New Disk - Alert for SMART failure, Manual SMART test passes

[ZooKeeper]

I have 4 new 8TB drives (shucked WD EasyStores). I tested all of them on a non-prod FreeNAS system using the burn-in/testing method described here and they all passed. The first disk I moved into my production server, replacing an older 2TB disk. During resilvering, my production box issued an alert via e-mail and GUI:

Code:

Device: /dev/da13 [SAT], Failed SMART usage Attribute: 5 Reallocated_Sector_Ct.

Resilvering completed successfully. An additional short and long SMART test from the production server's standpoint also passes (SMART output below). What gives? Any idea what may be wrong here or why FreeNAS is generating this alert?

I appreciate any help and insight you guys can provide.

FreeNas Version 9.10 Stable - Up to date on patches
Dell r510 - Dual Xeon L5609/128GB RAM

Code:

[root@NAS2] ~# smartctl -a /dev/da13
smartctl 6.5 2016-05-07 r4318 [FreeBSD 10.3-STABLE amd64] (local build)
Copyright (C) 2002-16, Bruce Allen, Christian Franke, www.smartmontools.org

=== START OF INFORMATION SECTION ===
Device Model:	 WDC WD80EMAZ-00WJTA0
Serial Number:	<REDACTED>
LU WWN Device Id: 5 000cca 252cd090a
Firmware Version: 83.H0A83
User Capacity:	8,001,563,222,016 bytes [8.00 TB]
Sector Sizes:	 512 bytes logical, 4096 bytes physical
Rotation Rate:	5400 rpm
Form Factor:	  3.5 inches
Device is:		Not in smartctl database [for details use: -P showall]
ATA Version is:   ACS-2, ATA8-ACS T13/1699-D revision 4
SATA Version is:  SATA 3.2, 6.0 Gb/s (current: 3.0 Gb/s)
Local Time is:	Mon Jan 22 22:24:28 2018 CST
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:		 (   93) seconds.
Offline data collection
capabilities:			 (0x5b) SMART execute Offline immediate.
					Auto Offline data collection on/off support.
					Suspend Offline collection upon new
					command.
					Offline surface scan supported.
					Self-test supported.
					No 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:	 (1001) minutes.
SCT capabilities:			(0x003d)	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	 0x000b   100   100   016	Pre-fail  Always	   -	   0
  2 Throughput_Performance  0x0004   130   130   054	Old_age   Offline	  -	   110
  3 Spin_Up_Time			0x0007   100   100   024	Pre-fail  Always	   -	   0
  4 Start_Stop_Count		0x0012   100   100   000	Old_age   Always	   -	   6
  5 Reallocated_Sector_Ct   0x0033   100   100   005	Pre-fail  Always	   -	   0
  7 Seek_Error_Rate		 0x000a   100   100   067	Old_age   Always	   -	   0
  8 Seek_Time_Performance   0x0004   128   128   020	Old_age   Offline	  -	   18
  9 Power_On_Hours		  0x0012   100   100   000	Old_age   Always	   -	   247
 10 Spin_Retry_Count		0x0012   100   100   060	Old_age   Always	   -	   0
 12 Power_Cycle_Count	   0x0032   100   100   000	Old_age   Always	   -	   6
 22 Unknown_Attribute	   0x0023   100   100   025	Pre-fail  Always	   -	   100
192 Power-Off_Retract_Count 0x0032   100   100   000	Old_age   Always	   -	   14
193 Load_Cycle_Count		0x0012   100   100   000	Old_age   Always	   -	   14
194 Temperature_Celsius	 0x0002   180   180   000	Old_age   Always	   -	   36 (Min/Max 24/54)
196 Reallocated_Event_Count 0x0032   100   100   000	Old_age   Always	   -	   0
197 Current_Pending_Sector  0x0022   100   100   000	Old_age   Always	   -	   0
198 Offline_Uncorrectable   0x0008   100   100   000	Old_age   Offline	  -	   0
199 UDMA_CRC_Error_Count	0x000a   200   200   000	Old_age   Always	   -	   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%	   245		 -
# 2  Short offline	   Completed without error	   00%	   220		 -
# 3  Extended offline	Completed without error	   00%	   202		 -
# 4  Extended offline	Completed without error	   00%		22		 -
# 5  Short offline	   Completed without error	   00%		 6		 -

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.

[root@NAS2] ~# 

 

[dlavigne]

Did you decide what to do with this disk?

 

[ZooKeeper]

Short answer - Continue to use it.

Long Answer - I ended up swapping the disk out with another one of my new disks and the alert went away. Aside from obvious details in the SMART output changing (power on hours, spin up count, etc), the report was the same. I let the new disk run for 24 hours and still no alert. I then swapped out the next disk to upgrade with another fresh disk (call it disk C at this point) and the SMART alert then triggered again within the FreeNAS interface, for both new disks.

At this point I was more than annoyed, again since all disks passed burn in testing in my non-prod system. I then started to do some digging. Looking at the status of my vpool, I noticed that I had the ashift issue, likely due to mixing new disks that use 4k sectors and old disks that use 512b sectors. So my new disks were generating the typical message about using a non native block size. I don't know if this would cause FreeNAS to assume there is a SMART related issue or not. Maybe the drives running with 512b sectors instead of native 4k sectors throws SMART off its game and considers that an error? No idea, I'll let some SMART folks figure that out.

In the end, I wanted to fix the ashift so my new disks use their native block size. I moved my data elsewhere, destroyed my vpool and recreated it, putting 3 of my new 8TB disks in a mirror and the other 9x2TB disks in their own arrays. As I replace the older disks over time, I'll continue this same process. So far it's been running 5 days and FreeNAS is no longer indicating any errors, SMART or otherwise.