RAID1 rebuild fails due to disk errors
- by overlord_tm
Quick info: Dell R410 with 2x500GB drives in RAID1 on H700 Adapter
Recently one of drives in RAID1 array on server failed, lets call it Drive 0. RAID controller marked it as fault and put it offline. I replaced faulty disk with new one (same series and manufacturer, just bigger) and configured new disk as hot spare.
Rebuild from Drive1 started immediately and after 1.5 hour I got message that Drive 1 failed. Server was unresponsive (kernel panic) and required reboot. Given that half hour before this error rebuild was at about 40%, I estimated that new drive is not in sync yet and tried to reboot just with Drive 1.
RAID controller complained a bit about missing RAID arrays, but it found foreign RAID array on Drive 1 and I imported it. Server booted and it runs (from degraded RAID).
Here is SMART data for disks.
Drive 0 (the one that failed first)
ID# ATTRIBUTE_NAME FLAGS VALUE WORST THRESH FAIL RAW_VALUE
1 Raw_Read_Error_Rate POSR-K 200 200 051 - 1
3 Spin_Up_Time POS--K 142 142 021 - 3866
4 Start_Stop_Count -O--CK 100 100 000 - 12
5 Reallocated_Sector_Ct PO--CK 200 200 140 - 0
7 Seek_Error_Rate -OSR-K 200 200 000 - 0
9 Power_On_Hours -O--CK 086 086 000 - 10432
10 Spin_Retry_Count -O--CK 100 253 000 - 0
11 Calibration_Retry_Count -O--CK 100 253 000 - 0
12 Power_Cycle_Count -O--CK 100 100 000 - 11
192 Power-Off_Retract_Count -O--CK 200 200 000 - 10
193 Load_Cycle_Count -O--CK 200 200 000 - 1
194 Temperature_Celsius -O---K 112 106 000 - 31
196 Reallocated_Event_Count -O--CK 200 200 000 - 0
197 Current_Pending_Sector -O--CK 200 200 000 - 0
198 Offline_Uncorrectable ----CK 200 200 000 - 0
199 UDMA_CRC_Error_Count -O--CK 200 200 000 - 0
200 Multi_Zone_Error_Rate ---R-- 200 198 000 - 3
And Drive 1 (the drive which was reported healthy from controller until rebuild was attempted)
ID# ATTRIBUTE_NAME FLAGS VALUE WORST THRESH FAIL RAW_VALUE
1 Raw_Read_Error_Rate POSR-K 200 200 051 - 35
3 Spin_Up_Time POS--K 143 143 021 - 3841
4 Start_Stop_Count -O--CK 100 100 000 - 12
5 Reallocated_Sector_Ct PO--CK 200 200 140 - 0
7 Seek_Error_Rate -OSR-K 200 200 000 - 0
9 Power_On_Hours -O--CK 086 086 000 - 10455
10 Spin_Retry_Count -O--CK 100 253 000 - 0
11 Calibration_Retry_Count -O--CK 100 253 000 - 0
12 Power_Cycle_Count -O--CK 100 100 000 - 11
192 Power-Off_Retract_Count -O--CK 200 200 000 - 10
193 Load_Cycle_Count -O--CK 200 200 000 - 1
194 Temperature_Celsius -O---K 114 105 000 - 29
196 Reallocated_Event_Count -O--CK 200 200 000 - 0
197 Current_Pending_Sector -O--CK 200 200 000 - 3
198 Offline_Uncorrectable ----CK 100 253 000 - 0
199 UDMA_CRC_Error_Count -O--CK 200 200 000 - 0
200 Multi_Zone_Error_Rate ---R-- 100 253 000 - 0
In extended error logs from SMART I found:
Drive 0 has only one error
Error 1 [0] occurred at disk power-on lifetime: 10282 hours (428 days + 10 hours)
When the command that caused the error occurred, the device was active or idle.
After command completion occurred, registers were:
ER -- ST COUNT LBA_48 LH LM LL DV DC
-- -- -- == -- == == == -- -- -- -- --
10 -- 51 00 18 00 00 00 6a 24 20 40 00 Error: IDNF at LBA = 0x006a2420 = 6956064
Commands leading to the command that caused the error were:
CR FEATR COUNT LBA_48 LH LM LL DV DC Powered_Up_Time Command/Feature_Name
-- == -- == -- == == == -- -- -- -- -- --------------- --------------------
61 00 60 00 f8 00 00 00 6a 24 20 40 00 17d+20:25:18.105 WRITE FPDMA QUEUED
61 00 18 00 60 00 00 00 6a 24 00 40 00 17d+20:25:18.105 WRITE FPDMA QUEUED
61 00 80 00 58 00 00 00 6a 23 80 40 00 17d+20:25:18.105 WRITE FPDMA QUEUED
61 00 68 00 50 00 00 00 6a 23 18 40 00 17d+20:25:18.105 WRITE FPDMA QUEUED
61 00 10 00 10 00 00 00 6a 23 00 40 00 17d+20:25:18.104 WRITE FPDMA QUEUED
But Drive 1 has 883 errors. I see only few last ones and all errors I can see look like this:
Error 883 [18] occurred at disk power-on lifetime: 10454 hours (435 days + 14 hours)
When the command that caused the error occurred, the device was active or idle.
After command completion occurred, registers were:
ER -- ST COUNT LBA_48 LH LM LL DV DC
-- -- -- == -- == == == -- -- -- -- --
01 -- 51 00 80 00 00 39 97 19 c2 40 00 Error: AMNF at LBA = 0x399719c2 = 966203842
Commands leading to the command that caused the error were:
CR FEATR COUNT LBA_48 LH LM LL DV DC Powered_Up_Time Command/Feature_Name
-- == -- == -- == == == -- -- -- -- -- --------------- --------------------
60 00 80 00 00 00 00 39 97 19 80 40 00 1d+00:25:57.802 READ FPDMA QUEUED
2f 00 00 00 01 00 00 00 00 00 10 40 00 1d+00:25:57.779 READ LOG EXT
60 00 80 00 00 00 00 39 97 19 80 40 00 1d+00:25:55.704 READ FPDMA QUEUED
2f 00 00 00 01 00 00 00 00 00 10 40 00 1d+00:25:55.681 READ LOG EXT
60 00 80 00 00 00 00 39 97 19 80 40 00 1d+00:25:53.606 READ FPDMA QUEUED
Given those errors, is there any way I can rebuild RAID back, or should I make backup, shutdown server, replace disks with new ones and restore it? What about if I dd faulty disk to new one from linux running on USB/CD?
Also, if anyone have more experiences, what could be causes for those errors? Crappy controller or disks? Disks are about 1 year old, but it is pretty unbelievable to me that both would die within so short timespan.
