Issue with hard drive upgrade and xraid

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leo037 wrote:

sent you a message

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Thx.

One aspect here - the system has been expanded several times.  The original disks were 4 TB, with later expansions to 6 TB, 10 TB, and now 16 TB.  As a result, the system has 4 different RAID groups in the data volume - md124, md125, md126, and md127.  These are all concatenated together to form the data volume.  When you replace a disk, all of these groups need to be resynced.  

Physically, each of these groups has a corresponding partition on each disk.  Looking at disks 1-5 (sda-sde), these partitions look like this:

Number  Start (sector)    End (sector)  Size       Code  Name
   1              64         8388671   4.0 GiB     FD00  
   2         8388672         9437247   512.0 MiB   FD00  
   3         9437248      7814033072   3.6 TiB     FD00  
   4      7814033080     11721045119   1.8 TiB     FD00  
   5     11721045120     19532873679   3.6 TiB     FD00  
   6     19532873680     31251759055   5.5 TiB     FD00  

(The first two partitions are for the OS and swap, and not part of the data volume).

But the final partition (number 6) has not been created on disk 6 (sdf).  The serial number is 2BKLVLET

Number  Start (sector)    End (sector)  Size       Code  Name
   1              64         8388671   4.0 GiB     FD00  
   2         8388672         9437247   512.0 MiB   FD00  
   3         9437248      7814033072   3.6 TiB     FD00  
   4      7814033080     11721045119   1.8 TiB     FD00  
   5     11721045120     19532873679   3.6 TiB     FD00 

It is also missing from RAID group md127:

md124 : active raid5 sda5[6] sdf5[11] sde5[10] sdd5[9] sdc5[8] sdb5[7]
      19528915840 blocks super 1.2 level 5, 64k chunk, algorithm 2 [6/6] [UUUUUU]
      
md125 : active raid5 sda4[6] sdf4[11] sde4[10] sdd4[9] sdc4[8] sdb4[7]
      9766874560 blocks super 1.2 level 5, 64k chunk, algorithm 2 [6/6] [UUUUUU]
      
md126 : active raid5 sda3[6] sdf3[11] sde3[10] sdd3[9] sdc3[8] sdb3[7]
      19510833920 blocks super 1.2 level 5, 64k chunk, algorithm 2 [6/6] [UUUUUU]
      bitmap: 0/30 pages [0KB], 65536KB chunk

md127 : active raid5 sda6[0] sde6[4] sdd6[3] sdc6[2] sdb6[1]
      23437242368 blocks super 1.2 level 5, 64k chunk, algorithm 2 [5/5] [UUUUU]

Since the system is running FlexRAID (RAID-5), all the RAID groups need to include all the disks in order for the system to expand.

There's not enough info in the log zip to see why this partition wasn't created, and then added to md127.  But the disk does appear healthy. 

I suggest removing the disk, and connecting it to a PC. From there, you can either unformat the disk (deleting all the "volumes" on it using the Windows disk manager), or just format it.  Then you can add it back to the NAS.  If you choose to reformat it, then you will then have to format it again in the NAS before the system will add it back to the data volume.