Creating a bootable Ignite DVD with a USB writer

This FAQ is an amalgamation of several documents, plus my own personal experience in performing the tasks.

The purpose of this exercise is to create a bootable DVD with the contents of a previously-taken make_net_recovery archive. The DVD is intended to be the only media required to recover a HP server.

You may of course be aware that the Ignite host script /opt/ignite/data/scripts/examples/make_opticaldisc_recovery will perform the whole deal - the make_net_recovery and make_media_install. This script though needs some editing and testing to work with a USB DVD writer. If that is a chosen route for you, you may still find value in reading the notes below, not least for the detail on how to prepare your Ignite server to accept the DVD writer. Note that some HP servers allow virtualised use of Wintel-hosted DVD writers, though not the models of servers detailed below in this example.


READ ALL OF THIS FAQ BEFORE STARTING TO PROCEED

(There are a number of potential "gotchas" that you need to be aware of before completing all steps)


The primary purpose of the bootable DVD is to provide for a DR solution when it isn't possible or pratical to build an Ignite server in-situ at the DR site. The bootable DVD is intended to provide a single source of recovery.

For obvious reasons this method should be fully tested - not least because the nature of DVD media is such that you don't want to find that your precious bootable DVD disk is unreadable at your DR premises.

For this exercise I employed the following hardware;

[ul]
[li]An RX1620 server (the Ignite server and DVD-writer host)[/li]
[li] An RX4640 server - the host "template" server whose Ignite recovery image will be employed.[/li]
[li] A HP DVD1040e external USB 2.0 DVD writer. (http://www.amazon.co.uk/exec/obidos/ASIN/B000PHZUT4/nextag78-21/ref=nosim) [/li]
[li] Suitable DVD +R or +RW media for the drive. I used cheap HP DVD+R 16x "orange" label media. Note that dual-layer media isn't supported for this purpose.[/li]
[/ul]

Note that through http://docs.hp.com/en/13702/3-UpdatetoUSBDriverSupportonHPUX11iv2.pdf the HP DVD1040e USB 2.0 DVD writer appears to be the only DVD writer officially supported.

The following caveats apply;

[ol]
[li] The operating system in use is 11i v2 (11.23)[/li]
[li] You will need a change request/access to upgrade/reboot servers in preparation for performing the steps detailed (unless you have performed this already.)[/li]
[li] You should have the facility to test the completed bootable DVD before accepting the solution as a valid one [/li]
[/ol]

Preliminary Steps

1. Check USB 2.0 ports.

Your Ignite server should have USB 2.0-capable ports. In this example the RX1620 server is so-equipped.

2. Check and upgrade if necessary Ignite server & client

The installed version of Ignite for the Ignite server should be version C.7.7.98 or higher.

If it isn't, and you have the facility to upgrade the software on the server concerned, then upgrade Ignite using a download source such as;

http://h20392.www2.hp.com/portal/swdepot/displayProductsList.do?category=OE (and search for Ignite on page.)

I would recommend upgrading the client server (in this case an RX4640.) I believe the client host can be at a lower version of Ignite, but the advantages conferred by having all versions synchronised seem invaluable.

3. Check if patch PHKL_37814 is installed.

This patch introduces USB 2.0 DVD writing support. Note it has a number of dependency-associated patches and might have been installed as a BUNDLE<date>.

If you have the patch installed already, don't be so sure all is well. The patch readme at http://www13.itrc.hp.com/service/cki/patchDocDisplay.do?admit=109447627+1230115265499+28353475&patchId=pdb_na-PHKL_37814-1%29
is garbage - referring to a version D.11.23.0804 or higher of USB-00 as being the only means to use the enhanced capabilities of the patch.

However http://docs.hp.com/en/13702/3-UpdatetoUSBDriverSupportonHPUX11iv2.pdf indicates that USB driver support for HP-UX will be maintained exclusively through patches (such as PHKL_37814) and that prior to the installation of the patch, you should remove USB-00.

I chose the latter advice to follow, removing USB-00 and installing PHKL_37814 and its dependances. Both routines require a reboot of the Ignite server.

If you have already installed PHKL_37814 and you still have USB-00 installed (viewable via swlist | grep USB) then swremove PHKL_3714 (requiring a reboot) and then USB-00 (requiring a reboot) and reinstall PHKL_3714 and it's dependencies (requiring a reboot.)

4. Perform a make_net_recovery

You may wish to use an already-taken make_net_recovery archive of the client target server. Note that you should if required, ensure that all of vg00 is archived.

The make_net_recovery archive subsequently written to the Ignite server shouldn't be much more than 3.9-4.0GB in size. Although your DVD media has a 4.7GB capacity, experience indicates that the LIF image and boot utilities that are combined with the archive take around 200MB. Okay, that should still leave you with space, but even with a 4.1-4.4GB make_net_recovery archive I have found that the DVD creation fails, though strictly-speaking there should be sufficient space on the DVD media to allow the full capacity to be employed.

If necessary you might have to work on the host server a little to ensure that all extraneous files and directories - such as core and crash dumps are removed/excluded so that the make_net_recovery archive will fit inside say 4.0GB. Remember though that the archive is gzipped and so a vg00 disk space usage of say 11GB after swap will create a make_net_recovery archive of around 3.9GB. During installation the gzipped archive will be expanded accordingly, off the DVD.

Implementation steps

Okay, at this point you should have an Ignite server with a suitable version of Ignite installed/upgraded, and prefereably the Ignite client whose image will be used will have also had a suitable Ignite version installed/upgraded.

Patch PHKL_37814 will have been installed, together with its dependencies, and package USB-00 WILL NOT BE PRESENT.

Before continuing it would be best to ensure the DVD writer can be seen on our Ignite server (in this example an RX1620) before continuing further.

Around the back of the server are two x USB 2.0 ports. If your server is (most likely) racked you will need either to find an gangplug adapter and some duct tape to run the cable from a wall adapter to your rack safely, or one of those neat IEC/<your countries mains adapter> converters. Either way your USB 2.0 cable supplied with the writer should be plugged into the rear of the HP server, the other end into the DVD writer and the power turned onto the writer. Pop a blank DVD +R so you don't have to go back to the server room later for this.

On the Ignite server, do an ioscan -FnCdisk and you should see an new entry for a HP dvd1040 writer, but no device files.

I next performed an insf -e but if you have "strange" devices attached to your Ignite server, such as a modem, be aware this command may redo and change permissions and ownership on such files from your chosen desires. As it is my RX1620 is pretty ordinary, so I could run insf -e without concern.

Do another ioscan You should see device files now for the writer, such as /dev/dsk/c5t0d0 and the character device file /dev/rdsk/c5t0d0.

Rather than wait for a later error, you may as well create the SCSI device control files now. These are required for the control of the writer, using the SCSI command set.

mknod /dev/rscsi/c5t0l0 c 203 0x050002

chmod 0600 /dev/rscsi/c5t0l0

Okay, now to manipulate the make_net_recovery archive. I have seen an example of people using the archive as-created, but I prefer to copy the file and give it a human-readable title.

The make_net_recovery archive should be something like;

/var/opt/ignite/recovery/archives/<hostname>/2008-11-14,09:06

In this case the gzip'ped file 2008-11-14,09:06 has the default format of date and time the archive was first written-to.

Create a directory for the key essential directories, files and ISO image that will be created by the writing-to-DVD routine. Such as;

/var/opt/ignite/recovery/archives/bootable_dvd

Inside this directory create another called archives and another called pseudo_root

cd to archives and copy the original make_net_recovery_archive and change its name. You could conceivably symbolically-link - but I've not tried that.

cp /var/opt/ignite/recovery/archives/<hostname>/2008-11-14,09:06 B.11.23_archive_IA.gz

Okay, hopefully you are with me so far.

Write the image to DVD

Either in a script, or from the command-line, execute the following command;

(from the command-line, substituting "client hostname" for the name of your Ignite client.)

cd /opt/ignite/data/scripts/examples
./make_media_install \
> -r B.11.23 -o IA \
> -f /var/opt/ignite/clients/<client hostname>/recovery/latest/archive_cfg \
> -f /var/opt/ignite/clients/<client hostname>/recovery/latest/control_cfg \
> -f /var/opt/ignite/clients/<client hostname>/recovery/latest/system_cfg \
> -a B.11.23_archive_IA.gz \
> -m /var/opt/ignite/recovery/archives/bootable_dvd \
> -p /var/opt/ignite/recovery/archives/bootable_dvd \
> -c /dev/rdsk/c5t0d0 \
> -M /mnt2

The location of your config files might not follow the /var/opt/ignite/clients/<client hostname>/recovery/latest convention, so change to suit.

The -M argument is for the mounting of the written DVD at a mount point (that has to exist) after the process of writing is complete. This doesn't always work to plan, but I've left it in as on one occasion it has worked.)

Upon executing the command the process is automatic. You will see output similar to that below;

=== Step 1: Make Ignite-UX config files for golden image archive(s) ===
+ /opt/ignite/lbin/make_arch_config -L /var/opt/ignite/recovery/archives/bootable_dvd/archives/. -n B.11.23_archive_IA.gz -d B.11.23_archive_IA.gz (B.11.23) -c /var/opt/ignite/recovery/archives/bootable_dvd/cfgs/B.11.23_archive_IA.gz.cfg.tmp -m t -C g -r ipf -b 64 -i 1 -t 999

(after some steps are performed, which include the writing of the image.iso file to /var/opt/ignite/recovery/archives/bootable_dvd, then the LIF volume and media image will be combined, for writing to the DVD.)
(snip)
99.01% done, estimate finish Tue Dec 23 12:34:09 2008
99.26% done, estimate finish Tue Dec 23 12:34:08 2008
99.50% done, estimate finish Tue Dec 23 12:34:09 2008
99.75% done, estimate finish Tue Dec 23 12:34:09 2008
Total translation table size: 2048
Total rockridge attributes bytes: 1463
Total directory bytes: 8192
Path table size(bytes): 72
Max brk space used 19000
2014999 extents written (3935 MB)
=== Step 5: Combine LIF volume and media image ===
+ /opt/ignite/lbin/instl_combine -C /var/opt/ignite/recovery/archives/bootable_dvd/image.iso
El Torito offset for LIF volume is: 0x50f800
Adjusting LIF file: ISL (Old iplstart: 4096; New iplstart: 5310464)
Adjusting LIF file: AUTO
Adjusting LIF file: INDEX
Adjusting LIF file: CONFIG
Adjusting LIF file: HPUX
Adjusting LIF file: IINSTALL
Adjusting LIF file: IINSTALLFS
Adjusting LIF file: INSTCMDSIA
Adjusting LIF file: SYSCMDSIA
Adjusting LIF file: SCRIPTS
Adjusting LIF file: PAD
=== Step 6: Write image file to tape/CD/DVD media ===
+ /opt/ignite/lbin/growisofs -Z /dev/rdsk/c5t0d0=/var/opt/ignite/recovery/archives/bootable_dvd/image.iso
Executing 'builtin_dd if=/var/opt/ignite/recovery/archives/bootable_dvd/image.iso of=/dev/rscsi/c5t0l0 obs=32k seek=0'
/dev/rscsi/c5t0l0: "Current Write Speed" is 6.6x1385KBps.
0/4126717952 ( 0.0%) @0x, remaining ??:??
0/4126717952 ( 0.0%) @0x, remaining ??:??
0/4126717952 ( 0.0%) @0x, remaining ??:??
0/4126717952 ( 0.0%) @0x, remaining ??:??
0/4126717952 ( 0.0%) @0x, remaining ??:??
0/4126717952 ( 0.0%) @0x, remaining ??:??
0/4126717952 ( 0.0%) @0x, remaining ??:??
0/4126717952 ( 0.0%) @0x, remaining ??:??
0/4126717952 ( 0.0%) @0x, remaining ??:??
0/4126717952 ( 0.0%) @0x, remaining ??:??
3506176/4126717952 ( 0.1%) @0.7x, remaining 783:59
34471936/4126717952 ( 0.8%) @6.5x, remaining 85:04
64618496/4126717952 ( 1.6%) @6.4x, remaining 48:11
96927744/4126717952 ( 2.3%) @6.8x, remaining 34:38
129728512/4126717952 ( 3.1%) @6.9x, remaining 27:12
158826496/4126717952 ( 3.8%) @6.1x, remaining 23:19
(snip)
3947986944/4126717952 (95.7%) @8.0x, remaining 0:17
3985670144/4126717952 (96.6%) @8.0x, remaining 0:13
4023353344/4126717952 (97.5%) @8.0x, remaining 0:09
4061069312/4126717952 (98.4%) @8.0x, remaining 0:06
4098752512/4126717952 (99.3%) @8.0x, remaining 0:02
builtin_dd: 2015008*2KB out
/dev/rscsi/c5t0l0: flushing cache
/dev/rscsi/c5t0l0: closing track
/dev/rscsi/c5t0l0: closing session
/dev/rscsi/c5t0l0: reloading tray
=== Step 7: Mount CD/DVD media for examination ===

(and that's it.)


If the auto-mounting of the DVD doesn't work, then do so with;

mount -F cdfs -o rr /dev/dsk/c5t0d0 /mnt2

Taking a look at the contents reveals that our image is remarkably similar to the contents of "bootable_dvd", minus the iso image file itself;

/mnt2# ls -al
total 390200
drwxr-x--- 1 root sys 2048 Dec 23 12:37 .
drwxr-xr-x 37 root root 8192 Dec 24 10:48 ..
-r--r--r-- 1 bin bin 5242880 Aug 27 05:21 EFI_CD_image
drwxr-x--- 1 root sys 2048 Dec 15 11:26 archives
-r--r--r-- 1 root sys 2048 Dec 23 12:31 boot.catalog
-rw-r----- 1 root sys 194519040 Dec 23 12:37 bootvol.lif
drwxr-x--- 1 root sys 2048 Dec 23 12:37 cfgs
drwxr-x--- 1 root sys 2048 Dec 23 12:32 depots
drwxr-x--- 1 root sys 2048 Dec 12 11:35 pseudo_root

Our make_net_recovery archive is in archives, and impact statements were written in cfgs/B.11.23_archive_IA.gz.cfg

Test the bootable DVD
Test the DVD in a suitable server's DVD ROM (i.e. one with the same architecture and one you can have an outage on.)

Open-up an MP console session and with the fresh DVD in the drive, reboot the server with shutdown -r -y 0

Stop the boot process and boot from the Internal DVD drive.

Okay, rather than copious screenshots, I'll just display the initial part of the boot, which is otherwise identical to any other boot from Ignite source. Suffice to say you are prompted for the language for your keyboard, and after some other initial screens the tabbed Ignite interactive screens are (not surprisingly) displayed.

I suggest that you arrange to actually rebuild the server using the DVD, to confirm it is correct in every way.

Please select a boot option

HP-UX Primary Boot: 0/1/1/0/4/0.0.0
Core LAN Gb B
EFI Shell [Built-in]
Internal Bootable DVD
boot lan adapter
DVD drive on 3/0
Boot Option Maintenance Menu
System Configuration


Use ^ and v to change option(s). Use Enter to select an option
Use ^ and v to change option(s). Use Enter to select an option
Loading.: Internal Bootable DVD
Searching for devices
HP Smart Array 6400-128 Controller (version 2.74) 1 Logical Drive
HP PCI-X 1Port 4Gb Fibre Channel Adapter (driver 1.09, firmware 4.00.090)
HP PCI-X 1Port 4Gb Fibre Channel Adapter (driver 1.09, firmware 4.00.090)
Starting: Internal Bootable DVD
(C) Copyright 1999-2006 Hewlett-Packard Development Company, L.P.
All rights reserved

HP-UX Boot Loader for IPF -- Revision 2.029

Press Any Key to interrupt Autoboot
\EFI\BOOT\AUTO ==> boot :IINSTALL
Seconds left till autoboot - 0
AUTOBOOTING...> System Memory = 32737 MB
loading section 0
....................................................................... (complete)
loading section 1
................ (complete)
loading symbol table
loading ram disk file IINSTALLFS).
......................................................................................
(complete)
Launching :IINSTALL
...