[SOLVED] 1.5TB Failed then 4TB failed rebuild now using 2TB and its "too small"


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Basics:

unRAID Server Pro

version: 5.0.5

 

Background:

One of my drives appeared to have some issues as it was automatically removed from the array.  I had 3 other drives "spare" on my shelf, so I first tried to replace it was my former parity 4TB drive that I believed to have no issues, I just ended up replacing it as a new 4TB drive i put in was a few bits larger (HPA maybe).  I didn't preclear the former 4TB parity drive, which may turn out to have been a problem.

 

I did start the "rebuild" process after I changed the drive assigned from the faulty 1.5TB to the 4TB and let the process run for a many hours.  When I checked back in on it, 4 of my other drives were showing errors now, despite the fact they shouldn't even be needed for this process.  On top of that, the rebuild went from having "hours" remaining to "weeks".  Clearly something was wrong so I stopped the process, shut the machine down and went through every connector to ensure they were all snug.  Given the 4 drives showing errors were all off the same break-out cable, I figured it must have gotten loose on the SATA card.

 

I turn the machine back on and the only drive with issues was the one that I was trying to rebuild.  As I now have my doubts on the reliability of that former 4TB parity drive, I opted to hook up a new, precleared/passed 2TB drive I had instead for the rebuild.  Here is where the problem stands:

 

When I change the settings to select the 2TB drive, it thinks the drive that is replacing is the 4TB drive.  The actual drive it is replacing is a 1.5TB drive - the 4TB is the one I canceled the rebuild on.

 

Question:

 

How do I get my parity to rebuild the 1.5TB of data on the 2TB drive when server thinks I should have a 4TB in that slot?

 

I don't believe the data is lost as the parity drive shouldn't have changed what's stored on it.

 

Any direction would be appreciated as this is not the typical error I have dealt with before when replacing drives.

 

Thanks in advance! :)

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How do I get my parity to rebuild the 1.5TB of data on the 2TB drive when server thinks I should have a 4TB in that slot?

 

You can't, since you started rebuilding with a 4TB disk the filesystem was expanded to that capacity, rebuild was canceled but it's not possible now to swap to a smaller drive.

 

If the old disk was OK you could do a new config, but if it's bad you can only use a 4TB or bigger (depending on parity size).

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At this point, would I be best off preclearing the drive that I had to abort the rebuild on, assuming it was okay and the rebuild issue was related to some other factor?  My only other available drive is larger than the parity drive, so that would present a new challenge having to replace the parity drive first before being able to rebuilt the other drive.

 

If I preclear the 4TB that the array now things is in the slot and then try to rebuild to it, I am now starting to question if the parity drive has the necessary info to rebuild the 1.5TB of lost data or did it get changed when I tried to rebuild it my first attempt (thus its expectation I should be putting in a 4TB for the rebuild)

 

EDIT:

 

What if the drive that started this process is actually still okay?  It still connected to the array and I am able to run smart status and hdparm on it.  Although I wouldn't be able to set this drive back to the space the server thinks it should be (disk9), would I be able to add it like a new disk (disk12) and rebuild the parity?  I realize that if the drive really is bad then I will have messed up my parity and never be able to restore it.  The issue with this process would be that I doubt the software will let me leave "Disk9" as "no device" and then rebuild the parity.

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EDIT:

 

What if the drive that started this process is actually still okay?  It still connected to the array and I am able to run smart status and hdparm on it.  Although I wouldn't be able to set this drive back to the space the server thinks it should be (disk9), would I be able to add it like a new disk (disk12) and rebuild the parity?  I realize that if the drive really is bad then I will have messed up my parity and never be able to restore it.  The issue with this process would be that I doubt the software will let me leave "Disk9" as "no device" and then rebuild the parity.

 

If the 1.5TB disk is OK you could do a new config, reassign all your disks and sync parity, but this is more risky, if the disk is really bad you'll be left with a bad disk and no parity.

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Thanks for the info.  I think I will start with hooking the 4TB drive I had issues with again, but before trying to rebuild the data to it, I am going to do some testing on it.  I'll run at a preclear cycle and check some of the drive info before and after the test to see if error rates have risen or not.  This will take a few days to perform, given the size of the drive!  I'll be back, hopefully with good news :)

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Without doing anything but powering down the server, hooking up the 4TB drive that I previously cancelled the rebuild on, the drive automatically returned to rebuilding itself.

 

I guess I will let this ride out as long as the estimated time remains reasonable (800 minutes) and the "error" count doesn't increase.  Assuming it completes this time, I would think my next step would be to run a parity check without correcting errors.  If it passes, then maybe run a full parity check again and do some testing of the drive, just as an additional reliability check.

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Things have become more "challenging" now and the potential for data loss has risen I believe.

 

The rebuild of the former 1.5TB drive on to 4TB drive completed, however 3 negative observations:

 

1.  Despite the array showing up and running okay, when I check disk9's contents it doesn't have 1.5TB of data.  It actually has under 400GB.

2.  My parity status is listed as:  Parity is Valid:.  Last parity check  16885  days ago .  Parity updated  172293584  times to address sync errors (that means my last parity check was done before I was born)

3.  During the rebuild of disk9 , for some reason my device status shows disk10 as having the same number of write to it as disk9 had , however it has a huge error rate:  writes: 18842983 errors: 154394030

 

Why the array was trying to write to disk10 during the rebuild of disk9 makes no sense to me.  As I type this, disk10 was just kicked out of the array, which surely is from the error counts, however prior to its dropping I did check the files and like disk9, it was well below the 1.5TB it should have had.

 

I'm starting to get that drowning feeling as things go from concerning to very concerning (as I am fully aware 2 drives going down is unrecoverable).

 

I defer back to those of higher skill and seek your advice as to what might be happening and the best course of action moving forward.

 

Thanks for any advice/assistance you can provide in advance.  Boat anchor is not the option as too many hundreds of hours went in to building this and transferring DVD's to digital form!  :)

 

I went to download and attach my syslog, but I don't have anything in it, which is another suspicious matter.  I checked through both UnMenu as well as the Main UnRaid GUI interface.

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this is the drive that started the problems some time ago.  As I had spare drives, I initially tried replacing it was a 4TB drive but it ended up being a few bit bigger than my parity drive so I ended up replacing the parity instead.  I then used the old parity drive to replace the drive I am posting here:

 

SMART status Info for /dev/sdi

 

smartctl 6.2 2013-07-26 r3841 [i686-linux-3.9.11p-unRAID] (local build)

Copyright © 2002-13, Bruce Allen, Christian Franke, www.smartmontools.org

 

=== START OF INFORMATION SECTION ===

Model Family:    Western Digital Caviar Green (AF)

Device Model:    WDC WD15EARS-00J2GB0

Serial Number:    WD-WCAYY0273566

LU WWN Device Id: 5 0014ee 2afdf0659

Firmware Version: 80.00A80

User Capacity:    1,500,301,910,016 bytes [1.50 TB]

Sector Size:      512 bytes logical/physical

Device is:        In smartctl database [for details use: -P show]

ATA Version is:  ATA8-ACS (minor revision not indicated)

SATA Version is:  SATA 2.6, 3.0 Gb/s

Local Time is:    Thu Mar 24 11:02:23 2016 EDT

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:  (0x82) Offline data collection activity

was completed without error.

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: (34560) 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: ( 394) minutes.

Conveyance self-test routine

recommended polling time: (  5) minutes.

SCT capabilities:       (0x3031) 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    0x002f  200  200  051    Pre-fail  Always      -      0

  3 Spin_Up_Time            0x0027  220  154  021    Pre-fail  Always      -      5966

  4 Start_Stop_Count        0x0032  096  096  000    Old_age  Always      -      4206

  5 Reallocated_Sector_Ct  0x0033  200  200  140    Pre-fail  Always      -      0

  7 Seek_Error_Rate        0x002e  100  253  000    Old_age  Always      -      0

  9 Power_On_Hours          0x0032  045  045  000    Old_age  Always      -      40258

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  100  100  000    Old_age  Always      -      121

192 Power-Off_Retract_Count 0x0032  200  200  000    Old_age  Always      -      44

193 Load_Cycle_Count        0x0032  193  193  000    Old_age  Always      -      23910

194 Temperature_Celsius    0x0022  126  102  000    Old_age  Always      -      26

196 Reallocated_Event_Count 0x0032  200  200  000    Old_age  Always      -      0

197 Current_Pending_Sector  0x0032  200  200  000    Old_age  Always      -      1

198 Offline_Uncorrectable  0x0030  200  200  000    Old_age  Offline      -      0

199 UDMA_CRC_Error_Count    0x0032  200  200  000    Old_age  Always      -      0

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  Short offline      Completed without error      00%    40236        -

 

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.

 

Here is the 4TB drive I tried to rebuild the above on to:

 

Statistics for /dev/sdf WDC_WD40EFRX-68WT0N0_WD-WCC4E1333752

 

smartctl -a -d ata /dev/sdf

smartctl 6.2 2013-07-26 r3841 [i686-linux-3.9.11p-unRAID] (local build)

Copyright © 2002-13, Bruce Allen, Christian Franke, www.smartmontools.org

 

=== START OF INFORMATION SECTION ===

Device Model:    WDC WD40EFRX-68WT0N0

Serial Number:    WD-WCC4E1333752

LU WWN Device Id: 5 0014ee 209efb4a8

Firmware Version: 80.00A80

User Capacity:    4,000,785,948,160 bytes [4.00 TB]

Sector Sizes:    512 bytes logical, 4096 bytes physical

Rotation Rate:    5400 rpm

Device is:        Not in smartctl database [for details use: -P showall]

ATA Version is:  ACS-2 (minor revision not indicated)

SATA Version is:  SATA 3.0, 6.0 Gb/s (current: 3.0 Gb/s)

Local Time is:    Thu Mar 24 11:06:05 2016 EDT

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:  (0x00) Offline data collection activity

was never started.

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: (52080) 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: ( 521) minutes.

Conveyance self-test routine

recommended polling time: (  5) minutes.

SCT capabilities:       (0x703d) 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  180  178  021    Pre-fail  Always      -      7983

  4 Start_Stop_Count        0x0032  100  100  000    Old_age  Always      -      186

  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  097  097  000    Old_age  Always      -      2666

10 Spin_Retry_Count        0x0032  100  100  000    Old_age  Always      -      0

11 Calibration_Retry_Count 0x0032  100  253  000    Old_age  Always      -      0

12 Power_Cycle_Count      0x0032  100  100  000    Old_age  Always      -      15

192 Power-Off_Retract_Count 0x0032  200  200  000    Old_age  Always      -      3

193 Load_Cycle_Count        0x0032  200  200  000    Old_age  Always      -      381

194 Temperature_Celsius    0x0022  127  104  000    Old_age  Always      -      25

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  100  253  000    Old_age  Offline      -      0

199 UDMA_CRC_Error_Count    0x0032  200  200  000    Old_age  Always      -      0

200 Multi_Zone_Error_Rate  0x0008  100  253  000    Old_age  Offline      -      0

 

SMART Error Log Version: 1

No Errors Logged

 

SMART Self-test log structure revision number 1

No self-tests have been logged.  [To run self-tests, use: smartctl -t]

 

 

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.

 

Here is the "disk10" that had all the errors during the rebuild of disk9 (above):

 

SMART status Info for /dev/sdo

 

smartctl 6.2 2013-07-26 r3841 [i686-linux-3.9.11p-unRAID] (local build)

Copyright © 2002-13, Bruce Allen, Christian Franke, www.smartmontools.org

 

=== START OF INFORMATION SECTION ===

Model Family:    Seagate Barracuda 7200.11

Device Model:    ST31500341AS

Serial Number:    9VS2L1L4

LU WWN Device Id: 5 000c50 015af8095

Firmware Version: CC1H

User Capacity:    1,500,301,910,016 bytes [1.50 TB]

Sector Size:      512 bytes logical/physical

Rotation Rate:    7200 rpm

Device is:        In smartctl database [for details use: -P show]

ATA Version is:  ATA8-ACS T13/1699-D revision 4

SATA Version is:  SATA 2.6, 3.0 Gb/s

Local Time is:    Thu Mar 24 11:09:23 2016 EDT

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:  (0x82) Offline data collection activity

was completed without error.

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: (  609) 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: (  1) minutes.

Extended self-test routine

recommended polling time: ( 299) minutes.

Conveyance self-test routine

recommended polling time: (  2) minutes.

SCT capabilities:       (0x103f) SCT Status supported.

SCT Error Recovery Control supported.

SCT Feature Control supported.

SCT Data Table supported.

 

SMART Attributes Data Structure revision number: 10

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  118  099  006    Pre-fail  Always      -      185620484

  3 Spin_Up_Time            0x0003  100  092  000    Pre-fail  Always      -      0

  4 Start_Stop_Count        0x0032  096  096  020    Old_age  Always      -      4420

  5 Reallocated_Sector_Ct  0x0033  099  099  036    Pre-fail  Always      -      53

  7 Seek_Error_Rate        0x000f  074  060  030    Pre-fail  Always      -      25605074

  9 Power_On_Hours          0x0032  043  043  000    Old_age  Always      -      50207

10 Spin_Retry_Count        0x0013  100  100  097    Pre-fail  Always      -      8

12 Power_Cycle_Count      0x0032  100  100  020    Old_age  Always      -      146

184 End-to-End_Error        0x0032  100  100  099    Old_age  Always      -      0

187 Reported_Uncorrect      0x0032  100  100  000    Old_age  Always      -      0

188 Command_Timeout        0x0032  100  100  000    Old_age  Always      -      1

189 High_Fly_Writes        0x003a  001  001  000    Old_age  Always      -      270

190 Airflow_Temperature_Cel 0x0022  071  046  045    Old_age  Always      -      29 (Min/Max 28/38)

194 Temperature_Celsius    0x0022  029  054  000    Old_age  Always      -      29 (0 7 0 0 0)

195 Hardware_ECC_Recovered  0x001a  040  030  000    Old_age  Always      -      185620484

197 Current_Pending_Sector  0x0012  100  100  000    Old_age  Always      -      0

198 Offline_Uncorrectable  0x0010  100  100  000    Old_age  Offline      -      0

199 UDMA_CRC_Error_Count    0x003e  200  200  000    Old_age  Always      -      3

240 Head_Flying_Hours      0x0000  100  253  000    Old_age  Offline      -      271673861352864

241 Total_LBAs_Written      0x0000  100  253  000    Old_age  Offline      -      2254842753

242 Total_LBAs_Read        0x0000  100  253  000    Old_age  Offline      -      3816245401

 

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  Short offline      Completed without error      00%    38352        -

 

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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this is the drive that started the problems some time ago.  As I had spare drives, I initially tried replacing it was a 4TB drive but it ended up being a few bit bigger than my parity drive so I ended up replacing the parity instead.  I then used the old parity drive to replace the drive I am posting here:

 

SMART status Info for /dev/sdi

197 Current_Pending_Sector  0x0032   200   200   000    Old_age   Always       -       1

 

The first disk that failed appears to have issues, good news is that if the rebuild is not successful, and with some luck, you should be able to recover most data from it.

 

Both other disks look fine, there are some CRC_UDMA errors on disk10, this usually indicates bad sata cable, but very few errors to be an issue, and nothing that would explain disappearing data, but disk 10 showing errors during the rebuild can explain the missing data on disk9, those parity sync errors are also troubling, a rebuild should not cause sync errors.

 

That many disks showing errors and dropping out, would point to cable/controller/power supply issue, at this point, and if you have access to another server I would use it, do a new config to create an array with all disks except the old disk9, check that disk10 shows all data and do a parity sync, and then try to copy all possible data from old disk9 to the new array.

 

If you can't use another server try at least a different power supply and controller(s).

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Only "extra" items I have are single SATA cables (not breakout cables) and hard drives.

 

What information in the first Smart Report I posted brings you to the conclusion it was a problem?

 

I've got to try and figure this out with the limited options I have with the hope of not having to go to the basement and dig out DVD's and re-rip hundreds of them.

 

If disk9's original 1.5TB HDD, the original problem, is actually still functioning, is it too late to put it back in to the array now that the server thinks a 4TB drive replaced it?  I can also check, or just replace the sata cable on disk10.  If its on a breakout cable, then I would have to order one online.

 

If this makes any difference, I did make a backup of my Flash Drive before these drive swaps started (ie. taken on Mar.21).

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Original disk9 has one pending sector, that usually means bad sector(s), a single pending sector can be a false positive, but since the disk failed it's probably not, you can confirm by doing an extended SMART test, grab a new SMART report, a failure will look like this:

 

Num  Test_Description    Status                  Remaining  LifeTime(hours)  LBA_of_first_error
# 1  Extended offline    Completed: read failure       90%      6681         2850171655

 

 

If it passes it's ok but if it fails with a read error it's really bad and shouldn't be used in the array, but you should still be able to copy most of it's data if needed.

 

The issue here is that you're having multiple errors and it's difficult to do a successful rebuild like that.

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The idea was that if the original disk9 (WDC_WD15EARS-00_WD-WCAYY0273566) 1.5TB drive I put in was truly fine and lets just say it was a loose cable or one tiny thing that triggered its stoppage, then is their a way to return that to array in the location the 4TB I tried to rebuild in its place?

 

If it can go back in, then maybe the disk10 (ST31500341AS_9VS2L1L4) that somehow came up with errors during the previous drives repair and then somehow lost 2/3 of the information could be restored?

 

Here's another odd observation:  when i view the drives not in the protected array (using UnMenu's Disk Management Section), the two drives mentioned above are listed as 1TB in size, yet both are actually 1.5TB, as you can see from their model/serial numbers).

 

Model/Serial Temp Size Device Mounted File System

WDC_WD15EARS-00_WD-WCAYY0273566 26°C 1T /dev/sdi

 

 

partition (1,465,138,552 blocks): /dev/sdi1 reiserfs

 

 

ST31500341AS_9VS2L1L4 28°C 1T /dev/sdn

 

 

partition (1,465,138,552 blocks): /dev/sdn1 reiserfs

 

------------

 

I am running the long smart test on the original "disk9" right now, using the option in UnMenu which appears to run the command line:  smartctl -t long -d ata /dev/sdi 2>&1

 

I don't believe I've run this test before, so I am not sure how long it will take before results are presented.  I will post them once they appear, or in the morning should it take a while (I'm -5:00GMT - Eastern Time Zone = 00:34 Mar.27 currently)

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The idea was that if the original disk9 (WDC_WD15EARS-00_WD-WCAYY0273566) 1.5TB drive I put in was truly fine and lets just say it was a loose cable or one tiny thing that triggered its stoppage, then is their a way to return that to array in the location the 4TB I tried to rebuild in its place?

 

If it can go back in, then maybe the disk10 (ST31500341AS_9VS2L1L4) that somehow came up with errors during the previous drives repair and then somehow lost 2/3 of the information could be restored?

 

If old disk9 passes the extended SMART test you can try to do a new config, this may also help with disk10 missing data.

 

-take a screenshot of current array

-go to tools and click new config

-reassign all disks, using old disk9, don't assign parity for now, leave it empty

-start array and check if all data is there, especially disks 9 and 10

-if all looks fine, stop array, assign parity and start array to begin parity sync

 

if disk10 is still not showing all data don't assign parity, you can try and see how the emulated disk looks like, but the many sync errors you mentioned above are troubling for this option.

 

 

Here's another odd observation:  when i view the drives not in the protected array (using UnMenu's Disk Management Section), the two drives mentioned above are listed as 1TB in size, yet both are actually 1.5TB, as you can see from their model/serial numbers).

 

Model/Serial Temp Size Device Mounted File System

WDC_WD15EARS-00_WD-WCAYY0273566 26°C 1T /dev/sdi

 

 

partition (1,465,138,552 blocks): /dev/sdi1 reiserfs

 

 

ST31500341AS_9VS2L1L4 28°C 1T /dev/sdn

 

 

partition (1,465,138,552 blocks): /dev/sdn1 reiserfs

 

------------

 

The disk sizes are wrong but the partition sizes are correct, I haven't used Unmenu in so long that I don't remember if it's normal, but would think not, you should consider upgrading to v6 after solving this, many new features like system notifications, SMART warnings, etc and it's harder to support v5 because most users don't use it anymore.

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I do agree I need to upgrade to version 6.  Historically I was upgrading the software each time I need support for larger hard drives, however I will make an effort to stay more current for various reasons you mentioned.

 

I bailed out of UnMenu as I waited the 6 hours and I thought it would display the results of the long smart test, but instead when I reloaded the page it seemed to just start it all over again.

 

This time, I used the command line unmenu showed " smartctl -t long -d ata /dev/sdi 2>&1 " it was running.

 

Testing has begun.

Please wait 394 minutes for test to complete.

Test will complete after Sun Mar 27 16:57:24 2016

 

I just have to figure out how to display the results.  I was looking through the Wiki and I believe one of these gives me results:

smartctl -a -A /dev/sdi

or

smartctl  -a  -d  ata  /dev/sdi

 

I'll give them a try after the estimated time of completion.

 

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So the original drive with issues seems to look good after 3 smart tests (one was aborted by my mistake).  I see nothing that worries me, beyond the fact it fell out of the array initially for reasons I am unsure of.

 

EDIT:  I'm starting to think temperature may be the culprit in all my issues.  Despite me having three 4 in 3 drive cages in the server, each with its own intake fan in front, the drives in the middle were hitting higher temperatures than those in the top and bottom.  I checked the fan and its running.  I cleaned out all the filters, as they were dusty.  I've been running a window fan right in front of the server during all the current issues and the drive temps have been perfect.  With respect to the two drives in question, disk10's Short Smart Report is showing the drive's worst as 54C:

194 Temperature_Celsius    0x0022  030  054  000    Old_age  Always      -      30 (0 7 0 0 0)

 

Disk 9's Long Smart Report must be faulty, as it says the temperature worst is 102C yet the current temp is 123C:

194 Temperature_Celsius    0x0022  123  102  000    Old_age  Always      -      29

 

Disk 9 Long Smart Report:

 

smartctl 6.2 2013-07-26 r3841 [i686-linux-3.9.11p-unRAID] (local build)

Copyright © 2002-13, Bruce Allen, Christian Franke, www.smartmontools.org

 

=== START OF INFORMATION SECTION ===

Model Family:    Western Digital Caviar Green (AF)

Device Model:    WDC WD15EARS-00J2GB0

Serial Number:    WD-WCAYY0273566

LU WWN Device Id: 5 0014ee 2afdf0659

Firmware Version: 80.00A80

User Capacity:    1,500,301,910,016 bytes [1.50 TB]

Sector Size:      512 bytes logical/physical

Device is:        In smartctl database [for details use: -P show]

ATA Version is:  ATA8-ACS (minor revision not indicated)

SATA Version is:  SATA 2.6, 3.0 Gb/s

Local Time is:    Sun Mar 27 21:08:11 2016 EDT

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:                (34560) 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:        ( 394) minutes.

Conveyance self-test routine

recommended polling time:        (  5) minutes.

SCT capabilities:              (0x3031) 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    0x002f  200  200  051    Pre-fail  Always      -      0

  3 Spin_Up_Time            0x0027  220  154  021    Pre-fail  Always      -      5958

  4 Start_Stop_Count        0x0032  096  096  000    Old_age  Always      -      4207

  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  045  045  000    Old_age  Always      -      40340

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  100  100  000    Old_age  Always      -      122

192 Power-Off_Retract_Count 0x0032  200  200  000    Old_age  Always      -      44

193 Load_Cycle_Count        0x0032  193  193  000    Old_age  Always      -      23923

194 Temperature_Celsius    0x0022  123  102  000    Old_age  Always      -      29

196 Reallocated_Event_Count 0x0032  200  200  000    Old_age  Always      -      0

197 Current_Pending_Sector  0x0032  200  200  000    Old_age  Always      -      1

198 Offline_Uncorrectable  0x0030  200  200  000    Old_age  Offline      -      0

199 UDMA_CRC_Error_Count    0x0032  200  200  000    Old_age  Always      -      0

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%    40334        -

# 2  Extended offline    Aborted by host              90%    40329        -

# 3  Extended offline    Completed without error      00%    40324        -

# 4  Short offline      Completed without error      00%    40236        -

 

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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With respect to the two drives in question, disk10's Short Smart Report is showing the drive's worst as 54C:

194 Temperature_Celsius    0x0022  030  054  000    Old_age  Always      -      30 (0 7 0 0 0)

 

Above what I like but not enough to damage, usually it's >60C.

 

Disk 9's Long Smart Report must be faulty, as it says the temperature worst is 102C yet the current temp is 123C:

194 Temperature_Celsius    0x0022  123  102  000    Old_age  Always      -      29

 

This is normal for some disks, it means worst temp was 50C (123-102+29), hot but also ok.

 

I consider critical HDD temp anything above 55C but do try to keep them <45C.

 

 

Disk 9 passed the extended test, so you can try the new config.

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I usually worry about sustained temps over 50C, but being conservation on this is better than liberal! :)

 

The drive with the unrealistic temperature, I'm guessing its reporting in Fahrenheit, based on your math you converted with.  Darn Americans, if only the world could get them to change to Metric and end confusion like this! lol

 

I'm just running the long Smart Test on disk10.  I'll have the results of it by morning.  If all looks "safe", I will attempt the steps you suggested earlier.

 

Regardless of my outcome, I would like to thank you now for the assistance, guidance, hand holding and reassurances.  They all prove invaluable when I working in an area outside my comfort zone, especially being a person with OCD tendencies.  We hate to "try" something unless we know the outcome ahead of time.  Risk taking is not one of my best qualities, thanks to 3/4 of my life being plagued with health issues and trying to avoid any further problems.  Life's a bitch, then you date one, then you find Ms. Wright!  (ya, my girlfriends last name is "Wright", so how can I go wrong with that!)  :)

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These steps worked:

-take a screenshot of current array

-go to tools and click new config

-reassign all disks, using old disk9, don't assign parity for now, leave it empty

-start array and check if all data is there, especially disks 9 and 10

-if all looks fine, stop array, assign parity and start array to begin parity sync

 

Both the original disk9 and disk10 had all their data on them, so I am now just waiting for the Parity to build.  Only one small hiccup in that I lost power during the first attempt and since I had the server on my "bench" cleaning and pulling drives, I didn't have it in its UPS.  At the moment, its done syncing all my data drives (the largest was 2TB) and is just zero'ing out the 2TB left on the parity drive.  In 3 hours, it should be golden!

 

I will take the advice from earlier and upgrade to whatever version of 6 that is either official or stable.  I'm pretty sure I can find a thread on that process.

 

Then, I will have to replace my parity drive (thanks to HPA crap) as my one spare 4TB data drive is a few thousand bits larger.  Then, I can integrate the smaller 4TB in to the array to replace my smallest drive, then repeat the process for two other drives I have that are bigger than those in the server now.  Weeks of fun!  :)

 

Thanks for the help, this issue is officially resolved now! :)

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