I realize this question has been asked on this mailing list countless 
times, I think the difference here is I just want to gain a better 
understanding as to whats happening 'under the hood' as I track this 
problem to its source.

 From the logs, I get lots of:

Authenticate/Decrypt packet error: bad packet ID (may be a replay): [ 
#19084 ] -- see the man page entry for --no-replay and --replay-window 
for more info or silence this warning with --mute-replay-warnings

In fact, I get so many messages that if unwatched it fills up the disk 
on my VPS.

Now, connectivity is fine, the tunnel is used for commercial purposes, 
is quite stable and I can download a Debian iso at around 3mbits/sec.  
It's just while I'm downloading happily, my syslog is getting spammed to 
death with this message.

The server is run by StrongVPN, so settings like fragment, mssfix etc 
are provided by them. I have other StrongVPN tunnels that use the same 
settings with no bad packet messages, so in this case I'm sure the 
config is fine.

My research into the problem, mostly points to 2 places.  Duplicate 
packets, often caused by wireless networks and out of order packets.

Now from this server I can rule out wireless because it's VPS to VPS. 
And I don't think the packets are out of order, because I don't get any 
replay-backtrack messages.

In the meantime, I've moved this connection out of production so I can 
experiment with configs and tcpdumps.

So can anyone suggest where to look next?
Thanks a lot!


My config:

remote <REDACTED>
key-direction 1
client
dev tun0
resolv-retry infinite
nobind
persist-key
persist-tun
;http-proxy-retry
;http-proxy <REDACTED> 80
verb 3
;replay-window 64 20  -- this is from my own experimentation
reneg-sec 86400
echo <REDACTED>
tun-mtu 1500
route-method exe
route-delay 2
;redirect-gateway def1
comp-lzo no
explicit-exit-notify 2
fragment 1390
mssfix 1390
hand-window 30
<ca>
<REDACTED>
</ca>
<key>
<REDACTED>
</key>
<cert>
<REDACTED>
</cert>
<tls-auth>
<REDACTED>
</tls-auth>
route-noexec
script-security 2
up /etc/openvpn/up.sh  -- This script just sets up policy routing in 
Linux because the tunnel is not the default gw
down /etc/openvpn/down.sh


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