I had a 4TB drive that was nearly full, so I upgraded it to 12 TB to match my parity drives. I shut down the array and replaced the drive. Then switched to the new drive in the array configuration. I brought the array up and it started to sync ran for a few minutes then paused.  It would not resume. I brought the array down again and tried it in maintenance mode and the same result. I then tested the drive using SEAtools with the short and long tests no issues found. I then tried to sync the array again in maintenance mode and it failed. 

 

 

Mar 27 07:04:43 TowerMHS kernel: md: disk4 write error, sector=39147800
Mar 27 07:04:43 TowerMHS kernel: md: disk4 write error, sector=39147808
Mar 27 07:04:43 TowerMHS kernel: md: disk4 write error, sector=39147816
Mar 27 07:04:43 TowerMHS kernel: md: disk4 write error, sector=39147824
Mar 27 07:04:43 TowerMHS kernel: md: disk4 write error, sector=39147832
Mar 27 07:04:43 TowerMHS kernel: md: disk4 write error, sector=39147840
Mar 27 07:04:43 TowerMHS kernel: md: disk4 write error, sector=39147848
Mar 27 07:04:43 TowerMHS kernel: md: disk4 write error, sector=39147856
Mar 27 07:04:43 TowerMHS kernel: Buffer I/O error on dev sdv1, logical block 23437770496, async page read
Mar 27 07:04:43 TowerMHS kernel: Buffer I/O error on dev sdv1, logical block 23437770497, async page read
Mar 27 07:04:43 TowerMHS kernel: Buffer I/O error on dev sdv1, logical block 23437770498, async page read
Mar 27 07:04:43 TowerMHS kernel: Buffer I/O error on dev sdv1, logical block 23437770499, async page read
Mar 27 07:04:43 TowerMHS kernel: Buffer I/O error on dev sdv1, logical block 23437770500, async page read
Mar 27 07:04:43 TowerMHS kernel: Buffer I/O error on dev sdv1, logical block 23437770501, async page read
Mar 27 07:04:43 TowerMHS kernel: Buffer I/O error on dev sdv1, logical block 23437770502, async page read
Mar 27 07:04:43 TowerMHS kernel: Buffer I/O error on dev sdv1, logical block 23437770503, async page read
Mar 27 07:04:43 TowerMHS kernel: sd 7:0:20:0: [sdv] Synchronizing SCSI cache
Mar 27 07:04:43 TowerMHS kernel: sd 7:0:20:0: [sdv] Synchronize Cache(10) failed: Result: hostbyte=0x01 driverbyte=DRIVER_OK
Mar 27 07:04:43 TowerMHS kernel: mpt2sas_cm0: mpt3sas_transport_port_remove: removed: sas_addr(0x5001e677b7084fe7)
Mar 27 07:04:43 TowerMHS kernel: mpt2sas_cm0: removing handle(0x001f), sas_addr(0x5001e677b7084fe7)
Mar 27 07:04:43 TowerMHS kernel: mpt2sas_cm0: enclosure logical id(0x5001e677b7084fff), slot(7)
Mar 27 07:04:43 TowerMHS kernel: md: recovery thread: exit status: -4
Mar 27 07:04:57 TowerMHS kernel: mpt2sas_cm0: handle(0x1f) sas_address(0x5001e677b7084fe7) port_type(0x1)
Mar 27 07:04:58 TowerMHS kernel: scsi 7:0:26:0: Direct-Access     ATA      ST12000NM001G-2M SN04 PQ: 0 ANSI: 6
Mar 27 07:04:58 TowerMHS kernel: scsi 7:0:26:0: SATA: handle(0x001f), sas_addr(0x5001e677b7084fe7), phy(7), device_name(0x0000000000000000)
Mar 27 07:04:58 TowerMHS kernel: scsi 7:0:26:0: enclosure logical id (0x5001e677b7084fff), slot(7) 
Mar 27 07:04:58 TowerMHS kernel: scsi 7:0:26:0: atapi(n), ncq(y), asyn_notify(n), smart(y), fua(y), sw_preserve(y)
Mar 27 07:04:58 TowerMHS kernel: scsi 7:0:26:0: qdepth(32), tagged(1), scsi_level(7), cmd_que(1)
Mar 27 07:04:58 TowerMHS kernel: sd 7:0:26:0: Attached scsi generic sg22 type 0
Mar 27 07:04:58 TowerMHS kernel: end_device-7:1:9: add: handle(0x001f), sas_addr(0x5001e677b7084fe7)
Mar 27 07:04:58 TowerMHS kernel: sd 7:0:26:0: Power-on or device reset occurred
Mar 27 07:04:58 TowerMHS kernel: sd 7:0:26:0: [sdaa] 23437770752 512-byte logical blocks: (12.0 TB/10.9 TiB)
Mar 27 07:04:58 TowerMHS kernel: sd 7:0:26:0: [sdaa] 4096-byte physical blocks
Mar 27 07:04:58 TowerMHS kernel: sd 7:0:26:0: [sdaa] Write Protect is off
Mar 27 07:04:58 TowerMHS kernel: sd 7:0:26:0: [sdaa] Mode Sense: 7f 00 10 08
Mar 27 07:04:58 TowerMHS kernel: sd 7:0:26:0: [sdaa] Write cache: enabled, read cache: enabled, supports DPO and FUA
Mar 27 07:04:58 TowerMHS kernel: sdaa: sdaa1
Mar 27 07:04:58 TowerMHS kernel: sd 7:0:26:0: [sdaa] Attached SCSI disk
Mar 27 07:04:59 TowerMHS unassigned.devices: Disk with ID 'Sabrent_296D07911DDE06527222 (nvme0n1)' is not set to auto mount.
Mar 27 07:04:59 TowerMHS unassigned.devices: Disk with ID 'ST12000NM001G-2MV103_ZLW1YV50 (sdaa)' is not set to auto mount.
Mar 27 07:05:00 TowerMHS  emhttpd: error: hotplug_devices, 1730: No such file or directory (2): Error: tagged device ST12000NM001G-2MV103_ZLW1YV50 was (sdv) is now (sdaa)
Mar 27 07:05:00 TowerMHS  emhttpd: read SMART /dev/sdaa

 

This same backplane bay etc was used by the smaller drive for many months with no issues.

Please post the diagnostics.

This is the latest attempt to sync this morning. 

towermhs-diagnostics-20230327-0708.zip

Doesn't look like a disk problem, replace/swap cables with a different disk and try again.

Well it looks like the issue was the EPC Feature of the Seagate 12 TB drive. I found this other thread 6.9.x, LSI Controllers & Ironwolf Disks Disabling - Summary & Fix - Page 5 - General - Unraid and ran the SeaChest tools to disable it and its been running for about 40 minutes, it would only run a minute or two prior.