PowerEdge R6615 - ConnectX-6 DX Firmware Update Failure - Hybrid Firmware State Requires Resolution

Dear Dell Support Team,

I am requesting immediate assistance with a complex firmware issue on my Dell PowerEdge R6615 server involving Mellanox ConnectX-6 DX network adapters that are stuck in a hybrid firmware state preventing Dell firmware updates.

System Configuration

• Server Model: Dell PowerEdge R6615
• BIOS Version: 1.10.6
• Network Cards: 2x Mellanox ConnectX-6 Dx Dual Port 100 GbE QSFP56 Adapters
• Part Number: 0F6FXM_08P2T2_Ax
• PSID: DEL0000000027 (Correct Dell PSID)

Critical Issue Summary

ConnectX-6 DX adapters are in a problematic hybrid state with Dell PSID but generic Mellanox firmware, causing all Dell firmware updates to fail with "Bad parameter" errors. The secure firmware is rejecting updates due to cryptographic validation failures.

Current Firmware State:

• Dell Package: Network_Firmware_2CMVW_LN_22.41.10.00_01.BIN
• Current Firmware: 22.27.6106 (Generic Mellanox - incompatible with Dell PSID)
• Target Firmware: 22.41.1000
• Security Attributes: secure-fw (blocking updates)

Error Messages

• "Update failure. Bad parameter" from Dell update package
• "Burning FS4 image failed: Bad parameter" from mstflint
• "Changing PSID is unsupported under Secure FW" from Mellanox tools

Root Cause Analysis

The adapters were previously updated with generic Mellanox firmware while retaining Dell PSID DEL0000000027. This created a hybrid state where:

• Hardware shows correct Dell part number and PSID
• Firmware is non-Dell version (22.27.6106)
• Secure firmware rejects Dell updates due to state inconsistency
• All standard firmware tools fail with identical "Bad parameter" errors

Comprehensive Troubleshooting Completed

• UEFI Secure Boot: Disabled
• Network Interfaces: Brought down during update attempts
• Driver Modules: Unloaded (mlx5_core, mlx5_ib)
• MST Service: Restarted multiple times
• Firmware Resets: Performed on both cards using mstfwreset
• Multiple Tools Tested: Dell package, mstflint, mlxfwmanager, Dell mlxfwmanager
• Force Parameters: Attempted with --ignore_dev_data, --nofs flags

All methods fail identically, confirming this is a secure firmware validation issue requiring Dell-specific resolution.

Current Device Status

Device Type: ConnectX6DXPart Number: 0F6FXM_08P2T2_AxPSID: DEL0000000027Current FW: 22.27.6106Security Attributes: secure-fwPCI Addresses: 0000:45:00.0, 0000:82:00.0

Business Impact

• Production server requires firmware update for security patches
• Cards are functional but cannot receive Dell firmware updates
• Prevents compliance with Dell security recommendations

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