Recent netbsd-5 changes seem to make (autoconfig) raidframe trouble

[Markus W Kilbinger <mk%kilbi.de@localhost>]

Hi!

I've just upgrade 2 of our i386 machines (using autoconfig raidframe)
with actual (over night) netbsd-5 changes and see the attached
raidframe problems errors:

NetBSD 5.1_STABLE (OLL) #28: Mon Nov 22 09:25:40 MET 2010
        kilbi@mutter:/u/NetBSD/netbsd-5/src/sys/arch/i386/compile/OLL
total memory = 511 MB
avail memory = 497 MB
[...]
ahc0 at pci0 dev 11 function 0: Adaptec 29160 Ultra160 SCSI adapter
ahc0: interrupting at irq 11
ahc0: aic7892: Ultra160 Wide Channel A, SCSI Id=7, 32/253 SCBs
scsibus0 at ahc0: 16 targets, 8 luns per target
[...]
sd0 at scsibus0 target 0 lun 0: <IBM, DNES-309170W, SAH0> disk fixed
sd0: 8748 MB, 11474 cyl, 5 head, 312 sec, 512 bytes/sect x 17916240 sectors
sd0: sync (25.00ns offset 30), 16-bit (80.000MB/s) transfers, tagged queueing
sd1 at scsibus0 target 1 lun 0: <IBM, DNES-309170W, SAH0> disk fixed
sd1: 8748 MB, 11474 cyl, 5 head, 312 sec, 512 bytes/sect x 17916240 sectors
sd1: sync (25.00ns offset 30), 16-bit (80.000MB/s) transfers, tagged queueing
cd0 at scsibus0 target 3 lun 0: <PLEXTOR, CD-ROM PX-40TS, 1.10> cdrom removable
cd0: sync (50.00ns offset 15), 8-bit (20.000MB/s) transfers
Kernelized RAIDframe activated
raid1: RAID Level 1
raid1: Components: /dev/sd0a /dev/sd1a
raid1: Total Sectors: 1048512 (511 MB)
raid2: RAID Level 1
raid2: Components: /dev/sd0b /dev/sd1b
raid2: Total Sectors: 1048512 (511 MB)
raid0: RAID Level 1
raid0: Components: /dev/sd0e /dev/sd1e
raid0: Total Sectors: 40585465449861472 (19817121801690 MB)
boot device: raid1
root on raid1a dumps on raid1b
root file system type: ffs
raid0: IO Error.  Marking /dev/sd0e as failed.
raid0: IO failed after 5 retries.
raid0: WARNING: raid0: total sector size in disklabel (15818944) != the size of 
raid (40585465449861472)
raid0: IO failed after 5 retries.
raid0: WARNING: raid0: total sector size in disklabel (15818944) != the size of 
raid (40585465449861472)
raid0: IO failed after 5 retries.
raid0: WARNING: raid0: total sector size in disklabel (15818944) != the size of 
raid (40585465449861472)
wsdisplay0: screen 1 added (80x25, vt100 emulation)
wsdisplay0: screen 2 added (80x25, vt100 emulation)
wsdisplay0: screen 3 added (80x25, vt100 emulation)
wsdisplay0: screen 4 added (80x25, vt100 emulation)
[...]
###################
Disk: /dev/rsd0d
NetBSD disklabel disk geometry:
cylinders: 11474, heads: 5, sectors/track: 312 (1560 sectors/cylinder)
total sectors: 17916240

BIOS disk geometry:
cylinders: 1023, heads: 255, sectors/track: 63 (16065 sectors/cylinder)
total sectors: 17916240

Partition table:
0: NetBSD (sysid 169)
    start 63, size 17916177 (8748 MB, Cyls 0-1115/59/48), Active
1: <UNUSED>
2: <UNUSED>
3: <UNUSED>
Bootselector disabled.
First active partition: 0
###################
# /dev/rsd0d:
type: SCSI
disk: DNES-309170W
label: mydisk1
flags:
bytes/sector: 512
sectors/track: 312
tracks/cylinder: 5
sectors/cylinder: 1560
cylinders: 11474
total sectors: 17916240
rpm: 3600
interleave: 1
trackskew: 0
cylinderskew: 0
headswitch: 0           # microseconds
track-to-track seek: 0  # microseconds
drivedata: 0 

8 partitions:
#        size    offset     fstype [fsize bsize cpg/sgs]
 a:   1048576        63       RAID                     # (Cyl.      0*-    672*)
 b:   1048576   1048639       RAID                     # (Cyl.    672*-   1344*)
 c:  17916177        63     unused      0     0        # (Cyl.      0*-  11484*)
 d:  17916240         0     unused      0     0        # (Cyl.      0 -  11484*)
 e:  15819025   2097215       RAID                     # (Cyl.   1344*-  11484*)
###################
Components:
           /dev/sd0e: failed
           /dev/sd1e: optimal
No spares.
/dev/sd0e status is: failed.  Skipping label.
Component label for /dev/sd1e:
   Row: 0, Column: 1, Num Rows: 1, Num Columns: 2
   Version: 2, Serial Number: 9125342, Mod Counter: 1237292157
   Clean: No, Status: 0
   sectPerSU: 32, SUsPerPU: 1, SUsPerRU: 1
   Queue size: 100, blocksize: 512, numBlocks: 15818944
   RAID Level: 1
   Autoconfig: Yes
   Root partition: No
   Last configured as: raid0
Parity status: clean
Reconstruction is 100% complete.
Parity Re-write is 100% complete.
Copyback is 100% complete.

This seems to be caused by netbsd-5 source changes between

  Sun Nov 21 11:58:22 MET 2010

(the raidframe partitions are detected as usual) and

  Mon Nov 22 09:26:02 MET 2010

Both machines seem to run fine otherwise, though /dev/sd0e is marked
failed (hope it will be reconstructable when the problem is solved).

More Info to provide?

Markus.