I think Christopher is on target.

Taking Christopher's thinking in another direction, the rsync (when spawned) is 
operating on a live changing filesystem and to complicate things the rsync is 
operating only on the RW layer of the unionfs filesystem... all on a slow CF 
drive with DMA disabled (in your case).  What happens when rsync is 
transferring a file from /oldroot/mnt/asturw that unionfs changes indirectly ?  
I don't know that answer, but it is indeed complicated, though I would expect 
rsync would be be happier if operating directly with a changing filesystem 
rather than indirectly via a unionfs layer.  Of course things could work 
perfectly 99.99... % of the time, it is the 0.00...1 % of the time at issue.

Personally I always use separate partitions for /oldroot/mnt/asturw and /mnt/kd 
when setting-up the system using setup.php or initial-setup.  In this case your 
rsync backup scheme would have to be called twice, once for /oldroot/mnt/asturw 
and once for /mnt/kd, but the good news is unionfs is not involved with /mnt/kd 
in this case, which contains all the live, changing files.

Lonnie


On Feb 20, 2014, at 6:19 AM, The Cadillac Kid wrote:

> I have had failed CF cards act like this and work fine after a power cycle 
> for awhile... what I "THINK" happens is that the wear levelling in the car 
> gets to the point it responds too slowly to the kernel..  the eventual result 
> will be linux remounts the card read only after so many failed reads / 
> writes..
> 
> the cards i lost in the field would test perfectly fine with linux and 
> windows utilities...  put them back into service in the soekris and same 
> errors would come back after a few days.... or sometimes a few hours
> -Christopher
> 
> 
> 
> On Wednesday, February 19, 2014 7:39 AM, David Kerr <[email protected]> wrote:
> rsync is running on a separate server, a ReadyNAS, connects to astlinux over 
> ssh to pull the contents of asturw and save it on the server....
> 
> rsync -avz --delete -b --backup-dir=/c/home/david/PBXbackup-old -e "ssh 
> -p<myport>" [email protected]:/oldroot/mnt/asturw  /c/home/david/PBXbackup
> 
> David
> 
> 
> 
> On Tue, Feb 18, 2014 at 10:21 PM, Benjamin L. Naber <[email protected]> 
> wrote:
> Are you using rsync to copy files to the same CF that your firmware is
> on?
> 
> If so, you are going to cause the CF to fail earlier than expected, or
> if it really is failing but no showing signs, you will surely cause it
> to fail.
> 
> Perform your backups to some other media such as USB flash/hard drive,
> or you can get really fancy and make it backup over the network via NFS.
> 
> ~Benjamin
> 
> 
> On Tue, 2014-02-18 at 21:25 -0500, David Kerr wrote:
> > So, I removed the CF card and plugged it into another linux system and
> > ran fsck.  No errors were found.  So I backed up everything then put
> > the same card back into my Alix system and rebooted.  Everything is
> > working fine.  I have no idea what the problem was but I will keep an
> > eye on the logs closely for the next few days and see what happens.  I
> > have backup and am running a rsync backup or asturw hourly so I can
> > recover if necessary.  If problems occur again I can always replace
> > the Alix board as I have a second one that I used for test purposes in
> > the past, but is presently unused.
> >
> >
> > David
> >
> >
> > On Fri, Feb 14, 2014 at 12:58 AM, Darrick Hartman
> > <[email protected]> wrote:
> >         Back it up and get a new card. It looks like you are having
> >         some sort of hardware problems.
> >
> >         -----Original Message-----
> >         From: David Kerr [[email protected]]
> >         Received: Thursday, 13 Feb 2014, 11:42PM
> >         To: AstLinux Users Mailing List
> >         [[email protected]]
> >         Subject: [Astlinux-users] Is my CF card failing?
> >
> >         My log is full of the following messages.  Many day's worth.
> >          Looks like I have a CF card problem?  Appears that CDRs are
> >         not being logged either.  I'm afraid to reboot the device in
> >         case it doesn't come back up again.
> >
> >
> >         Thoughts?
> >         David
> >
> >
> >
> >
> >
> >
> >
> >
> >         Feb 13 23:54:32 pbx user.err kernel: end_request: I/O error, dev 
> > sda, sector 3145704
> >         Feb 13 23:54:32 pbx user.err kernel: EXT2-fs (sda2): previous I/O 
> > error to superblock detected
> >         Feb 13 23:54:32 pbx user.info kernel: sd 0:0:0:0: [sda] Unhandled 
> > error code
> >         Feb 13 23:54:32 pbx user.info kernel: sd 0:0:0:0: [sda] Result: 
> > hostbyte=DID_BAD_TARGET driverbyte=DRIVER_OK
> >         Feb 13 23:54:32 pbx user.info kernel: sd 0:0:0:0: [sda] CDB: 
> > Write(10): 2a 00 00 03 ff c0 00 00 08 00
> >         Feb 13 23:54:32 pbx user.err kernel: end_request: I/O error, dev 
> > sda, sector 262080
> >         Feb 13 23:54:32 pbx user.err kernel: Buffer I/O error on device 
> > sda2, logical block 0
> >         Feb 13 23:54:32 pbx user.warn kernel: lost page write due to I/O 
> > error on sda2
> >         Feb 13 23:54:32 pbx user.crit kernel: EXT2-fs (sda2): error: 
> > ext2_get_inode: unable to read inode block - inode=171522, block=360453
> >         Feb 13 23:54:32 pbx user.info kernel: sd 0:0:0:0: [sda] Unhandled 
> > error code
> >         Feb 13 23:54:32 pbx user.info kernel: sd 0:0:0:0: [sda] Result: 
> > hostbyte=DID_BAD_TARGET driverbyte=DRIVER_OK
> >         Feb 13 23:54:32 pbx user.info kernel: sd 0:0:0:0: [sda] CDB: 
> > Read(10): 28 00 00 08 05 30 00 00 08 00
> >         Feb 13 23:54:32 pbx user.err kernel: end_request: I/O error, dev 
> > sda, sector 525616
> >         Feb 13 23:54:32 pbx user.err kernel: EXT2-fs (sda2): previous I/O 
> > error to superblock detected
> >         Feb 13 23:54:32 pbx user.info kernel: sd 0:0:0:0: [sda] Unhandled 
> > error code
> >         Feb 13 23:54:32 pbx user.info kernel: sd 0:0:0:0: [sda] Result: 
> > hostbyte=DID_BAD_TARGET driverbyte=DRIVER_OK
> >         Feb 13 23:54:32 pbx user.info kernel: sd 0:0:0:0: [sda] CDB: 
> > Write(10): 2a 00 00 03 ff c0 00 00 08 00
> >         Feb 13 23:54:32 pbx user.err kernel: end_request: I/O error, dev 
> > sda, sector 262080
> >
> >         
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