Enabling SATA RAID on DL180 G5

Yes, I have encountered this with low-end cards and buggy drivers. However, no, not on an up-to-date Adaptec rebranded card. Wow is all I can say. One thing to consider, maybe it is more a bug with the drive than the RAID controller.

I don't have a good answer, but since you seem to have exhausted most of your options other than replacing the card, (and replacing the drives did the trick) here's a few ideas you can consider for your troubleshooting:

• The WD drives were RE (RAID Edition) drives, right? The time limited error recovery is important, so if you don't have that and the drive is attempting to recover the sector, you are going to get a looooong pause from that drive. If the RAID controller is being patient and not dropping the drive you'll have a big problem on your hands.

• Check the SMART data on the drives you removed and see if there is anything interesting.

Another comment about the importance of time limited error recovery (TLER) feature, from NAS / RAID vendor support:

As I mention before, we always suggest customers to use enterprise level drives if they use the drives in RAID settings. Enterprise level drives have more consistent responding time so that the RAID will be safer.

I hate to say "don't use SATA" in critical production environments, but I've seen this situation quite often. SATA drives are not generally meant for the duty cycle you describe, although you did spec drives specifically rated for 24x7 operation in your setup. My experience has been that SATA drives can fail in unpredictable ways, often times affecting the entire storage array, even when using RAID 1+0, as you've done. Sometimes the drives fail in a manner that can stall the entire bus. One thing to note is whether you're using SAS expanders in your setup. That can make a difference in how the remaining disks are impacted by a drive failure.

But it may have made more sense to go with midline/nearline (7200 RPM) SAS drives versus SATA. There's a small price premium over SATA, but the drives will operate/fail more predictably. The error-correction and reporting in the SAS interface/protocol is more robust than the SATA set. So even with drives whose mechanics are the same, the SAS protocol difference may have prevented the pain you experienced during your drive failure.