Solved with the "Reviving the T2 chip" suggestion. https://support.apple.com/en-gb/guide/apple-configurator-2/apdebea5be51/mac
I hope Apple will look into this since the current workaround is a bit convoluted (you need another Mac) and definitely not obvious.
Luckily the revive didn't mess with the drive so no data loss.
Thank you albertaki !
Guido
pizzarguy
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Just tried Beta 4 and got the same error and same log error. Went into recovery more and lower security to none but no change. Still error out.
May be worth looking at your log: cat /var/log/install.log
Thanks for the pointer. I tried one more time with a new volume and get this in the log:
2020-07-31 08:37:41-07 Mac-Pro osinstallersetupd[1096]: Retrieved package com.apple.dmg.BaseSystem (linkfile-validated:///Volumes/EtaBeta/macOS%20Install%20Data/UpdateBundle/AssetData/Restore/BaseSystem.chunklist:::/Volumes/EtaBeta/macOS%20Install%20Data/UpdateBundle/AssetData/Restore/BaseSystem.dmg)
2020-07-31 08:37:41-07 Mac-Pro osinstallersetupd[1096]: Starting bridgeOS update prepare
2020-07-31 08:38:14-07 Mac-Pro osinstallersetupd[1096]: bridgeOS prepare summary: 17P6065 -> 18P50335d, update = 18.16.10335.5.4, brain = 18.16.10335.5.4, variant = com.apple.bridgeOSCustomer, macOS = 19G73 (customer), project = BridgeOSInstall-77, userAuth = 0, prod fused = 1, model = j160ap, client = InstallAssistant, retries = 2, session = 9EFAC8A8-1385-4DC5-A188-0903C60C6B85: Error Domain=BOSErrorDomain Code=204 "An error occurred during preflight." UserInfo={NSLocalizedDescription=An error occurred during preflight., UpdateBundleIdentifier=com.apple.bridgeOSCustomer, NSUnderlyingError=0x7f8a86423a70 {Error Domain=BridgeOSSoftwareUpdateError Code=19 "MSU - 37 (FCRT migration failed.);NSPOSIXErrorDomain - 2 (failed to statfs /private/var/hardware);" UserInfo={SystemPartitionSize=1979666432, MSUErrorCode=37, MSUErrorDescription=FCRT migration failed., NSLocalizedDescription=MSU - 37 (FCRT migration failed.);NSPOSIXErrorDomain - 2 (failed to statfs /private/var/hardware);}}}
2020-07-31 08:38:14-07 Mac-Pro osinstallersetupd[1096]: bridgeOS update prepare complete
2020-07-31 08:38:14-07 Mac-Pro osinstallersetupd[1096]: bridgeOS update prepare failed: Error Domain=BOSErrorDomain Code=204 "An error occurred during preflight." UserInfo={NSLocalizedDescription=An error occurred during preflight., UpdateBundleIdentifier=com.apple.bridgeOSCustomer, NSUnderlyingError=0x7f8a86423a70 {Error Domain=BridgeOSSoftwareUpdateError Code=19 "MSU - 37 (FCRT migration failed.);NSPOSIXErrorDomain - 2 (failed to statfs /private/var/hardware);" UserInfo={SystemPartitionSize=1979666432, MSUErrorCode=37, MSUErrorDescription=FCRT migration failed., NSLocalizedDescription=MSU - 37 (FCRT migration failed.);NSPOSIXErrorDomain - 2 (failed to statfs /private/var/hardware);}}}
2020-07-31 08:38:14-07 Mac-Pro osinstallersetupd[1096]: Operation queue failed with error: Error Domain=com.apple.OSInstallerSetup.error Code=602 "An error occurred installing macOS." UserInfo={NSLocalizedRecoverySuggestion=You can try again to complete the installation., NSLocalizedDescription=An error occurred installing macOS., NSUnderlyingError=0x7f8a86423aa0 {Error Domain=BOSErrorDomain Code=204 "An error occurred during preflight." UserInfo={NSLocalizedDescription=An error occurred during preflight., UpdateBundleIdentifier=com.apple.bridgeOSCustomer, NSUnderlyingError=0x7f8a86423a70 {Error Domain=BridgeOSSoftwareUpdateError Code=19 "MSU - 37 (FCRT migration failed.);NSPOSIXErrorDomain - 2 (failed to statfs /private/var/hardware);" UserInfo={SystemPartitionSize=1979666432, MSUErrorCode=37, MSUErrorDescription=FCRT migration failed., NSLocalizedDescription=MSU - 37 (FCRT migration failed.);NSPOSIXErrorDomain - 2 (failed to statfs /private/var/hardware);}}}}}
2020-07-31 08:38:14-07 Mac-Pro InstallAssistant[1095]: Stopped operation queue with Error Domain=com.apple.OSInstallerSetup.error Code=602 "An error occurred installing macOS." UserInfo={NSUnderlyingError=0x7fe4a750ec50 {Error Domain=BOSErrorDomain Code=204 "An error occurred during preflight." UserInfo={NSUnderlyingError=0x7fe4a7587f80 {Error Domain=BridgeOSSoftwareUpdateError Code=19 "MSU - 37 (FCRT migration failed.);NSPOSIXErrorDomain - 2 (failed to statfs /private/var/hardware);" UserInfo={SystemPartitionSize=1979666432, MSUErrorCode=37, MSUErrorDescription=FCRT migration failed., NSLocalizedDescription=MSU - 37 (FCRT migration failed.);NSPOSIXErrorDomain - 2 (failed to statfs /private/var/hardware);}}, NSLocalizedDescription=An error occurred during preflight., UpdateBundleIdentifier=com.apple.bridgeOSCustomer}}, NSLocalizedRecoverySuggestion=You can try again to complete the installation., NSLocalizedDescription=An error occurred installing macOS.}
Getting the same exact issue. Tried either a new volume or a new partition. Same issue in both cases. Then tried to install Catalina on the new volume via recovery and from there download Beta 3 and try to upgrade onto the same drive. Same exact error.
I have a 2019 MacPro (12 cores, 96Gb, ProVega2, 4TB Drive) with XDR Display. Not sure if it's a hardware or software issue.