ReadyNAS Duo won't boot after 4.1.9 upgrade #19206828

Replied in case#19206828

Please boot to telnet mode and forward port 23 for us.
Then we can login unit and do some checking.

My ReadyNAS is waiting for you. Please let me know if you need more information.

If you did boot the nas in telnet mode, and forward the port 23 to internet. Please post the internet address in the case#19206828

Only one disk in box. So it works in degrade mode, and no redundancy.
Now the disk 1(SN:9VP4ENG2) is faulty, has much ATA errors(about 4763 ATA error).
So you must get a new disk and clone the disk 1.

It is better do clone job as below instruction:
CLONE DISK:
Use a Knoppix 6.2 Live CD for this guide. Can be found at www.knoppix.net
Using dd_rescue command allows you to copy data from one drive to another block for block. This is especially useful for recovering a failed drive. Often when a drive fails, the drive is still accessible, it has just surpassed the S.M.A.R.T. error threshold. dd_rescue allows you to ignore the bad sectors and continue cloning the bad drive to a new healthy drive.

1) Connect your old drive and new drive to your PC
2) Boot up using your Linux live CD
3) Launch a terminal window.
4) Run fdisk -l to make sure the system sees both of the hard drives.
5) Run hdparm -i /dev/sdx on both of the drives to find which drive is your source drive and which drive is your destination drive
6) Once you know which drive is which you can start the clone process.
dd_rescue /dev/sdx(source disk) /dev/sdx(destination drive)
7) You will see the process start, just keep an eye on it, it might take a few hours for the clone job to finish, depending on the size of the drive.

Once the process is complete, there will be no notification, the transfer will just stop and you will see the terminal prompt again.

If you see a lot of errors or see that there is no more data being shown as succxfer: it means the drive got marked faulty by the kernel. At this point reboot the system and make sure you know which drive is which again, as it is possible they lettering might switch. Run the dd-rescue command again but this time with -r option. This will start the cloning again but this time will start from the back of the drive and will make sure to get the data that has not been cloned yet.

After the clone finish, it is better put device in telnet mode for us again.
We can check the system and volume in new disk.

If it's the disk, why was it working fine until I tried the 4.1.9 upgrade?

Sounds like a coincidental failure. Did you get any reports of ATA errors before the firmware update? It'd be surprising if you didn't with that count

Before some system files and process are in memory. When you update the ifrmware, you must reboot the device. So it will re-read the system files from disks. But disk failed, so failed read the files and failed boot up.
You also can check the disk with disk vendor's tool.

I extracted the disk from the RN and put it into a USB box. I connected to a Linux (Ubuntu) system and did a low level format and partition. Then I put it back into the RN and did a OS reinstall. It eventually failed with a bunch of ATA errors. So, then I took it back out of the RN, put it back into the USB box and again connected it to my Linux system. This time I'm running a read write test using "badblocks" utility (badblocks -b 4096 -p 4 -c 16384 -w -s /dev/sdb1). I'm going on pass # 3 and have yet to see an error. This disk just isn't that old and it's passing all my disk tests external to the ReadyNAS. The disk was also recently rebooted prior to my "upgrade to 4.1.9 and it booted and was running fine under 4.1.8. Come on guys ... I know I may be missing something, but when "x" is working and you change "y" and then "x" no longer works, it's usually due to "y".