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Firmware Upgrade & Config Backup/Restore
Objective
Validate that the z40 Gateway Router can:
- Upgrade firmware through the Director UI once the firmware package is staged.
- Roll back to a last-known-good firmware image if necessary.
- Perform a full factory reset to return the device to default state.
- Back up its configuration to an external SFTP target via Director and restore from a saved backup.
- Ensure that all actions are observable in logs, survive reboots, and preserve or restore connectivity.
Prerequisites
- z40 onboarded to the Director tenant, with active tunnels to the cloud vGR concentrator.
- A Windows or Linux client connected to LAN00 via a switch for validation traffic.
- Administrative access to both Director and z40 WebUI.
- Latest firmware image file available.
- An SFTP server reachable from Director with valid credentials.
- A known-good baseline configuration (e.g., DHCP scope, VLAN settings) to validate after restore.
Test 1 — Firmware Staging in Director
Setup
- Log in to Director with administrator credentials.
- Navigate to the Firmware Management section.
- Select the option to Upload Firmware Package.
Steps
- Log in to the object storage service (MinIO) with the credentials provided.
- Navigate to the firmware bucket.
- Upload the new firmware file.
- Update the manifest file if prompted so the Director recognizes the new build.
- Confirm that the new firmware entry appears in the firmware list with its version number.
Validation
- The firmware version is listed and selectable in Director.
- Metadata such as version number and file size display correctly.
Evidence
- Firmware version appears in the Director firmware list.
Test 2 — Firmware Upgrade on z40
Setup
- In Director, navigate to Edge Controllers → [z40] → System → Firmware Update.
- Review the Firmware Table, which shows:
- Current Version (running build).
- Updatable Version (new build available).
Steps
- Click Upgrade next to the Updatable Version.
- Confirm the reboot prompt.
- Wait for the z40 to download the image, install it, and reboot.
- After reboot, return to the Firmware Update page.
Validation
- Current Version now matches the Updatable Version that was shown before the upgrade.
- z40 shows Online in Director.
- Tunnels to vGR re-establish.
- LAN client regains internet reachability.
Evidence
- Firmware table shows Current Version updated to the new build.
- Device status in Director is Online.
- Test client can ping or browse to an external site.
Persistence Check
- Manually reboot the z40 again; confirm firmware version persists.
Test 3 — Firmware Recovery (Last-Good)
Setup
- From the Director interface or CLI access tool, select Firmware Recovery.
Steps
- At the recovery prompt, enter lastgood.
- Confirm when asked.
- Allow the system to restore the previous working firmware and reboot.
Validation
- Firmware Update page shows Current Version reverted to the prior build.
- Device reconnects to Director and tunnels re-establish.
- LAN client connectivity restored.
Evidence
- Firmware table shows the reverted version under Current Version.
- Director shows device Online.
- LAN client passes traffic.
Persistence Check
- Reboot device again and confirm version remains restored.
Test 4 — Factory Reset
Setup
Two supported methods: WebUI/CLI command or physical reset button.
Steps
WebUI/CLI Path:
- Navigate to System → Factory Reset.
- Select Reset and confirm prompt.
Hardware Path:
- Press and hold the reset button for the documented duration (typically >10 seconds).
- Watch for LED sequence indicating reset.
- Release button to trigger reset.
Validation
- Device reboots to factory defaults.
- WebUI requires default admin credentials.
- Previous configuration is wiped; device must be re-onboarded to Director.
Evidence
- WebUI shows login screen after reset.
- Director shows device requires provisioning.
Test 5 — Director CPE Configuration Backup
Setup
- In Director, navigate to Edge Controllers → [z40] → Maintenance → Backup/Restore.
- Configure SFTP target by adding server address, port, username, password, and path.
- Save and confirm SFTP target appears in the list.
Steps
- On the Backup tab, select the configured SFTP target.
- Click Start Backup.
- Observe progress bar during backup.
- Confirm completion message shows success.
- Verify backup entry appears in list with timestamp and size.
Validation
- Backup shows Success status.
- Backup file is delivered to SFTP server.
Evidence
- Backup entry listed with timestamp and Success status.
- Backup file visible on SFTP server.
Scope of Backup
Configuration backup includes (but is not limited to):
- /var/register
- /etc/amz
- /etc/frr
- /var/register/system/zwan.db
- /etc/rsyslog.d/15-amz.conf
- /etc/ipsec.d
- /etc/ssl
Test 6 — Director CPE Configuration Restore
Setup
Have a completed backup entry available in Director.
Steps
- On the Restore tab, select a backup entry.
- Click Restore.
- Confirm the restore action.
- Monitor progress bar.
- Confirm success message when restore completes.
- If failure occurs, retry restore until success.
Validation
- Device settings revert to the state of the selected backup.
- For example, if DHCP pool was altered before restore, it is restored to baseline.
- Director shows device Online with tunnels up.
Evidence
- Restore entry shows Success status.
- Device configuration matches baseline.
Persistence Check
- Reboot the device; confirm restored configuration persists.
Negative & Edge Cases
- Invalid firmware image: attempt to upload unsupported file → error message displayed.
- Recovery misuse: incorrect command entered instead of lastgood → error response.
- Backup failure: misconfigure SFTP credentials → backup fails with error.
- Restore failure: disconnect SFTP mid-restore → failure message, retry to success.
Notes & Tips
- Always capture Firmware Table before and after upgrade to demonstrate change.
- Allow 3–5 minutes for firmware upgrades and recovery reboots.
- For backups, confirm files exist both in Director list and on SFTP server.
- Clean up test backups after POC to avoid clutter.