On Sun, 20 May 2012, Stan Hoeppner wrote:
> On 5/19/2012 11:05 AM, Henrique de Moraes Holschuh wrote:
> > On Sat, 19 May 2012, Ramon Hofer wrote:
> >>>> And after a while there are more messages which I don't understand. I
> >>>> have taken a picture:
> >>>> http://666kb.com/i/c3wf606sc1qkcvgoc.jpg
> >>>
> >>> It shows that udev is having serious trouble handling one of the USB
> >>> devices.
> >>
> >> Yes but only when the lsi card is attached. When it's removed the
> >
> > Get a better PSU, and if that doesn't work, either junk the motherboard, or
> > give up on adding any cards that require a bit more power.
>
> This is absolutely horrible advice. Any moderate horsepower PCIe x16

Well, yes. But mostly because I didn't add the proper "but first check if
you cannot supply extra power using MOLEX connectors". I apologise for that
one.

I *have* been through oversubscribed power rails due to el-cheap-o PSUs and
onboard (motherboard) voltage regulators before, as well as due to
undersized PSUs (in servers), and I've also been through overload scenarios
caused by bad memory modules, and a bad keyboard (which had developed low
resistance paths akin to very small short-circuits). The system goes
slightly insane, all sort of weird defects show up, INCLUDING tripping the
overcurrent detector on the root USB hub due to +5V floating too much, etc.

> these SAS boards. Too much PCIe power draw isn't the issue here, unless
> the mobo is possibly defective. I doubt this is the case. It's most

Or the PSU can't supply enough power to whichever rail the onboard VRs are
using to supply the PCIe slots and the chipset (might not be the 3.3/5V
ones, some boards prefer to do it using the 12V rail and a DC-DC VR).

> likely a firmware bug in the HBA or the system BIOS, or a driver bug in
> 2.6.32, or a combination of these. We should know after Ramon runs
> through the task list I provided earlier.

AFAIK, the only kernel bug that could cause overcurrent misdetects is a
problem on interrupt sharing, which should not be possible in a modern board
where everything PCIe uses MSI/MSI-X (the Linux USB core is still incapable
of using MSI/MSI-X, at least up to kernel 3.2)... or memory corruption,
which is less deterministic.

Firmware bugs in SMM code can cause just about anything, but it seems
unlikely they'd mess with the overcurrent alarm report bits in the USB
chipset because of a disk controller.

--
"One disk to rule them all, One disk to find them. One disk to bring
them all and in the darkness grind them. In the Land of Redmond
where the shadows lie." -- The Silicon Valley Tarot
Henrique Holschuh


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On Sat, 19 May 2012 13:41:33 +0000, Camaleón wrote:

(...)

>> I have tried to check if I can see something in the mb BIOS to see if
>> it can tell me anything about the connected hardware. But I didn't find
>> anything in the PCI settings.
>
> Mmm, have you tried to set a RAID level instead using JBOD? It's just
> for testing... although this can only be done in a very early stage when
> the disks are completely empty with no data on them because I'm afraid
> changing this will destroy whatever contains.

I will play around this evening a bit.
Luckily my last attempt with the Supermicro HBAs wipped the disks already
so I have some disks to play with ;-)


>>> Are you reaching the GRUB2 menu? If yes, you can select "recovery
>>> mode/ single-user mode".
>>
>> Ah ok. Yes I have tried that with both kernels in recovery mode but
>> without luck.
>> There are alot more messages with the last two of them the over-current
>> messages :-o
>
> If you could upload an image with the screen you get, it would be great
> :-)

Here you go:
http://666kb.com/i/c3yd21ff71u88d4x8.jpg

But I could only get the last part when it stopped adding new lines. It
just was too fast to get anything before :-(


Best regards
Ramon


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On Sat, 19 May 2012 13:06:40 -0300, Henrique de Moraes Holschuh wrote:

> On Sat, 19 May 2012, Ramon Hofer wrote:
>> On Sat, 19 May 2012 04:19:33 -0500, Stan Hoeppner wrote:
>> > On 5/19/2012 2:52 AM, Ramon Hofer wrote:
>> >> On Fri, 18 May 2012 17:57:56 -0500, Stan Hoeppner wrote:
>> >>
>> >>> On 5/18/2012 9:39 AM, Shane Johnson wrote:
>> >>>
>> >>>> After that I would look to see if
>> >>>> something isn't shorting out a USB port.
>> >>>
>> >>> Yes, USB is the cause of the over-current errors, which is plainly
>> >>> evident in his screen shot. But we don't yet know if this USB
>> >>> problem is what's hanging the system. Further troubleshooting is
>> >>> required.
>> >>
>> >> The strange thing is as I mentioned in another post is that on the
>> >> mb usb port 8 there's nothing attached and I haven't found where
>> >> port 7 is :-?
>> >
>> > I wouldn't worry about the USB errors at this point. Unless there is
>> > some larger issue with insufficient power on the motherboard causing
>> > the USB current error, it's likely unrelated to the storage hardware
>> > issue.
>> > Fix it first, then worry about the USB errors. Given you have no
>> > device plugged into those ports, it could be a phantom error.
>>
>> Yes I hope you're right with the phantom error :-) Especially because I
>> can't find port 7. No label on the mb pcb nor in it's documentation.
>
> It might well mean one of the power planes is oversubscribed, and THAT
> can cause anything up to and including damage to hard disks, data
> corruption, and crashes.

Thanks for the suggestion, Henrique!
The PSU is a 750 W so I think it should be enough for now.


Best regards
Ramon


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On Sun, 20 May 2012 12:12:55 +0000, Ramon Hofer wrote:

> On Sat, 19 May 2012 13:41:33 +0000, Camaleón wrote:
>
>> Mmm, have you tried to set a RAID level instead using JBOD? It's just
>> for testing... although this can only be done in a very early stage
>> when the disks are completely empty with no data on them because I'm
>> afraid changing this will destroy whatever contains.
>
> I will play around this evening a bit. Luckily my last attempt with the
> Supermicro HBAs wipped the disks already so I have some disks to play
> with ;-)

Good :-)

Also, consider installing into the motherboard only the strictly required
devices to work (i.e., processor+heatsink, memory and a couple of hard
disks to test mdraid).

>> If you could upload an image with the screen you get, it would be great
>> :-)
>
> Here you go:
> http://666kb.com/i/c3yd21ff71u88d4x8.jpg

Thanks!

> But I could only get the last part when it stopped adding new lines. It
> just was too fast to get anything before :-(

Okay... I can't recall if you are already considered/tried disabling the
USB host controller from your BIOS.

Anyway, from the above messages it seems there are two USB hosts detected
("2-1" with 6 ports and "4-1" with 8 ports) and the latter is the one
exposing the over-current condition. Which OTOH is also weird because
according to the motherboard specifications¹, there has to be x2 USB 3
ports and x12 USB 2.0. There's something not matching here.

¹http://www.supermicro.com/products/motherboard/Core/P67/C7P67.cfm

Greetings,

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On Sat, 19 May 2012 11:31:51 -0500, Stan Hoeppner wrote:

> On 5/19/2012 5:33 AM, Ramon Hofer wrote:
>
>> Yes, I'm really thankful for the recommendation. And somehow I hoped
>> you could jump in and help me :-)
>
> I'm actively working on it, have been for a couple of hours on and off.
> I'm reading your responses as I go before responding so I hopefully
> don't recommend something you've already tried. I'm still researching.
> In the mean time, if you can, go ahead and flash the 9240 with the
> latest firmware, precisely following the instructions.

Should I first flash the new firmware and then test what you describe
below?

I am not very sure if I do the flashing right. Here's what I do:

1. Read the firmware readme file [1]

> Installation:
> =============
> Use MegaCLI to flash the SAS controllers. MegaCLI can be downloaded
> from the support and download section of www.lsi.com.
>
> Command syntax: MegaCli -adpfwflash -f imr_fw.rom -a0

So I download the MegaCLI from [2] and read the MegaCLI readme [3]:

> Installation Commands:
> ===================
> 1. Copy MegaCli.exe to a folder.
> 2. Run MegaCli from the Command Prompt. Use -h option to see help
menu.

I create a FreeDOS USB stick with unetbooting. Copy MegaCli.exe and the
imr_fw.rom [4] into a folder on the USB stick, boot it and run the above
command to flash the card?


[1] http://www.lsi.com/downloads/Public/MegaRAID%20Common%
20Files/20.10.1-0077_SAS_2008_FW_Image_APP-2.120.244-1482.txt

[2] http://www.lsi.com/downloads/Public/MegaRAID%20Common%
20Files/8.00.40_Dos_Megacli.zip

[3] http://www.lsi.com/downloads/Public/MegaRAID%20Common%20Files/
README_FOR_8.00.40_Dos_Megacli.zip.txt

[4] http://www.lsi.com/downloads/Public/MegaRAID%20Common%
20Files/20.10.1-0077_SAS_2008_FW_Image_APP-2.120.244-1482.zip


(...)

>> But I didn't know if it's ok to ask you by name.
>
> I've been doing a "reply-to-all" with each reply, hoping you'd follow
> suit. This list is very busy thus a reply-all ensures I won't miss your
> posts.

I'm using pan to read the newsgroup where's no reply to all button. But
there's a mail to field which I'm now testing :-)


> Please feel free to address me by name and/or contact me directly off
> list. I recommended this storage controller/expander solution to you
> and it's not working yet. I'm not going to leave you twisting in the
> wind. That's not how I roll. Besides, look at my RHS domain. I
> have a reputation to uphold.

That's very kind!
I know that everyone here does for free what they do. So I don't want to
ask for someone to spend his/her time for me. But of course I'm really
thankful for every single minute you spend to help me :-)


Best regards
Ramon


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On Sat, 19 May 2012 11:31:51 -0500, Stan Hoeppner wrote:

> On 5/19/2012 5:33 AM, Ramon Hofer wrote:
>
>> Yes, I'm really thankful for the recommendation. And somehow I hoped
>> you could jump in and help me :-)
>
> I'm actively working on it, have been for a couple of hours on and off.
> I'm reading your responses as I go before responding so I hopefully
> don't recommend something you've already tried. I'm still researching.
> In the mean time, if you can, go ahead and flash the 9240 with the
> latest firmware, precisely following the instructions.

There were no problems upgrading the fw :-)

Unfortunately it didn't solve he problem.

> Also try the following:
>
> 1. Power the Intel expander with a PSU 4 pin Molex connector instead of
> using a PCIe slot. Molex are the large standard plugs, usually white,
> used to connect hard drives for the past 25 years--two black wires, one
> red, one yellow. With the chassis laying on your desk and the side/top
> cover panel removed, lay the anti-static bag the expander shipped in on
> top of the drive cage frame or PSU, then lay the expander card on its
> back on top of the bag--heat sink facing the ceiling. Make sure it
> doesn't fall off and ground out to the metal chassis or mobo, etc. This
> will eliminate a possible PCIe power bug in the mobo.

Did that but again no improvement.
Over-current messages still present and boot process still not finished
properly.

But the over-current message is always present even with only mb, ram, cpu
and graphics card.

Btw this is a PCIe x1 ATI FireMV 2260 card. With it I have both PCIe x16
for the LSI and Intel cards available.


> 2. With the expander powered directly from the PSU, try the 9240 in
> each x16 slot until one works (I'm assuming you know that you must power
> down the system before inserting/removing cards or you'll very likely
> permanently damage the cards and/or mobo). If no success here...

No success with the hba in either of the two slots. I have also tried to
plug the graphics card to another slot.
And the expander was completely removed for these tests with no SAS cable
connected to the lsi card.


> 3. Go into the mobo BIOS and set and test these options:
>
> Quiet Boot: DISABLED
> Interrupt 19 Capture: DISABLED
> --save/reboot/test--
> PCI Express Port: ENABLED
> PEG Force Gen1: ENABLED
> Detect Non-Compliance Device: ENABLED --save/reboot/
test--
> XHCI Hand-off: ENABLED
> Active State Power Management: ENABLED PCIe (PCI
Express) Max Read
> Request Size: 4096 --save/reboot/test--

None of this worked.


> If none of this works, disable both on board SATA controllers:
>
> Serial-ATA Controller 0: DISABLED
> Serial-ATA Controller 1: DISABLED
>
> and connect all drives to the 9240, and re-enable Interrupt 19
Capture:
> ENABLED
>
> This will allow booting from the 9240. In the 9240 webBIOS, create a
> RAID1 array device of two disks, make it bootable, save and initialize
> the array. Reboot into the Squeeze install disk and install onto the
> RAID1 device. The initialization should continue transparently in the
> background while you're installing Debian. When finished reboot to see
> if the boot hang persists.

I was able to set a RAID1 in the WebBIOS and set the bootable option. But
I'm not sure if the setting was accepted. Even though when I set the
bootable option again the WebBIOS tells me the option is already set - so
it should be ok?

Unfortunately the Debian installer doesn't list the RAID1 storage
device :-?


> Hopefully you won't need to do all of these things as it will be very
> time consuming. I'm attempting to provide you a thorough
> troubleshooting guide that covers most/all the possible/likely causes of
> the hang.

Thank you very much for your help so far :-)


Best regards
Ramon


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On 5/20/2012 9:24 AM, Ramon Hofer wrote:
> On Sat, 19 May 2012 11:31:51 -0500, Stan Hoeppner wrote:
>
>> On 5/19/2012 5:33 AM, Ramon Hofer wrote:
>>
>>> Yes, I'm really thankful for the recommendation. And somehow I hoped
>>> you could jump in and help me :-)
>>
>> I'm actively working on it, have been for a couple of hours on and off.
>> I'm reading your responses as I go before responding so I hopefully
>> don't recommend something you've already tried. I'm still researching.
>> In the mean time, if you can, go ahead and flash the 9240 with the
>> latest firmware, precisely following the instructions.
>
> Should I first flash the new firmware and then test what you describe
> below?

Flash the firmware, then try too boot the system from the drives
attached to the mobo SATA port, as you have been. If the system locks
as it did before, this will tell us the firmware update didn't solve the
problem. Given that the shipped FW was from 2010, I have high hopes the
new FW will fix this problem. I'm surprised your card shipped with a FW
that old. From what company did you purchase the 9240-4i? I'm
wondering if it may have been sitting on a shelf for a while.

> I am not very sure if I do the flashing right. Here's what I do:
>
> 1. Read the firmware readme file [1]
>
>> Installation:
>> =============
>> Use MegaCLI to flash the SAS controllers. MegaCLI can be downloaded
>> from the support and download section of www.lsi.com.
>>
>> Command syntax: MegaCli -adpfwflash -f imr_fw.rom -a0
>
> So I download the MegaCLI from [2] and read the MegaCLI readme [3]:
>
>> Installation Commands:
>> ===================
>> 1. Copy MegaCli.exe to a folder.
>> 2. Run MegaCli from the Command Prompt. Use -h option to see help
> menu.
>
> I create a FreeDOS USB stick with unetbooting. Copy MegaCli.exe and the
> imr_fw.rom [4] into a folder on the USB stick, boot it and run the above
> command to flash the card?

Yep.

>
> [1] http://www.lsi.com/downloads/Public/MegaRAID%20Common%
> 20Files/20.10.1-0077_SAS_2008_FW_Image_APP-2.120.244-1482.txt
>
> [2] http://www.lsi.com/downloads/Public/MegaRAID%20Common%
> 20Files/8.00.40_Dos_Megacli.zip
>
> [3] http://www.lsi.com/downloads/Public/MegaRAID%20Common%20Files/
> README_FOR_8.00.40_Dos_Megacli.zip.txt
>
> [4] http://www.lsi.com/downloads/Public/MegaRAID%20Common%
> 20Files/20.10.1-0077_SAS_2008_FW_Image_APP-2.120.244-1482.zip
>
>
> (...)
>
>>> But I didn't know if it's ok to ask you by name.
>>
>> I've been doing a "reply-to-all" with each reply, hoping you'd follow
>> suit. This list is very busy thus a reply-all ensures I won't miss your
>> posts.
>
> I'm using pan to read the newsgroup where's no reply to all button. But
> there's a mail to field which I'm now testing :-)

Ahh, ok. I didn't realize some people read mailing lists via news groups.

When I reply-to-all, where does the copy end up that is sent to
ramonhofer@bluewin.ch? Surely you read your email in an MUA such as
ThunderBird or similar. You can reply-to-all from there.

>> Please feel free to address me by name and/or contact me directly off
>> list. I recommended this storage controller/expander solution to you
>> and it's not working yet. I'm not going to leave you twisting in the
>> wind. That's not how I roll. Besides, look at my RHS domain. I
>> have a reputation to uphold.
>
> That's very kind!
> I know that everyone here does for free what they do. So I don't want to
> ask for someone to spend his/her time for me. But of course I'm really
> thankful for every single minute you spend to help me :-)

I'll be with you until it's fixed, working, or until we identify the
root cause. It's always possible that the HBA is defective in some way.
If neither the firmware update no other measures fix the problem, you
may need to send the card back for replacement.

BTW, after you flash the FW, power off the machine and remove the Intel
Expander from its PCIe slot. Disconnect the 8087 cable from the 9240.
Then power up and see if the system boots from the mobo connected
drives. This will isolate the 9240 from the downstream SAS expander and
drives.

--
Stan


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On Sun, 20 May 2012, Ramon Hofer wrote:
> On Sat, 19 May 2012 13:06:40 -0300, Henrique de Moraes Holschuh wrote:
> > On Sat, 19 May 2012, Ramon Hofer wrote:
> >> On Sat, 19 May 2012 04:19:33 -0500, Stan Hoeppner wrote:
> >> > On 5/19/2012 2:52 AM, Ramon Hofer wrote:
> >> >> On Fri, 18 May 2012 17:57:56 -0500, Stan Hoeppner wrote:
> >> >>> On 5/18/2012 9:39 AM, Shane Johnson wrote:
> >> >>>> After that I would look to see if
> >> >>>> something isn't shorting out a USB port.
> >> >>>
> >> >>> Yes, USB is the cause of the over-current errors, which is plainly
> >> >>> evident in his screen shot. But we don't yet know if this USB
> >> >>> problem is what's hanging the system. Further troubleshooting is
> >> >>> required.
> >> >>
> >> >> The strange thing is as I mentioned in another post is that on the
> >> >> mb usb port 8 there's nothing attached and I haven't found where
> >> >> port 7 is :-?
> >> >
> >> > I wouldn't worry about the USB errors at this point. Unless there is
> >> > some larger issue with insufficient power on the motherboard causing
> >> > the USB current error, it's likely unrelated to the storage hardware
> >> > issue.
> >> > Fix it first, then worry about the USB errors. Given you have no
> >> > device plugged into those ports, it could be a phantom error.
> >>
> >> Yes I hope you're right with the phantom error :-) Especially because I
> >> can't find port 7. No label on the mb pcb nor in it's documentation.
> >
> > It might well mean one of the power planes is oversubscribed, and THAT
> > can cause anything up to and including damage to hard disks, data
> > corruption, and crashes.
>
> Thanks for the suggestion, Henrique!
> The PSU is a 750 W so I think it should be enough for now.

Yes, it is probably enough. You have to do a lot to overpower a *good* 750W
PSU (a crappy one, OTOH...).

You should still do all testing with the minimal hardware setup. From
experience, you also need to be able to test using no keyboard or a
different keyboard (and mouse)... USB is supposed to be safe from this crap
as it can detect overcurrent, but since it IS detecting overcurrent in your
case (be it a faulty alarm or not)...

--
"One disk to rule them all, One disk to find them. One disk to bring
them all and in the darkness grind them. In the Land of Redmond
where the shadows lie." -- The Silicon Valley Tarot
Henrique Holschuh


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On 5/20/2012 1:13 PM, Ramon Hofer wrote:

> There were no problems upgrading the fw :-)
>
> Unfortunately it didn't solve he problem.

Grrr.

>> 3. Go into the mobo BIOS and set and test these options:
>>
>> Quiet Boot: DISABLED
>> Interrupt 19 Capture: DISABLED
>> --save/reboot/test--
>> PCI Express Port: ENABLED
>> PEG Force Gen1: ENABLED
>> Detect Non-Compliance Device: ENABLED --save/reboot/
> test--
>> XHCI Hand-off: ENABLED
>> Active State Power Management: ENABLED PCIe (PCI
> Express) Max Read
>> Request Size: 4096 --save/reboot/test--
>
> None of this worked.

Grrr.

>
>> If none of this works, disable both on board SATA controllers:
>>
>> Serial-ATA Controller 0: DISABLED
>> Serial-ATA Controller 1: DISABLED
>>
>> and connect all drives to the 9240, and re-enable Interrupt 19
> Capture:
>> ENABLED
>>
>> This will allow booting from the 9240. In the 9240 webBIOS, create a
>> RAID1 array device of two disks, make it bootable, save and initialize
>> the array. Reboot into the Squeeze install disk and install onto the
>> RAID1 device. The initialization should continue transparently in the
>> background while you're installing Debian. When finished reboot to see
>> if the boot hang persists.
>
> I was able to set a RAID1 in the WebBIOS and set the bootable option. But
> I'm not sure if the setting was accepted. Even though when I set the
> bootable option again the WebBIOS tells me the option is already set - so
> it should be ok?
>
> Unfortunately the Debian installer doesn't list the RAID1 storage
> device :-?

Grrrr.

Does the mobo BIOS show the disk device? If not, does the 9240 BIOS
show the disk device, RAID level, and its size?

What we need to figure out is whether this is a BIOS problem at this
point or a Debian installer kernel driver problem.

>> Hopefully you won't need to do all of these things as it will be very
>> time consuming. I'm attempting to provide you a thorough
>> troubleshooting guide that covers most/all the possible/likely causes of
>> the hang.
>
> Thank you very much for your help so far :-)

Sorry it hasn't helped you make forward progress.

Did you already flash the C7P67 BIOS to the latest version? I can't recall.

--
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On 5/20/2012 1:13 PM, Ramon Hofer wrote:

> I was able to set a RAID1 in the WebBIOS and set the bootable option. But
> I'm not sure if the setting was accepted. Even though when I set the
> bootable option again the WebBIOS tells me the option is already set - so
> it should be ok?
>
> Unfortunately the Debian installer doesn't list the RAID1 storage
> device :-?

Are you using the very latest Squeeze installer ISO?

It's possible the driver in 2.6.32-5 used in the original Squeeze
installer doesn't work with the 9240. Support for the 9240 was added in
2.6.32-29:

http://bugs.debian.org/cgi-bin/bugreport.cgi?bug=604083

Something else to try:

If the disks that were attached to the mobo SATA ports are still intact
with Sqeueeze installed, boot the system with those attached to the mobo
SATA but with the 9240 and expander removed from the system.

Once booted, upgrade the kernel:

$ aptitude -t squeeze-backports install linux-image-3.2.0-0.bpo.2-amd64

Shutdown, install the 9240 only, power up and see if it boots without
hanging. If it does, power down, plug in the expander, cables, drives,
etc, power up and see if Debian sees the RAID1 virtual disk, and the
JBOD drives, if any are present.

--
Stan


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