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Goverp
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PostPosted: Mon Feb 18, 2013 3:56 pm    Post subject: Can anyone help me diagnose a disk error Reply with quote

My 4-disk RAID 5 array occasionally (about once a month) throws errors like the listing below. The errors started about 3 months ago, and as far as I remember are all alike.
Code:
Feb 18 12:17:17 acer kernel: ata1.00: exception Emask 0x50 SAct 0x1 SErr 0x800 action 0x6 frozen
Feb 18 12:17:17 acer kernel: ata1.00: irq_stat 0x08000000, interface fatal error
Feb 18 12:17:17 acer kernel: ata1.00: cmd 61/50:00:1e:34:c1/00:00:1a:00:00/40 tag 0 ncq 40960 out
Feb 18 12:17:17 acer kernel: res 40/00:04:1e:34:c1/00:00:1a:00:00/40 Emask 0x50 (ATA bus error)
Feb 18 12:17:17 acer kernel: ata1: hard resetting link
Feb 18 12:17:17 acer kernel: ata1: SATA link up 3.0 Gbps (SStatus 123 SControl 300)
Feb 18 12:17:17 acer kernel: ata1.00: configured for UDMA/133
Feb 18 12:17:17 acer kernel: sd 0:0:0:0: [sda] 
Feb 18 12:17:17 acer kernel: Result: hostbyte=0x00 driverbyte=0x08
Feb 18 12:17:17 acer kernel: sd 0:0:0:0: [sda] 
Feb 18 12:17:17 acer kernel: Sense Key : 0xb [current] [descriptor]
Feb 18 12:17:17 acer kernel: Descriptor sense data with sense descriptors (in hex):
Feb 18 12:17:17 acer kernel: 72 0b 00 00 00 00 00 0c 00 0a 80 00 00 00 00 00
Feb 18 12:17:17 acer kernel: 1a c1 34 1e
Feb 18 12:17:17 acer kernel: sd 0:0:0:0: [sda] 
Feb 18 12:17:17 acer kernel: ASC=0x0 ASCQ=0x0
Feb 18 12:17:17 acer kernel: sd 0:0:0:0: [sda] CDB:
Feb 18 12:17:17 acer kernel: cdb[0]=0x2a: 2a 00 1a c1 34 1e 00 00 50 00
Feb 18 12:17:17 acer kernel: end_request: I/O error, dev sda, sector 448869406
Feb 18 12:17:17 acer kernel: ata1: EH complete
Feb 18 12:17:17 acer kernel: md/raid:md127: Disk failure on sda3, disabling device.
Feb 18 12:17:17 acer kernel: md/raid:md127: Operation continuing on 3 devices.
Feb 18 12:17:17 acer kernel: RAID conf printout:
Feb 18 12:17:17 acer kernel: --- level:5 rd:4 wd:3
Feb 18 12:17:17 acer kernel: disk 0, o:0, dev:sda3
Feb 18 12:17:17 acer kernel: disk 1, o:1, dev:sdb3
Feb 18 12:17:17 acer kernel: disk 2, o:1, dev:sdc3
Feb 18 12:17:17 acer kernel: disk 3, o:1, dev:sdd3
Feb 18 12:17:17 acer kernel: RAID conf printout:
Feb 18 12:17:17 acer kernel: --- level:5 rd:4 wd:3
Feb 18 12:17:17 acer kernel: disk 1, o:1, dev:sdb3
Feb 18 12:17:17 acer kernel: disk 2, o:1, dev:sdc3
Feb 18 12:17:17 acer kernel: disk 3, o:1, dev:sdd3
Feb 18 12:17:17 acer mdadm[1601]: Fail event detected on md device /dev/md127, component device /dev/sda3

What's strange is that the disk showing the error keeps changing - first /dev/sdb, then /dev/sdd twice, now /dev/sda, which makes me wonder if it's really an I/O error.

The drives are all WD Caviar Blue; running the WD disk diagnostic program offline detects no problems, and SMART has recorded nothing. Just for good measure, after the above error, I ran the SMART offline long self-test against /dev/sda, but the SMART data (below) shows no problems at all.

I re-seated all the drive cables some time ago, but have had a couple of errors since then.

Can anyone suggest how I can diagnose this further, or explain what the kernel is trying to tell me?
Code:
acer ~ # smartctl -a /dev/sda
smartctl 5.42 2011-10-20 r3458 [x86_64-linux-3.6.11-gentoolxc] (local build)
Copyright (C) 2002-11 by Bruce Allen, http://smartmontools.sourceforge.net

=== START OF INFORMATION SECTION ===
Model Family:     Western Digital Caviar Blue Serial ATA
Device Model:     WDC WD3200AAJS-22B4A0
Serial Number:    WD-WCAT13916727
LU WWN Device Id: 5 0014ee 1014538b7
Firmware Version: 01.03A01
User Capacity:    320,072,933,376 bytes [320 GB]
Sector Size:      512 bytes logical/physical
Device is:        In smartctl database [for details use: -P show]
ATA Version is:   8
ATA Standard is:  Exact ATA specification draft version not indicated
Local Time is:    Mon Feb 18 14:14:36 2013 GMT
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:  (0x84) Offline data collection activity
                                        was suspended by an interrupting command from host.
                                        Auto Offline Data Collection: Enabled.
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:                ( 5400) 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:        (  66) minutes.
Conveyance self-test routine
recommended polling time:        (   5) minutes.
SCT capabilities:              (0x303f) SCT Status supported.
                                        SCT Error Recovery Control 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     0x002f   200   200   051    Pre-fail  Always       -       0
  3 Spin_Up_Time            0x0027   156   153   021    Pre-fail  Always       -       3158
  4 Start_Stop_Count        0x0032   098   098   000    Old_age   Always       -       2022
  5 Reallocated_Sector_Ct   0x0033   200   200   140    Pre-fail  Always       -       0
  7 Seek_Error_Rate         0x002e   200   200   000    Old_age   Always       -       0
  9 Power_On_Hours          0x0032   091   091   000    Old_age   Always       -       7117
 10 Spin_Retry_Count        0x0032   100   100   000    Old_age   Always       -       0
 11 Calibration_Retry_Count 0x0032   100   100   000    Old_age   Always       -       0
 12 Power_Cycle_Count       0x0032   099   099   000    Old_age   Always       -       1999
192 Power-Off_Retract_Count 0x0032   200   200   000    Old_age   Always       -       132
193 Load_Cycle_Count        0x0032   200   200   000    Old_age   Always       -       2022
194 Temperature_Celsius     0x0022   103   092   000    Old_age   Always       -       40
196 Reallocated_Event_Count 0x0032   200   200   000    Old_age   Always       -       0
197 Current_Pending_Sector  0x0032   200   200   000    Old_age   Always       -       0
198 Offline_Uncorrectable   0x0030   200   200   000    Old_age   Offline      -       0
199 UDMA_CRC_Error_Count    0x0032   200   200   000    Old_age   Always       -       5
200 Multi_Zone_Error_Rate   0x0008   200   200   000    Old_age   Offline      -       0

SMART Error Log Version: 1
No Errors Logged

SMART Self-test log structure revision number 1
Num  Test_Description    Status                  Remaining  LifeTime(hours)  LBA_of_first_error
# 1  Extended offline    Completed without error       00%      7117         -
# 2  Short offline       Completed without error       00%      7115         -
# 3  Short offline       Completed without error       00%      7111         -
# 4  Short offline       Completed without error       00%      7099         -
# 5  Short offline       Completed without error       00%      7092         -
# 6  Short offline       Completed without error       00%      7087         -
# 7  Short offline       Completed without error       00%      7077         -
# 8  Short offline       Completed without error       00%      7068         -
# 9  Short offline       Completed without error       00%      7063         -
#10  Short offline       Completed without error       00%      7061         -
#11  Short offline       Completed without error       00%      7056         -
#12  Short offline       Completed without error       00%      7051         -
#13  Short offline       Completed without error       00%      7047         -
#14  Short offline       Completed without error       00%      7038         -
#15  Conveyance offline  Completed without error       00%      7030         -
#16  Conveyance offline  Completed without error       00%      7030         -
#17  Short offline       Completed without error       00%      7028         -
#18  Short offline       Completed without error       00%      7017         -
#19  Short offline       Completed without error       00%      7017         -
#20  Short offline       Completed without error       00%      7015         -
#21  Short offline       Completed without error       00%      7007         -

SMART 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.

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NeddySeagoon
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PostPosted: Mon Feb 18, 2013 4:16 pm    Post subject: Reply with quote

Goverp,

Something happened at sector 448869406. and the kernel did its error handling thing (EH Complete)
Code:
Feb 18 12:17:17 acer kernel: end_request: I/O error, dev sda, sector 448869406
Feb 18 12:17:17 acer kernel: ata1: EH complete
Feb 18 12:17:17 acer kernel: md/raid:md127: Disk failure on sda3, disabling device.
Feb 18 12:17:17 acer kernel: md/raid:md127: Operation continuing on 3 devices.

but too late to avoid the drive being kicked out the the array.

Do the following
Code:
echo repair  > /sys/block/md127/md/sync_action

Before you start the above, have a look at dmesg and save all of the drives smart data to a set of files so you can refer to it later.
This will read all the drives in md127 and where there is a read error, the redundant data will be recreated. This will force bad blocks to be remapped.

When it completes, check the
Code:
  5 Reallocated_Sector_Ct   0x0033   200   200   140    Pre-fail  Always       -       0
196 Reallocated_Event_Count 0x0032   200   200   000    Old_age   Always       -       0
197 Current_Pending_Sector  0x0032   200   200   000    Old_age   Always       -       0
for each drive against the files you made at the start.
Non zero values do not indicate a dead/dying drive. The drive is supposed to reallocate failing sectors but preserve the data as it does so.
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NeddySeagoon

Computer users fall into two groups:-
those that do backups
those that have never had a hard drive fail.
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Goverp
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PostPosted: Thu Feb 21, 2013 4:11 pm    Post subject: Reply with quote

I looked at the SMART data, but it's unchanged. Unfortunately, I ran the WD diagnostics/repair utility before collecting the SMART data shown above, so there have been no more repairs. But looking at the data, there weren't any anyway - which at least is consistent with the WD utility, which found no errors despite doing a surface scan.

It probably does other stuff, but WD don't say. One time I ran it after one of these fleeting I/O errors did actually claim to have fixed an error, but it didn't say what sort of error, and whatever it did didn't change the SMART counters.

I'll stick to taking backups, and hope the failure goes hard in the next couple of months before the warranty expires. The cynic in me expects the SMART data to take a turn for the worse on expiry-date+1. ;-)
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PostPosted: Fri Feb 22, 2013 7:50 pm    Post subject: Reply with quote

Goverp,

You can try replacing the data cables or even just "wiping the contacts" by unplugging them and reconnecting them.
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NeddySeagoon

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