Thanks Jonathan,

I'm starting to expect it has to be the controller as well. About 20 minutes after I posted this message yesterday (and thus 20 minutes after ad6 got disconnected - atacontrol list showed "no device present" for it) the machine crashed while writing to the remaining ad4 drive (kernel panic). I attached the logs below. I also ran the long smart self test on both drives, and no errors were found on either drive (logs also attached).

Unfortunately I could not attach the new disks to my mainboard SATA because my mainboard SATA somehow hangs trying to detect them. So I cannot test if *not* using the controller is going to solve the problems, though I'm it seems logical at the moment it has to be the controller, especially if other people have had similar issues.

I guess I'll be buying another controller.

Regards,
Sebastiaan

Jonathan Groll wrote:
On Wed, Aug 13, 2008 at 03:10:56PM +0200, Sebastiaan van Erk wrote:
Hi,

Just an update on this issue.

Quick summary: I fixed the BIOS issues, the hardware monitor issues, and the rl0/rl1 watchdog timeout issues (it seems). However I'm still having problems with my SATA drives (or at least one of them). More info below.

BIOS:
I flashed my BIOS to the latest version about a year ago, and never noticed that there was any problem, but it turns out there was. I never reset the BIOS to default factory settings after the upgrade, and it seems the settings were corrupt. After having reset the BIOS to the "default optimized factory settings" it stopped crashing when I go into the H/W monitor and also when using healthd -d (output below):

Temp.= 40.0, 36.0, 66.0; Rot.=    0,    0,    0
 Vcore = 1.44, 3.12; Volt. = 3.34, 5.00,  1.95,  -0.11, -1.54
Temp.= 40.0, 36.0, 66.0; Rot.=    0,    0,    0
 Vcore = 1.44, 3.14; Volt. = 3.33, 4.97,  1.95,  -0.11, -1.54
Temp.= 40.0, 36.0, 66.0; Rot.=    0,    0,    0
 Vcore = 1.44, 3.12; Volt. = 3.34, 4.97,  1.95,  -0.11, -1.54
Temp.= 40.0, 36.0, 66.0; Rot.=    0,    0,    0
 Vcore = 1.44, 3.12; Volt. = 3.34, 5.00,  1.95,  -0.11, -1.54
Temp.= 40.0, 36.0, 66.0; Rot.=    0,    0,    0
 Vcore = 1.44, 3.12; Volt. = 3.34, 5.00,  1.95,  -0.11, -1.54

This also seems to have fixed the rl0 watchdog timeout problems. I no longer see those in my logs.

SATA DRIVES:

I'm still having problems with the SATA drives.

I tried connecting the 1TB Samsung drives to my mainboard, but then the box hangs when booting with the "Detecting IDE drives" message. The regular (PATA) IDE drives are detected first, and then it repeats the "Detecting IDE drives" message to detect the sata drives, and hangs. When I connect my 250GB SATA drives to my mainboard they detect fine, and the box boots normally.

I did another rsync of my old mirror (the 250GB disks) to the new mirror (1TB disks), but again one of the disks got detached. This time there are no other messages in the log, the only thing I see is the following:

Aug 13 14:35:27 piglet su: sebster to root on /dev/ttyp5
Aug 13 14:55:38 piglet kernel: ad6: FAILURE - device detached
Aug 13 14:55:38 piglet kernel: subdisk6: detached
Aug 13 14:55:38 piglet kernel: ad6: detached
Aug 13 14:55:38 piglet kernel: GEOM_MIRROR: Device gm1: provider ad6 disconnected.
Aug 13 15:00:00 piglet newsyslog[1800]: logfile turned over due to size>100K

(unfortunate that the log file just got rotated, but in the new log file there is nothing execpt the one expected line:

Aug 13 15:00:00 piglet newsyslog[1800]: logfile turned over due to size>100K

So, nothing after the disconnect...

The questions I have now is:
1) Could an upgrade to FreeBSD 7-STABLE fix the issue (it's a LOT of work for me, but I'll do it if there are SATA driver issues fixed).

I suspect the problem may be the SiI driver in Freebsd. As a reference
point, I've had a similar problem, even on 7-STABLE, but with sparc64
hardware (see earlier post in this thread).

It'll probably be simplest for you to just buy another controller of
another brand. On the other hand, it'll be worth knowing exactly what
is wrong with the SiI driver...

Cheers,
Jonathan
Aug 13 15:00:00 piglet newsyslog[1800]: logfile turned over due to size>100K
Aug 13 15:11:26 piglet su: sebster to root on /dev/ttyp4
Aug 13 15:34:55 piglet kernel: mirror/gm1s1e[WRITE(offset=875450693632, 
length=2048)]error = 6
Aug 13 15:34:55 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450695680, length=2048)]error = 6

[snip 335750 similar lines]

Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450931200, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450933248, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450935296, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450937344, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450939392, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450941440, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450943488, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450945536, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450947584, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450949632, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450951680, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450953728, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450955776, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450957824, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450959872, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450961920, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450963968, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450966016, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450968064, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450970112, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450972160, length=2048)]error = 6
Aug 13 15:36:30 piglet kernel: 
g_vfs_done():mirror/gm1s1e[WRITE(offset=875450974208, length=2048)]error = 6
Aug 13 15:42:23 piglet syslogd: kernel boot file is /boot/kernel/kernel
Aug 13 15:42:23 piglet kernel: Copyright (c) 1992-2008 The FreeBSD Project.
smartctl version 5.38 [i386-portbld-freebsd6.3] Copyright (C) 2002-8 Bruce Allen
Home page is http://smartmontools.sourceforge.net/

=== START OF INFORMATION SECTION ===
Device Model:     SAMSUNG HD103UJ
Serial Number:    S13PJ1BQ606865
Firmware Version: 1AA01112
User Capacity:    1,000,204,886,016 bytes
Device is:        In smartctl database [for details use: -P show]
ATA Version is:   8
ATA Standard is:  ATA-8-ACS revision 3b
Local Time is:    Thu Aug 14 11:28:13 2008 CEST

==> WARNING: May need -F samsung or -F samsung2 enabled; see manual for details.

SMART support is: Available - device has SMART capability.
SMART support is: Enabled

=== START OF READ SMART DATA SECTION ===
SMART overall-health self-assessment test result: PASSED

General SMART Values:
Offline data collection status:  (0x02) Offline data collection activity
                                        was completed without error.
                                        Auto Offline Data Collection: Disabled.
Self-test execution status:      (   0) The previous self-test routine completed
                                        without error or no self-test has ever 
                                        been run.
Total time to complete Offline 
data collection:                 (11811) seconds.
Offline data collection
capabilities:                    (0x7b) SMART execute Offline immediate.
                                        Auto Offline data collection on/off 
support.
                                        Suspend Offline collection upon new
                                        command.
                                        Offline surface scan supported.
                                        Self-test supported.
                                        Conveyance Self-test supported.
                                        Selective Self-test supported.
SMART capabilities:            (0x0003) Saves SMART data before entering
                                        power-saving mode.
                                        Supports SMART auto save timer.
Error logging capability:        (0x01) Error logging supported.
                                        General Purpose Logging supported.
Short self-test routine 
recommended polling time:        (   2) minutes.
Extended self-test routine
recommended polling time:        ( 198) minutes.
Conveyance self-test routine
recommended polling time:        (  21) minutes.
SCT capabilities:              (0x003f) SCT Status supported.
                                        SCT Feature Control supported.
                                        SCT Data Table supported.

SMART Attributes Data Structure revision number: 16
Vendor Specific SMART Attributes with Thresholds:
ID# ATTRIBUTE_NAME          FLAG     VALUE WORST THRESH TYPE      UPDATED  
WHEN_FAILED RAW_VALUE
  1 Raw_Read_Error_Rate     0x000f   100   100   051    Pre-fail  Always       
-       0
  3 Spin_Up_Time            0x0007   076   076   011    Pre-fail  Always       
-       8010
  4 Start_Stop_Count        0x0032   100   100   000    Old_age   Always       
-       8
  5 Reallocated_Sector_Ct   0x0033   100   100   010    Pre-fail  Always       
-       0
  7 Seek_Error_Rate         0x000f   253   253   051    Pre-fail  Always       
-       0
  8 Seek_Time_Performance   0x0025   100   100   015    Pre-fail  Offline      
-       10255
  9 Power_On_Hours          0x0032   100   100   000    Old_age   Always       
-       272
 10 Spin_Retry_Count        0x0033   100   100   051    Pre-fail  Always       
-       0
 11 Calibration_Retry_Count 0x0012   100   100   000    Old_age   Always       
-       0
 12 Power_Cycle_Count       0x0032   100   100   000    Old_age   Always       
-       8
 13 Read_Soft_Error_Rate    0x000e   100   100   000    Old_age   Always       
-       0
183 Unknown_Attribute       0x0032   100   100   000    Old_age   Always       
-       0
184 Unknown_Attribute       0x0033   100   100   099    Pre-fail  Always       
-       0
187 Reported_Uncorrect      0x0032   100   100   000    Old_age   Always       
-       0
188 Unknown_Attribute       0x0032   100   100   000    Old_age   Always       
-       0
190 Airflow_Temperature_Cel 0x0022   057   052   000    Old_age   Always       
-       43 (Lifetime Min/Max 43/48)
194 Temperature_Celsius     0x0022   056   050   000    Old_age   Always       
-       44 (Lifetime Min/Max 43/50)
195 Hardware_ECC_Recovered  0x001a   100   100   000    Old_age   Always       
-       195799724
196 Reallocated_Event_Count 0x0032   100   100   000    Old_age   Always       
-       0
197 Current_Pending_Sector  0x0012   100   100   000    Old_age   Always       
-       0
198 Offline_Uncorrectable   0x0030   100   100   000    Old_age   Offline      
-       0
199 UDMA_CRC_Error_Count    0x003e   100   100   000    Old_age   Always       
-       0
200 Multi_Zone_Error_Rate   0x000a   100   100   000    Old_age   Always       
-       0
201 Soft_Read_Error_Rate    0x000a   100   100   000    Old_age   Always       
-       0

SMART Error Log Version: 1
No Errors Logged

SMART Self-test log structure revision number 0
Warning: ATA Specification requires self-test log structure revision number = 1
Num  Test_Description    Status                  Remaining  LifeTime(hours)  
LBA_of_first_error
# 1  Offline             Completed without error       00%       261         -
# 2  Offline             Aborted by host               40%       251         -
# 3  Short offline       Aborted by host               00%       250         -

SMART Selective Self-Test Log Data Structure Revision Number (0) should be 1
SMART Selective self-test log data structure revision number 0
Warning: ATA Specification requires selective self-test log data structure 
revision number = 1
 SPAN  MIN_LBA  MAX_LBA  CURRENT_TEST_STATUS
    1        0        0  Not_testing
    2        0        0  Not_testing
    3        0        0  Not_testing
    4        0        0  Not_testing
    5        0        0  Not_testing
Selective self-test flags (0x0):
  After scanning selected spans, do NOT read-scan remainder of disk.
If Selective self-test is pending on power-up, resume after 0 minute delay.

smartctl version 5.38 [i386-portbld-freebsd6.3] Copyright (C) 2002-8 Bruce Allen
Home page is http://smartmontools.sourceforge.net/

=== START OF INFORMATION SECTION ===
Device Model:     SAMSUNG HD103UJ
Serial Number:    S13PJ1BQ607102
Firmware Version: 1AA01112
User Capacity:    1,000,204,886,016 bytes
Device is:        In smartctl database [for details use: -P show]
ATA Version is:   8
ATA Standard is:  ATA-8-ACS revision 3b
Local Time is:    Thu Aug 14 11:28:39 2008 CEST

==> WARNING: May need -F samsung or -F samsung2 enabled; see manual for details.

SMART support is: Available - device has SMART capability.
SMART support is: Enabled

=== START OF READ SMART DATA SECTION ===
SMART overall-health self-assessment test result: PASSED

General SMART Values:
Offline data collection status:  (0x02) Offline data collection activity
                                        was completed without error.
                                        Auto Offline Data Collection: Disabled.
Self-test execution status:      (   0) The previous self-test routine completed
                                        without error or no self-test has ever 
                                        been run.
Total time to complete Offline 
data collection:                 (12131) seconds.
Offline data collection
capabilities:                    (0x7b) SMART execute Offline immediate.
                                        Auto Offline data collection on/off 
support.
                                        Suspend Offline collection upon new
                                        command.
                                        Offline surface scan supported.
                                        Self-test supported.
                                        Conveyance Self-test supported.
                                        Selective Self-test supported.
SMART capabilities:            (0x0003) Saves SMART data before entering
                                        power-saving mode.
                                        Supports SMART auto save timer.
Error logging capability:        (0x01) Error logging supported.
                                        General Purpose Logging supported.
Short self-test routine 
recommended polling time:        (   2) minutes.
Extended self-test routine
recommended polling time:        ( 203) minutes.
Conveyance self-test routine
recommended polling time:        (  22) minutes.
SCT capabilities:              (0x003f) SCT Status supported.
                                        SCT Feature Control supported.
                                        SCT Data Table supported.

SMART Attributes Data Structure revision number: 16
Vendor Specific SMART Attributes with Thresholds:
ID# ATTRIBUTE_NAME          FLAG     VALUE WORST THRESH TYPE      UPDATED  
WHEN_FAILED RAW_VALUE
  1 Raw_Read_Error_Rate     0x000f   100   100   051    Pre-fail  Always       
-       0
  3 Spin_Up_Time            0x0007   077   077   011    Pre-fail  Always       
-       7810
  4 Start_Stop_Count        0x0032   100   100   000    Old_age   Always       
-       10
  5 Reallocated_Sector_Ct   0x0033   100   100   010    Pre-fail  Always       
-       0
  7 Seek_Error_Rate         0x000f   253   253   051    Pre-fail  Always       
-       0
  8 Seek_Time_Performance   0x0025   100   100   015    Pre-fail  Offline      
-       9978
  9 Power_On_Hours          0x0032   100   100   000    Old_age   Always       
-       272
 10 Spin_Retry_Count        0x0033   100   100   051    Pre-fail  Always       
-       0
 11 Calibration_Retry_Count 0x0012   100   100   000    Old_age   Always       
-       0
 12 Power_Cycle_Count       0x0032   100   100   000    Old_age   Always       
-       10
 13 Read_Soft_Error_Rate    0x000e   100   100   000    Old_age   Always       
-       0
183 Unknown_Attribute       0x0032   100   100   000    Old_age   Always       
-       0
184 Unknown_Attribute       0x0033   100   100   099    Pre-fail  Always       
-       0
187 Reported_Uncorrect      0x0032   100   100   000    Old_age   Always       
-       0
188 Unknown_Attribute       0x0032   100   100   000    Old_age   Always       
-       0
190 Airflow_Temperature_Cel 0x0022   059   054   000    Old_age   Always       
-       41 (Lifetime Min/Max 41/46)
194 Temperature_Celsius     0x0022   058   053   000    Old_age   Always       
-       42 (Lifetime Min/Max 41/47)
195 Hardware_ECC_Recovered  0x001a   100   100   000    Old_age   Always       
-       31616
196 Reallocated_Event_Count 0x0032   100   100   000    Old_age   Always       
-       0
197 Current_Pending_Sector  0x0012   100   100   000    Old_age   Always       
-       0
198 Offline_Uncorrectable   0x0030   100   100   000    Old_age   Offline      
-       0
199 UDMA_CRC_Error_Count    0x003e   100   100   000    Old_age   Always       
-       0
200 Multi_Zone_Error_Rate   0x000a   100   100   000    Old_age   Always       
-       0
201 Soft_Read_Error_Rate    0x000a   100   100   000    Old_age   Always       
-       0

SMART Error Log Version: 1
No Errors Logged

SMART Self-test log structure revision number 0
Warning: ATA Specification requires self-test log structure revision number = 1
Num  Test_Description    Status                  Remaining  LifeTime(hours)  
LBA_of_first_error
# 1  Offline             Completed without error       00%       261         -
# 2  Offline             Aborted by host               40%       251         -
# 3  Short offline       Aborted by host               00%       250         -

SMART Selective Self-Test Log Data Structure Revision Number (0) should be 1
SMART Selective self-test log data structure revision number 0
Warning: ATA Specification requires selective self-test log data structure 
revision number = 1
 SPAN  MIN_LBA  MAX_LBA  CURRENT_TEST_STATUS
    1        0        0  Not_testing
    2        0        0  Not_testing
    3        0        0  Not_testing
    4        0        0  Not_testing
    5        0        0  Not_testing
Selective self-test flags (0x0):
  After scanning selected spans, do NOT read-scan remainder of disk.
If Selective self-test is pending on power-up, resume after 0 minute delay.

Attachment: smime.p7s
Description: S/MIME Cryptographic Signature

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