In my case, the home rig is not a certified system so I wrote it up to *something* not working quite right because of that. While I dont believe that is exactly the case, it wasnt a huge deal for me so I didnt look into it too much. As far as keeping it from happening in the future, I'm not sure how to answer that other than "I always expect updates to cause problems so that when they dont, I'm pleasantly surprised". I run all our hosts from flash drives and keep images of the running configs on my desktop, laptop, and cell phone. When doing a backup, I use one of the spare flash drives and apply the image to it then push the update. If there are any problems with the update I shutdown and replace the updated drive with the old drive and start trying to figure out what went wrong and why. I know this doesnt really help your situation because of the geography involved and is generally convoluted but it works and makes the big wigs happy because there are multiple "backup" points during upgrades.
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