Errors attempting to format SAS drives for use in UnRAID


Go to solution Solved by upsidedownlemon,

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I'm looking for some advise with some SAS drives I have purchased.

Background: I have been using UnRAID for about 18 months on consumer grade hardware. Currently working on my 3-2-1 backups which is the reason for these SAS drives - to act as cold offsite storage. I am potentially interested in using them for an array in future, especially once I get my solar set up and energy does not cost as much.

 

As it feels like I have read every forum thread on this issue, I am including lots of details for others in my position.

 

I purchased 5 x SEAGATE 4TB SAS drives (ST4000NM0023 SEAGATE  DKS2E-H4R0SS with 7FA6 firmware, date 15227, DOM 11/2014) to act as cold storage for my main UnRAID server. Along with this I have a ICY BOX 4-bay SAS/SATA enclosure with a IBM H1110 + SFF8087 (Broadcom / LSI SAS2008 PCI-Express Fusion-MPT SAS-2) I purchased off eBay which has been flashed with 20.00.07.00 and is in IT mode (wonder if it's possible to not be in IT mode after firmware flashing? At this point I feel like I would be happy with single-disk RAID pool).

 

Admittedly this is all new to me, the drives were cheap so I figured I'd give it a go. I have this hardware installed in a spare Dell Optiplex 9020 workstation - hence the unlicensed UnRAID install.

 

Prior to doing all the research I have done, I thought I needed to be messing with some of the settings in the HBA card (e.g boot support - BIOS & OS, OS only, BIOS only, disabled etc). I now (think ?) I understand that the HBA card is providing direct access to the disks and this setting would not change anything.

 

When the disks were firstly installed to UnRAID I was getting errors as the drives had 520 byte sectors on them. I used `sg_format -v --format --size=512 /dev/sdX` which took ~16 hours or so. After this, I was still not able to see the drive in the drop-down in UnRAID.

I was also unsuccessful in initializing the drives in Windows.

 

I came across openSeaChest which I ran against 1 drive to reformat into 512 byte sectors. After this completed, I am now able to see the drive in the UnRAID GUI, however I get issues when attempting to format the device. The other drives have only been run through sg_format and do not show up in UnRAID GUI.

 

It feels like I have been through every permutation of PCIe slots for the HBA card, cables, re-format options, BIOS settings and drives and am still not able to format the drive so I can write data. I have not tried another machine however am happy to do so

 

Running smartctl I can see the device is now 512 byte sectors, SMART status is OK, drives are (a bit) old with ~7 years power on time etc.

 

Running gdisk I can see similar info from the drive, though looks like there are some errors

 

root@Tower2:~# gdisk /dev/sdc
GPT fdisk (gdisk) version 1.0.8

Caution: invalid backup GPT header, but valid main header; regenerating
backup header from main header.

Warning! Main and backup partition tables differ! Use the 'c' and 'e' options
on the recovery & transformation menu to examine the two tables.

Warning! One or more CRCs don't match. You should repair the disk!
Main header: OK
Backup header: ERROR
Main partition table: OK
Backup partition table: ERROR

Partition table scan:
  MBR: protective
  BSD: not present
  APM: not present
  GPT: damaged

****************************************************************************
Caution: Found protective or hybrid MBR and corrupt GPT. Using GPT, but disk
verification and recovery are STRONGLY recommended.
****************************************************************************

Command (? for help): p
Disk /dev/sdc: 7814037168 sectors, 3.6 TiB
Model: DKS2E-H4R0SS    
Sector size (logical/physical): 512/512 bytes
Disk identifier (GUID): CBBB871C-C891-4CBF-BD23-0647EE876F75
Partition table holds up to 128 entries
Main partition table begins at sector 2 and ends at sector 33
First usable sector is 34, last usable sector is 7814037134
Partitions will be aligned on 2048-sector boundaries
Total free space is 2014 sectors (1007.0 KiB)

Number  Start (sector)    End (sector)  Size       Code  Name
   1            2048      7814037134   3.6 TiB     8300  Linux filesystem

Command (? for help): 

 

Attempting to delete the partition and re-create in gdisk:

 

Command (? for help): d
Using 1

Command (? for help): n
Partition number (1-128, default 1): 
First sector (34-7814037134, default = 2048) or {+-}size{KMGTP}: 
Last sector (2048-7814037134, default = 7814037134) or {+-}size{KMGTP}: 
Current type is 8300 (Linux filesystem)
Hex code or GUID (L to show codes, Enter = 8300): 
Changed type of partition to 'Linux filesystem'

Command (? for help): w

Final checks complete. About to write GPT data. THIS WILL OVERWRITE EXISTING
PARTITIONS!!

Do you want to proceed? (Y/N): Y
OK; writing new GUID partition table (GPT) to /dev/sdc.
The operation has completed successfully.
root@Tower2:~# gdisk /dev/sdc
GPT fdisk (gdisk) version 1.0.8

Caution: invalid backup GPT header, but valid main header; regenerating
backup header from main header.

Warning! Main and backup partition tables differ! Use the 'c' and 'e' options
on the recovery & transformation menu to examine the two tables.

Warning! One or more CRCs don't match. You should repair the disk!
Main header: OK
Backup header: ERROR
Main partition table: OK
Backup partition table: ERROR

Partition table scan:
  MBR: protective
  BSD: not present
  APM: not present
  GPT: damaged

****************************************************************************
Caution: Found protective or hybrid MBR and corrupt GPT. Using GPT, but disk
verification and recovery are STRONGLY recommended.
****************************************************************************

Command (? for help): 

 

Attempting to format the drive in UnRAID gives a bunch of `disk1 write error, sector=x` errors.

 

I found some other  threads  from people with the same drives however none of them solved my problems. Some people referred to seeing logs that the drive was locked however I do not see that, and the fact I am able to change sector size & write partition table leads me to believe it's not a write-protection issue (I also don't see anything obvious on the drive sticker as being an encryption key). 

 

 

Been on this for about 5 days and I still don't feel all that close, any thoughts, ideas, suggestions would be greatly appreciated. SAS drives are new to me so I may be missing something obvious (like not knowing what IT mode was, the fact these drives had 520 byte sectors on them, etc!). Also combination of 3 new bits of hardware and lack of experience, I am not sure if I should be looking at faulty hardware or faulty operator (me!)

 

Diagnostics attached - thanks!

tower2-diagnostics-20230113-1530.zip

Edited by upsidedownlemon
add another name for hba card + fix explanation for lots of detail
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6 minutes ago, JorgeB said:

Confirm the drive is not write protected, there were cases before where they were despite nothing being reported on SMART.

 

I get this when I plug the drive in

 

Jan 13 01:28:21 Tower2 kernel: mpt2sas_cm0: handle(0x9) sas_address(0x5000c50062df90aa) port_type(0x1)
Jan 13 01:28:21 Tower2 kernel: scsi 1:0:1:0: Direct-Access     SEAGATE  DKS2E-H4R0SS     7FA6 PQ: 0 ANSI: 5
Jan 13 01:28:21 Tower2 kernel: scsi 1:0:1:0: SSP: handle(0x0009), sas_addr(0x5000c50062df90aa), phy(1), device_name(0x5000c50062df90a8)
Jan 13 01:28:21 Tower2 kernel: scsi 1:0:1:0: enclosure logical id (0x500507604385d55c), slot(2) 
Jan 13 01:28:21 Tower2 kernel: scsi 1:0:1:0: qdepth(254), tagged(1), scsi_level(6), cmd_que(1)
Jan 13 01:28:21 Tower2 kernel: scsi 1:0:1:0: Power-on or device reset occurred
Jan 13 01:28:21 Tower2 kernel: sd 1:0:1:0: Attached scsi generic sg1 type 0
Jan 13 01:28:21 Tower2 kernel: end_device-1:1: add: handle(0x0009), sas_addr(0x5000c50062df90aa)
Jan 13 01:28:21 Tower2 kernel: sd 1:0:1:0: [sdc] Spinning up disk...
Jan 13 01:28:35 Tower2 kernel: .............ready
Jan 13 01:28:35 Tower2 kernel: sd 1:0:1:0: [sdc] 7814037168 512-byte logical blocks: (4.00 TB/3.64 TiB)
Jan 13 01:28:35 Tower2 kernel: sd 1:0:1:0: [sdc] Write Protect is off
Jan 13 01:28:35 Tower2 kernel: sd 1:0:1:0: [sdc] Mode Sense: 13 00 10 08
Jan 13 01:28:35 Tower2 kernel: sd 1:0:1:0: [sdc] Write cache: disabled, read cache: enabled, supports DPO and FUA
Jan 13 01:28:35 Tower2 kernel: sd 1:0:1:0: [sdc] Preferred minimum I/O size 512 bytes
Jan 13 01:28:35 Tower2 kernel: Alternate GPT is invalid, using primary GPT.
Jan 13 01:28:35 Tower2 kernel: sdc: sdc1
Jan 13 01:28:35 Tower2 kernel: sd 1:0:1:0: [sdc] Attached SCSI disk

 

which looks like Write Protect is off

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  • Solution

I have resolved this issue for these 4TB SAS drives - ST4000NM0023 .

 

Steps to resolve:

  • Go to https://apps1.seagate.com/downloads/request.html and enter serial z1z7fbz0
    • None of the serials on my drives prompted for a new firmware, so I found this on the original listing however could also search other listings for the same drive model
  • Download firmware E007
  • Flash the firmware to the drives with openSeaChest
    openSeaChest_Firmware -d /dev/sg2 --downloadFW fwfilename
  • Format with sg_format
    sg_format -v --format --size=512 --six --fmpinfo=0 /dev/sg2
    • I have tried without both --six and --fmpinfo, the ~16 hour process still happens but the drive still cannot be written to at the end without these options (for me, anyway)
  • Now the drive can successfully be formatted and partitioned, hurray!
  • Like 1
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  • 11 months later...

@upsidedownlemon thanks for sharing this info.

I flashed the firmware, but I couldn't format my ST4000NM0023 (from a Hitachi nas) with the --size=512 option, --size=520 formats fine.

After some experimenting I discovered the following workaround:

sg_format -v --format --size=520 --six --fmtpinfo=3 /dev/sg1

Let this format for a couple of seconds, then ctrl-c and power off the drive, then power on the drive again and let it initialize.

Then format with the --size=512 option:

sg_format -v --format --size=512 --six --fmtpinfo=0 /dev/sg1

seagtate.jpg

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