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Help recovering Areca hardware raid array

Carnage-

n00b
Joined
Feb 12, 2015
Messages
9
I had a 4 disk raid 5 array setup on an areca hardware controller and attempted to migrate it to a 5 disk configuration, part way through the process, the new disk failed. I shut the machine down to minimize any data loss issues while a new disk arrived. I also ordered 2 new disks to backup the (important) raid content to in case the recovery process failed. When the machine powered back on, the raid controller wouldn't export the volume and expose it to the OS so I was unable to access the data at all (bios marked the array as degraded). After a couple of reboots (attempting to get it to show up to the OS) a second disk dropped from the array. The disk itself is perfectly fine: when plugged in directly, the motherboard picks it up, however the controller refuses to recognize it.

Deciding this was far beyond my abilities, I sent it off to a professional company for assistance, their original quote of £200-400 quickly spiraled upwards into the £1000's and they were unable to produce an acceptable result eg not 100% recovered.

So now I'm left to do it myself. I expect many pessimistic responses as to my chances of getting anything back - the data is (currently) in a total mess, restoring it will take time but it is possible.

Here is where I am at the moment:

  • 4 new 2TB disks are on their way Next day delivery along with a disk cloner to make backup copies of the source disks from the original array.
  • The state of the data on the disks is as follows: Part of the array is a 5 disk degraded array, part of it is a 4 disk fully working array and part of it is void space part of neither
    array.
  • To recover I will need to rebuild the 5 disk array and the 4 disk array and stitch the results back together.
  • No existing tool can do this automatically.
  • Algorithm to find end of 5 disk part is straight foward, utilising a binary search compare A xor B xor C == D if true current stripe belongs to 4 disk array/void space otherwise its
    the 5 disk array
  • Algorithm to find void space also fairly easy: 5 disk array has 4 data blocks per stripe, 4 disk array has 3 thus 5 disk array is 3/4 size (in terms of stripes) of 4 disk array.
    Put another way the migration consumes 4 stripes for every 3 written. Void space is thus 1/3 the size of 5 disk array.

Things I don't know

  • Stripe/block size the array was using. I assume I used the defaults which probably means 4k or 64k
  • Space taken up at the start of the disk for the controllers meta data.
  • Data/parity layout of the disks. (can probably be calculated using data from void space and new array (any blocks appearing in both are data any appearing only once are parity))

The filesystem was ext4.

Can anyone offer advice as to how I go about figuring out the above and reconstructing the array. (easier methods or software that can do this would also be appreciated)
 
Please post the entire log from the Areca. What card do you have? What firmware is it currently running? What brand/model drives? Do you know the EXACT drive order as they were previously plugged into the controller previously? Before you do ANYTHING, you will first make bit-perfect copies of the existing drives with dd.
 
The Areca should be able to rebuild array before you boot into OS.
PS: Check the 5v regulation of your PSU.
What PSU is it?
 
Please post the entire log from the Areca.

Is there an easy way to get this from the CLI?

What card do you have? What firmware is it currently running?

I'm 99% sure its an arc-1220 don't know about the firmware version - how do I find this (from the cli if possible)

What brand/model drives?

The remaining good drives are samsung spinpoint's of various guises.

Do you know the EXACT drive order as they were previously plugged into the controller previously?

Probably. They were stacked in an 3->4 bay converter in order assuming the DR company I sent them to didn't remove them from the enclosure they will still be in order.

Before you do ANYTHING, you will first make bit-perfect copies of the existing drives with dd.

Drive cloner + new drives are sat in the boot of my car currently. I don't trust myself with dd :p

The Areca should be able to rebuild array before you boot into OS.

It is refusing to recognise one of the disks in the array so this seems unlikely unless you know of a command to force it to find the disk

PS: Check the 5v regulation of your PSU.

Whats the best method to do this?

What PSU is it?

Its a coolmaster 380W PSU - I have been wondering if it is the problem, but several psu calculators suggest that I'm well within its range with the devices I'm running off it.

Final question: Am I safe to RMA the failed drive or might I still need it?
 
Haven't used Areca cards very much but if you can't get the card to recognize the array, you should check out R-Studio. R-Studio has saved me from RAID card fuckups (especially Ad(cr)aptec ones) several times when my disks themselves were still fine.

For the failed disk, if you can recover ANY info from it, I would try to clone it to a good disk or image file (if you have a disk to clone it to or space on another disk (outside of this array) for an image file) before RMAing it, but it may be completely useless.
 
For the cli, here are the commands, please post the info.
event info -=> This should give you the entire log from the card
hw info -=> This should give you Fan Speeds/Temps/Voltages
sys info -=> This should give you the various firmwares on the card and the card type

As to the drive order, though the drives may still be in the cage, are you sure of the drive order and do you remember what order you plugged the SATA cables into the cage? This is important.

Is it currently showing the array as degraded or as failed (Or at all?)
 
For the cli, here are the commands, please post the info.
event info -=> This should give you the entire log from the card
hw info -=> This should give you Fan Speeds/Temps/Voltages
sys info -=> This should give you the various firmwares on the card and the card type

I'm struggling to get into the box from here; think my dyndns is out of date. I'll post output when I get home.

As to the drive order, though the drives may still be in the cage, are you sure of the drive order and do you remember what order you plugged the SATA cables into the cage? This is important.

The drives /were/ in order 1-4 down the cage, I cannot 100% garuntee this is still the case.

Is it currently showing the array as degraded or as failed (Or at all?)

I've not plugged the drives back in since I got them back from the DR company, before I sent them off it wasn't showing the array at all.

R-Studio has saved me from RAID card fuckups (especially Ad(cr)aptec ones) several times when my disks themselves were still fine.

I'm not sure this is going to work, as mentioned this isn't just 1 array; it's 3. If I find its not posisble to rebuild the array, I'll probably use R-Studio to recover the 100GB or so of data I need from the array. (The rest is either backups or backed up so a none issue) I would prefer to recover the array though as restoring the backups and bringing the server back to full working order may otherwise take weeks.

For the failed disk, if you can recover ANY info from it, I would try to clone it to a good disk or image file (if you have a disk to clone it to or space on another disk (outside of this array) for an image file) before RMAing it, but it may be completely useless.

It's spitting read errors left right and center I'm not sure I'd get a clean copy. I honestly don't know why the controller didn't fail the migration almost instantly.
 
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Code:
Date-Time            Device           Event Type            Elapsed Time Errors
===============================================================================
2015-02-02 18:29:47  H/W MONITOR      Raid Powered On
2015-01-24 10:03:52  H/W MONITOR      Raid Powered On
2015-01-24 09:55:57  RS232 Terminal   VT100 Log In
2015-01-24 09:47:17  RS232 Terminal   VT100 Log In
2015-01-24 09:47:03  H/W MONITOR      Raid Powered On
2015-01-24 09:40:47  H/W MONITOR      Raid Powered On
2015-01-24 09:37:36  H/W MONITOR      Raid Powered On
2015-01-24 09:34:06  RS232 Terminal   VT100 Log In
2015-01-24 09:33:56  H/W MONITOR      Raid Powered On
2015-01-24 09:26:53  H/W MONITOR      Raid Powered On
2015-01-24 09:24:42  RS232 Terminal   VT100 Log In
2015-01-24 09:24:30  H/W MONITOR      Raid Powered On
2015-01-24 09:20:45  RS232 Terminal   VT100 Log In
2015-01-24 09:20:33  H/W MONITOR      Raid Powered On
2015-01-24 09:18:48  H/W MONITOR      Raid Powered On
2015-01-21 20:14:59  ARC-1220-VOL#00  Stop Migration        001:46:07
2015-01-21 20:09:25  IDE Channel #06  Device Failed
2015-01-21 20:09:25  Raid Set # 00    RaidSet Degraded
2015-01-21 20:09:25  ARC-1220-VOL#00  Volume Degraded
2015-01-21 19:10:36  IDE Channel #06  Reading Error
2015-01-21 19:10:25  IDE Channel #06  Reading Error
2015-01-21 18:40:59  IDE Channel #06  Reading Error
2015-01-21 18:32:14  IDE Channel #06  Reading Error
2015-01-21 18:29:19  IDE Channel #06  Reading Error
2015-01-21 18:28:51  ARC-1220-VOL#00  Start Migrating
2015-01-21 18:28:49  Raid Set # 00    Expand RaidSet
2015-01-21 18:24:04  SW API Interface API Log In
2015-01-21 18:14:46  IDE Channel #06  Device Inserted
2014-12-26 16:02:59  H/W MONITOR      Raid Powered On
2014-12-25 13:23:55  H/W MONITOR      Raid Powered On
2014-11-16 09:05:29  H/W MONITOR      Raid Powered On
2014-11-06 13:38:59  H/W MONITOR      Raid Powered On
2014-06-22 08:03:09  H/W MONITOR      Raid Powered On
2013-08-21 12:29:34  H/W MONITOR      Raid Powered On
2013-01-09 20:44:52  H/W MONITOR      Raid Powered On
2012-07-06 16:11:50  H/W MONITOR      Raid Powered On
2012-05-08 16:59:20  H/W MONITOR      Raid Powered On
2012-05-08 06:50:48  H/W MONITOR      Raid Powered On
2012-05-07 22:02:10  ARC-1220-VOL#00  Complete Init         002:13:36
2012-05-07 19:48:33  ARC-1220-VOL#00  Start Initialize
2012-05-07 19:48:31  ARC-1220-VOL#00  Modify Volume
2012-05-07 19:47:30  ARC-1220-VOL#00  Complete Migrate      034:42:57
2012-05-07 19:46:32  RS232 Terminal   VT100 Log In
2012-05-06 09:04:32  ARC-1220-VOL#00  Start Migrating
2012-05-06 09:04:30  Raid Set # 00    Expand RaidSet
2012-05-06 09:01:39  RS232 Terminal   VT100 Log In
2012-05-06 08:59:04  H/W MONITOR      Raid Powered On
2012-04-26 17:40:21  H/W MONITOR      Raid Powered On
2012-04-26 14:58:47  H/W MONITOR      Raid Powered On
2012-04-26 14:50:32  H/W MONITOR      Raid Powered On
2012-04-17 23:42:17  H/W MONITOR      Raid Powered On
2012-04-13 21:44:28  H/W MONITOR      Raid Powered On
2012-04-09 14:51:55  H/W MONITOR      Raid Powered On
2012-04-06 11:06:56  H/W MONITOR      Raid Powered On
2012-04-04 03:56:02  H/W MONITOR      Raid Powered On
2012-04-02 13:12:26  H/W MONITOR      Raid Powered On
2012-03-26 18:11:03  H/W MONITOR      Raid Powered On
2012-03-25 15:33:44  H/W MONITOR      Raid Powered On
2012-03-24 17:07:48  H/W MONITOR      Raid Powered On
2012-03-23 23:41:04  H/W MONITOR      Raid Powered On
2012-03-23 23:11:54  H/W MONITOR      Raid Powered On
2012-03-23 21:04:11  H/W MONITOR      Raid Powered On
2012-03-18 13:46:06  H/W MONITOR      Raid Powered On
2012-02-17 20:12:00  H/W MONITOR      Raid Powered On
===============================================================================

Code:
The Hardware Monitor Information
===========================================
Fan#1 Speed (RPM)   : 2178
Battery Status      : Not Installed
HDD #1  Temp.       : 0
HDD #2  Temp.       : 0
HDD #3  Temp.       : 0
HDD #4  Temp.       : 0
HDD #5  Temp.       : 0
HDD #6  Temp.       : 0
HDD #7  Temp.       : 0
HDD #8  Temp.       : 0
===========================================

I will note here, all the drives are currently sitting on my desk being cloned/waiting to be cloned.

Code:
The System Information
===========================================
Main Processor     : 500MHz
CPU ICache Size    : 32KB
CPU DCache Size    : 32KB
CPU SCache Size    : 0KB
System Memory      : 256MB/333MHz/ECC
Firmware Version   : V1.48 2009-12-31
BOOT ROM Version   : V1.48 2009-12-31
Serial Number      : Y005CAAHAR200121
Controller Name    : ARC-1220
===========================================
 
Based on the log, here is what I want you to do (and in this order)

Make the bit-perfect copies of all drives, then put the copies of all successful drives away. (Don't continue with anything UNTIL you complete this)
Update the firmware of your card to 1.51/1.52 whichever is greater.

The log doesn't show the second drive drop which you alluded to in your OP. Based on what I see, it is possible that the array information may have been lost on the card and you *might* still have a functioning array on the disks. But I don't want to have you start any recovery activities until we have copies so we can roll back any changes if necessary.

I know you said you expected that the drive order in the cage was still correct, but are you 100% sure that you know what the correct order for the 4 SATA cables plugged into the cage are?
 
Areca Backup Data Recovery is a userfriendly and reliable personal backup software for Windows and Linux, Areca Backup tool written in java that supports data compression & encryption and incremental backup.
A backup program which persistently interrupts with a FileNotFoundException (the Locked File Filter does NOT help) and 300 bugs unfixed is not useful for me, sorry. Win7 with UAC on is not an exotic system, and it does not work although I tried for hours.

This project as saved me so much time. No complex backup solutions just gets the job done!
 
I've looked here: ftp://ftp.areca.com.tw/RaidCards/BIOS_Firmware/OldProducts/ARC1220/ but the greatest firmware version is 1.49 is there somewhere else that I can get 1.51/1.52 from?

Don't know if this will help, but this is the diagnostic report from the DR company

A diagnostic of the drives found the 4 original disks of the RAID to be in good condition. The additional disk was found to be in a degraded condition operating slowly, likely to be a failing head from the many bad and slow reads observed. As such The RAID array is now left in a position of being partially reconfigured between a four and a 5 disks Array.

This has posed an issue with the recovery and attaining a structured result. To migrate the RAID to a five disk arrangement all data has to be reorganised between the disk and parity data recalculated. This extensive logical upheaval to the array is only good once the process complete in full. If there is a failure at any point during this process it will leave the data at best partially accessible and in the worse case not at all.

In this case the array had been reconfigured to approximately 40GB on each disks, leaving the RAID with two valid configurations. One with a four disks configuration of the original disks past this 40GB area and the new five disk configuration before this. This new configuration contains the super-block defining the partition which is why it is visible with size and name when constructed as a five disk array. No structure can be achieved, even following scans in this configuration, due to the fact that the EXT file system distributes the data for the referencing of the folder structure through out the file-system.

These references are known as Inodes and with the changes that have occurred these references no longer correlate to the position of the data. With this large logical discrepancy we have no way to access the data in a structured format in the condition that the RAID now is in. We also can not reverse this process and return the RAID to the four disk configuration or make any allowances for this change. At present no feasible method is available to retrieve structured data in this case.

I am certain about the order of the cables going into the cage; however the order that they were plugged in when this failure happened wasn't the original order they were plugged in when the array was built. At that time, the array (card and all) was in a different machine and I tidied up the cabling and drive arangement when I moved it over, I've no idea if the order was maintained at this point.

Would it not make more sense to operate on the copies of the disks and leave the original known good ones as the master copy - having had one brand new disk fail on me, I'm paranoid a second might.

Edit: I've just taken a look at the case/cables: I had to remove some of the cable ties around them to get the enclosure out, so I'm not 100% sure they are in the correct order still. Hypothetically, if I couldn't put them back in the right order; how would I go about correcting this?

Edit2: Cloning disks takes a Loooooooooooooooong time :/
 
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I've got a clone of all the disks, taking a look at the start of the first disk in a hex editor, there appears to be areca controller metadata on the disk, so it's looking hopeful that the array may still be functional.

What should I do next?
 
Re: disk order.

I have identified the part of the Areaca controller metadata which defines the disk order

Code:
0000250: 0000 0000 [b]0100[/b] 0000 0200 0000 1000 0000  ................

The highlighted block changes for each disk and is 0000 on the disk which is definatly number 1 (It has the mbr and GPT table on it) and is 0300 on the disk which I know to be number 4 (It was added after the rest)

So I am finally 100% confidant I can put the disks back into the controller in the correct order.
 
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