On Sun, Jun 06, 2010 at 03:25:09PM +1000, Edwin Groothuis wrote:
> For two years I've had a happy gmirror RAID1 system. And a week or
> three ago I was found a degraded system due to a broken disk.
> 
> I tried to replace the disk, first with one three sectors too small
> which didn't want to be entered in the array (as excepted), then
> with a same brand/type one which I added without a problem. Rebuilding,
> everything okay.
> 
>     [~] ed...@k7>sudo fdisk -s /dev/ad1
>     /dev/ad1: 1938021 cyl 16 hd 63 sec
>     Part        Start        Size Type Flags
>        1:          63  1953520002 0xa5 0x00
>     [~] ed...@k7>sudo fdisk -s /dev/ad3
>     /dev/ad3: 1938021 cyl 16 hd 63 sec
>     Part        Start        Size Type Flags
>        1:          63  1953520002 0xa5 0x80
> 
>     [~] ed...@k7>gmirror status
>           Name    Status  Components
>     mirror/gm0  COMPLETE  ad1
>                         ad3
> 
> 
> Until after a reboot, then GEOM complains about:
> 
>     GEOM: ad3s1: geometry does not match label (255h,63s != 16h,63s).
>     GEOM_MIRROR: Force device gm0 start due to timeout.
>     GEOM_MIRROR: Device mirror/gm0 launched (1/2).
> 
>     [~] ed...@k7>gmirror status
>         Name    Status  Components
>         mirror/gm0  DEGRADED  ad1
> 
> Forgetting and re-inserting the ad3 does attach it again and rebuild
> everything, until the next reboot.

I have one dual PIII machine doing the same to me.  I've been assuming
my issue is with the ATA controller.  But, in case it helps, here is the
interesting information from my box.

FreeBSD netmon.tcworks.net 7.2-STABLE FreeBSD 7.2-STABLE #2: Fri Dec  4 
14:52:34 CST 2009     r...@netmon.tcworks.net:/usr/obj/usr/src/sys/GENERIC  i386

CPU: Intel(R) Pentium(R) III CPU family      1133MHz (1129.76-MHz 686-class CPU)
  Origin = "GenuineIntel"  Id = 0x6b1  Stepping = 1
  
Features=0x383fbff<FPU,VME,DE,PSE,TSC,MSR,PAE,MCE,CX8,APIC,SEP,MTRR,PGE,MCA,CMOV,PAT,PSE36,MMX,FXSR,SSE>

real memory  = 2147483648 (2048 MB)
Physical memory chunk(s):
0x0000000000001000 - 0x000000000009efff, 647168 bytes (158 pages)
0x0000000000100000 - 0x00000000003fffff, 3145728 bytes (768 pages)
0x0000000001025000 - 0x000000007dbaafff, 2092457984 bytes (510854 pages)
avail memory = 2091831296 (1994 MB)

atapci0: <ServerWorks ROSB4 UDMA33 controller> port 
0x1f0-0x1f7,0x3f6,0x170-0x177,0x376,0xffa0-0xffaf at device 15.1 on pci0
atapci0: Reserved 0x10 bytes for rid 0x20 type 4 at 0xffa0
ata0: <ATA channel 0> on atapci0
atapci0: Reserved 0x8 bytes for rid 0x10 type 4 at 0x1f0
atapci0: Reserved 0x1 bytes for rid 0x14 type 4 at 0x3f6
ata0: reset tp1 mask=03 ostat0=50 ostat1=50
ata0: stat0=0x50 err=0x01 lsb=0x00 msb=0x00
ata0: stat1=0x00 err=0x01 lsb=0x14 msb=0xeb
ata0: reset tp2 stat0=50 stat1=00 devices=0x9<ATAPI_SLAVE,ATA_MASTER>
ioapic0: routing intpin 14 (ISA IRQ 14) to vector 50
ata0: [MPSAFE]
ata0: [ITHREAD]
ata1: <ATA channel 1> on atapci0
atapci0: Reserved 0x8 bytes for rid 0x18 type 4 at 0x170
atapci0: Reserved 0x1 bytes for rid 0x1c type 4 at 0x376
ata1: reset tp1 mask=03 ostat0=50 ostat1=00
ata1: stat0=0x50 err=0x01 lsb=0x00 msb=0x00
ata1: stat1=0x00 err=0x01 lsb=0x00 msb=0x00
ata1: reset tp2 stat0=50 stat1=00 devices=0x1<ATA_MASTER>
ioapic0: routing intpin 15 (ISA IRQ 15) to vector 51
ata1: [MPSAFE]
ata1: [ITHREAD]

ata0-slave: pio=PIO4 wdma=WDMA2 udma=UNSUPPORTED cable=40 wire
ata0-master: pio=PIO4 wdma=WDMA2 udma=UDMA100 cable=80 wire
ad0: setting PIO4 on ROSB4 chip
ad0: setting UDMA33 on ROSB4 chip
ad0: 238475MB <WDC WD2500JB-57REA0 20.00K20> at ata0-master UDMA33
ad0: 488397168 sectors [484521C/16H/63S] 16 sectors/interrupt 1 depth queue
ad0: Adaptec check1 failed
ad0: LSI (v3) check1 failed
ad0: LSI (v2) check1 failed
ad0: FreeBSD check1 failed
acd0: setting PIO4 on ROSB4 chip
acd0: <LG CD-ROM CRD-8521B/1.04> CDROM drive at ata0 as slave
acd0:  128KB buffer, PIO4
acd0: Reads: CDR, CDRW, CDDA stream, packet
acd0: Writes:
acd0: Audio: play, 255 volume levels
acd0: Mechanism: ejectable tray, unlocked
acd0: Medium: no/blank disc
ata1-master: pio=PIO4 wdma=WDMA2 udma=UDMA100 cable=80 wire
ad2: setting PIO4 on ROSB4 chip
ad2: setting UDMA33 on ROSB4 chip
ad2: 238475MB <WDC WD2500JB-57REA0 20.00K20> at ata1-master UDMA33
ad2: 488397168 sectors [484521C/16H/63S] 16 sectors/interrupt 1 depth queue
ad2: Adaptec check1 failed
ad2: LSI (v3) check1 failed
ad2: LSI (v2) check1 failed
ad2: FreeBSD check1 failed
ATA PseudoRAID loaded
SMP: AP CPU #1 Launched!
cpu1 AP:
     ID: 0x01000000   VER: 0x00040011 LDR: 0x00000000 DFR: 0xffffffff
  lint0: 0x00010700 lint1: 0x00000400 TPR: 0x00000000 SVR: 0x000001ff
  timer: 0x000200ef therm: 0x00000000 err: 0x00010000 pcm: 0x00010400
ioapic0: Assigning ISA IRQ 1 to local APIC 0
ioapic0: Assigning ISA IRQ 3 to local APIC 1
ioapic0: Assigning ISA IRQ 4 to local APIC 0
ioapic0: Assigning ISA IRQ 6 to local APIC 1
ioapic0: Assigning PCI IRQ 10 to local APIC 0
ioapic0: Assigning ISA IRQ 14 to local APIC 1
ioapic0: Assigning ISA IRQ 15 to local APIC 0
ioapic1: Assigning PCI IRQ 20 to local APIC 1
ioapic1: Assigning PCI IRQ 21 to local APIC 0
GEOM: new disk ad0
GEOM: new disk ad2
GEOM_MIRROR: Device mirror/gm0 launched (2/2).
Trying to mount root from ufs:/dev/mirror/gm0s1a
start_init: trying /sbin/init

13:41:25 Sun Jun 06 $ bzcat messages.2.bz2 | egrep -i 
"geom|mirror|ad[[:digit:]]"
Dec 11 02:01:34 netmon kernel: Preloaded elf module 
"/boot/kernel/geom_mirror.ko" at 0xc0e2e174.
Dec 11 02:01:34 netmon kernel: pnpbios: handle 10 device ID PNP0a03 (030ad041)
Dec 11 02:01:34 netmon kernel: ad0: setting PIO4 on ROSB4 chip
Dec 11 02:01:34 netmon kernel: ad0: setting UDMA33 on ROSB4 chip
Dec 11 02:01:34 netmon kernel: ad0: 238475MB <WDC WD2500JB-57REA0 20.00K20> at 
ata0-master UDMA33
Dec 11 02:01:34 netmon kernel: ad0: 488397168 sectors [484521C/16H/63S] 16 
sectors/interrupt 1 depth queue
Dec 11 02:01:34 netmon kernel: ad0: Adaptec check1 failed
Dec 11 02:01:34 netmon kernel: ad0: LSI (v3) check1 failed
Dec 11 02:01:34 netmon kernel: ad0: LSI (v2) check1 failed
Dec 11 02:01:34 netmon kernel: ad0: FreeBSD check1 failed
Dec 11 02:01:34 netmon kernel: ad2: setting PIO4 on ROSB4 chip
Dec 11 02:01:34 netmon kernel: ad2: setting UDMA33 on ROSB4 chip
Dec 11 02:01:34 netmon kernel: ad2: 238475MB <WDC WD2500JB-57REA0 20.00K20> at 
ata1-master UDMA33
Dec 11 02:01:34 netmon kernel: ad2: 488397168 sectors [484521C/16H/63S] 16 
sectors/interrupt 1 depth queue
Dec 11 02:01:34 netmon kernel: ad2: Adaptec check1 failed
Dec 11 02:01:34 netmon kernel: ad2: LSI (v3) check1 failed
Dec 11 02:01:34 netmon kernel: ad2: LSI (v2) check1 failed
Dec 11 02:01:34 netmon kernel: ad2: FreeBSD check1 failed
Dec 11 02:01:34 netmon kernel: GEOM: new disk ad0
Dec 11 02:01:34 netmon kernel: GEOM: new disk ad2
Dec 11 02:01:34 netmon kernel: GEOM_MIRROR: Device mirror/gm0 launched (2/2).
Dec 11 02:01:34 netmon kernel: Trying to mount root from ufs:/dev/mirror/gm0s1a
Dec 11 02:01:48 netmon kernel: ad2: setting PIO4 on ROSB4 chip
Dec 11 02:01:48 netmon kernel: ad2: setting UDMA33 on ROSB4 chip
Dec 11 02:01:48 netmon kernel: ad2: TIMEOUT - READ_DMA retrying (1 retry left) 
LBA=232068607
Dec 11 02:02:00 netmon kernel: ad2: setting PIO4 on ROSB4 chip
Dec 11 02:02:00 netmon kernel: ad2: setting UDMA33 on ROSB4 chip
Dec 11 02:02:00 netmon kernel: ad2: TIMEOUT - READ_DMA retrying (1 retry left) 
LBA=232766751
Dec 11 02:02:10 netmon kernel: ad0: setting PIO4 on ROSB4 chip
Dec 11 02:02:10 netmon kernel: ad0: setting UDMA33 on ROSB4 chip
Dec 11 02:02:10 netmon kernel: ad0: TIMEOUT - READ_DMA retrying (1 retry left) 
LBA=232006207
Dec 11 02:02:36 netmon kernel: ad0: setting PIO4 on ROSB4 chip
Dec 11 02:02:36 netmon kernel: ad0: setting UDMA33 on ROSB4 chip
Dec 11 02:02:36 netmon kernel: ad0: TIMEOUT - READ_DMA retrying (1 retry left) 
LBA=242232479
Dec 11 02:02:37 netmon kernel: ad2: WARNING - READ_DMA UDMA ICRC error 
(retrying request) LBA=242234911
Dec 11 02:02:37 netmon kernel: ad0: WARNING - READ_DMA UDMA ICRC error 
(retrying request) LBA=242235039
Dec 11 02:02:37 netmon kernel: ad2: WARNING - READ_DMA UDMA ICRC error 
(retrying request) LBA=242234911
Dec 11 02:02:37 netmon kernel: ad0: WARNING - READ_DMA UDMA ICRC error 
(retrying request) LBA=242235039
Dec 11 02:02:37 netmon kernel: ad2: FAILURE - READ_DMA 
status=51<READY,DSC,ERROR> error=84<ICRC,ABORTED> LBA=242234911
Dec 11 02:02:37 netmon kernel: ad0: FAILURE - READ_DMA 
status=51<READY,DSC,ERROR> error=84<ICRC,ABORTED> LBA=242235039
Dec 11 02:02:37 netmon kernel: GEOM_MIRROR: Request failed (error=5). 
ad2[READ(offset=124024274432, length=65536)]
Dec 11 02:02:37 netmon kernel: GEOM_MIRROR: Device gm0: provider ad2 
disconnected.
Dec 11 02:02:37 netmon kernel: GEOM_MIRROR: Request failed (error=5). 
ad0[READ(offset=124024339968, length=65536)]
Dec 11 02:02:37 netmon kernel: 
g_vfs_done():mirror/gm0s1e[READ(offset=112213082112, length=131072)]error = 5
Dec 11 02:02:47 netmon kernel: ad0: setting PIO4 on ROSB4 chip
Dec 11 02:02:47 netmon kernel: ad0: setting UDMA33 on ROSB4 chip
Dec 11 02:02:47 netmon kernel: ad0: TIMEOUT - READ_DMA retrying (1 retry left) 
LBA=242234911
Dec 11 02:02:47 netmon kernel: ad0: WARNING - READ_DMA UDMA ICRC error 
(retrying request) LBA=242235039
Dec 11 02:02:47 netmon kernel: ad0: WARNING - READ_DMA UDMA ICRC error 
(retrying request) LBA=242235039
Dec 11 02:02:47 netmon kernel: ad0: FAILURE - READ_DMA 
status=51<READY,DSC,ERROR> error=84<ICRC,ABORTED> LBA=242235039
Dec 11 02:02:47 netmon kernel: 
g_vfs_done():mirror/gm0s1e[READ(offset=112213082112, length=131072)]error = 5
Dec 11 02:02:50 netmon kernel: ad0: WARNING - READ_DMA UDMA ICRC error 
(retrying request) LBA=232478271
Dec 11 02:02:50 netmon kernel: ad0: WARNING - READ_DMA UDMA ICRC error 
(retrying request) LBA=232478271
Dec 11 02:02:50 netmon kernel: ad0: FAILURE - READ_DMA 
status=51<READY,DSC,ERROR> error=84<ICRC,ABORTED> LBA=232478271
Dec 11 02:02:50 netmon kernel: 
g_vfs_done():mirror/gm0s1e[READ(offset=107217682432, length=131072)]error = 5

I have just left it broken this boot.  I was annoyed by this issue and a
few others which all happend to bite me on Dec 11th, while I was trying
to get everything wrapped up for a vacation.

13:44:39 Sun Jun 06 $ geom mirror list
Geom name: gm0
State: DEGRADED
Components: 2
Balance: split
Slice: 4096
Flags: NONE
GenID: 2
SyncID: 1
ID: 3839024964
Providers:
1. Name: mirror/gm0
   Mediasize: 250059349504 (233G)
   Sectorsize: 512
   Mode: r8w4e5
Consumers:
1. Name: ad0
   Mediasize: 250059350016 (233G)
   Sectorsize: 512
   Mode: r1w1e1
   State: ACTIVE
   Priority: 0
   Flags: DIRTY, BROKEN
   GenID: 2
   SyncID: 1
   ID: 803371877


I guess I should rebuild it now that you've reminded me. :-)
 
-- 
Scott Lambert                    KC5MLE                       Unix SysAdmin
lamb...@lambertfam.org

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