prevents the NDU from failing. ...

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Symptoms

The PowerStore health check (PUHC) may fail the off_release_new_firmware_zip_existence_check validation, with the following error:

Checking if new FW zip exists in the stage of FW partition (off release check).......... Error.
New FW zip not present in the stage of FW partition. Please contact your service provider.

The health check is an off-release PUHC check that is contained in the Health Check thin package downloaded from the Dell Drivers & Downloads site. See the Additional Info section for information about the Health Check thin package.

The following snapshot is displayed in PowerStore Manager when the issue is detected:
Error on the PowerStore Manager

 

Cause

This PUHC check identifies if the pre-staged .zip file is missing from the FW partition. If the NDU target version includes a new FW zip file, the file is pre-staged into FW partition during the NDU pre-stage phase. After that, if the secondary M.2 is re-populated (for example, an M.2 replacement is performed or the corrective action plan for M.2 having an incorrect layout is executed), the pre-staged .zip file will be lost and will cause the NDU to fail at the step of upgrading firmware. 

Resolution

To resolve this issue, contact technical support for assistance. Reference KB# 000228388 for expedited attention and resolution.

 

Additional Information

For additional information about the Health Check thin package, see KB 000192601 PowerStore: How to Check the Health of the Cluster Before Software Upgrade Using Pre-Upgrade Health Check and System Check.

 

Affected Products

PowerStore
Article Properties
Article Number: 000228388
Article Type: Solution
Last Modified: 14 Jun 2025
Version:  4
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