I forgot to mention the nut on the power input. I guess you found that.
Only the final digits of the BIOS revision are meaningful. The 3.48/3.50 prefix appears to depend on the hardware revision.
I still don't think your BIOS is corrupt. However, changing versions may trigger a configuration rebuild. At some point, you should experience a long pause in the boot process with an 'initializing' message.
You're right, it was a nut on the power supply, not wifi. I'm so used to the only threaded port on an IO shield being wifi haha. As for the boot issues, it was a indeed a corrupt BIOS. I was able to use a CH341a chip programmer to update the top BIOS chip with the VEP1400-X-BIOS-3.48.0.9-23.bin file. Booted up no issue.
I read through half the forum (it's so looong lol) and saw your comments about a long first initialization of the BIOS after an upgrade. Mine did that every time, proceeded to the POST messages, and then threw the errors and before hanging with a red LED. I think something in the installation process didn't properly take or finalize, causing my problems. Anyway, the good news is a a few minutes to flash seemed to have fixed the boot issue. I did go back into DiagOS and run the updater one last time for the PIC which wasn't fully updated, and that caused issues. On reboot it kept saying something like "2 HDDs are supported, only one found" and throwing a SATA error. It forced reboot three times before reverting to the secondary BIOS. It then got into a boot loop. After an unplug/plug cycle though it booted up without issues. I went to back into the DiagOS and this time the 2.6 updater script said everything was up to date. I'm never updating this device again though lol.
I'm in the process of getting OPNsense up and running. It installed on the emmc without issue using the serial console image and the installer user, per OPNsense documentation. No issues on that end.
TL;DR:
The Vectra S1 is a rebranded VEP1445 with the upgrade to a 960gb SATA SSD. It should behave like any other 640. That said...
When using the vep1400x_ufw_2.x file to update firmware and BIOS, I STRONGLY recommend using interactive mode and rebooting between each update. It's slower and annoying but if you update both the BIOS and the BIOS w/NVRAM (options 2 and 5 in interactive mode) without rebooting, there is a potential to corrupt both BIOS chips and brick your board. If this happens, getting a cheap CH341a programmer and manually programming the top mounted BIOS chip with a x.9-23 BIOS binary file will likely resurrect your board. In hindsight, I probably would skip the PIC and CPLD firmware updates as the dell utility does not seem particularly robust. Most issues, like boot loops or bricking, seem tied to updating the firmware of those devices.
Also, for posterity, the vectra has better labeling of the physical ports.
Within OPNsense I think these correspond to the following. Note MGT1/2 and "upside down" from the pattern of the Eth ports.
Code:
igb0 Eth0 Intel(R) I350 (Copper)
igb1 Eth1 Intel(R) I350 (Copper)
igb2 Eth2 Intel(R) I350 (Copper)
igb3 Eth3 Intel(R) I350 (Copper)
ix0 SFP1 Intel(R) X553 N (SFP+)
ix1 SFP2 Intel(R) X553 N (SFP+)
ix2 Mgt1 Intel(R) X553 (1GbE)
ix3 Mgt2 Intel(R) X553 (1GbE)
All in all, I'm happy that I got something with specs somewhere between a netgate 7100 and 8200 (albeit with the noticeable loss of 2.5gbe) but for significantly less cash.