I'm getting an error installing on a new Dell workstation. I don't know the model number, to tell you the truth. But it has a 250Gb sata drive. Below is my setup storage config file, the output from parted, and the format.log file.

It says its trying to use a block size too small for the device? Note that I tried doing align-at:4K but it did not help.

=== setup-storage ===
disk_config disk1 align-at:4K disklabel:msdos
logical /         64G      ext3           rw        createopts="-b 2048"
logical  swap          1G-2G   swap   rw
logical /home 10%- ext3 rw,relatime createopts="-m 5 -j"


=== parted ===
Model: ATA ST250DM000-1BD14 (scsi)
Disk /dev/sda: 250GB
Sector size (logical/physical): 512B/4096B
Partition Table: msdos

Number  Start   End     Size    Type      File system  Flags
1      1052kB  250GB   250GB   extended               lba
5      1053kB  68.7GB  68.7GB  logical
6      68.7GB  70.5GB  1811MB  logical
7      70.5GB  250GB   180GB   logical


=== format.log ===
Starting setup-storage 1.4
disklist: sda
Using config file: /var/lib/fai/config/disk_config/BOOTLINUXONLY
Input was:
disk_config disk1 align-at:4K disklabel:msdos
logical /         64G      ext3           rw        createopts="-b 2048"
logical  swap          1G-2G   swap   rw
logical /home 10%- ext3 rw,relatime createopts="-m 5 -j" (CMD) parted -s /dev/sda unit TiB print 1> /tmp/OG8FYZDLQm 2> /tmp/AClj24_w0N
Executing: parted -s /dev/sda unit TiB print
Parted could not read a disk label (new disk?)
(STDOUT) Error: /dev/sda: unrecognised disk label
(CMD) parted -s /dev/sda mklabel msdos 1> /tmp/61V7OaRlLd 2> /tmp/RA7BtvH9pS
Executing: parted -s /dev/sda mklabel msdos
(CMD) parted -s /dev/sda unit TiB print 1> /tmp/h9FMDrZzR9 2> /tmp/TbtE8j2hxt
Executing: parted -s /dev/sda unit TiB print
(STDOUT) Model: ATA ST250DM000-1BD14 (scsi)
(STDOUT) Disk /dev/sda: 0.23TiB
(STDOUT) Sector size (logical/physical): 512B/4096B
(STDOUT) Partition Table: msdos
(STDOUT)
(STDOUT) Number  Start  End  Size  Type  File system  Flags
(STDOUT)
(CMD) parted -s /dev/sda unit B print free 1> /tmp/_B08Fqg3Tu 2> /tmp/iFKurQqqyt
Executing: parted -s /dev/sda unit B print free
(STDOUT) Model: ATA ST250DM000-1BD14 (scsi)
(STDOUT) Disk /dev/sda: 250059350016B
(STDOUT) Sector size (logical/physical): 512B/4096B
(STDOUT) Partition Table: msdos
(STDOUT)
(STDOUT) Number Start End Size Type File system Flags
(STDOUT)         32256B  250059350015B  250059317760B        Free Space
(STDOUT)
(CMD) parted -s /dev/sda unit chs print free 1> /tmp/jtkx87vHHA 2> /tmp/MT_i_zy9Ar
Executing: parted -s /dev/sda unit chs print free
(STDOUT) Model: ATA ST250DM000-1BD14 (scsi)
(STDOUT) Disk /dev/sda: 30401,80,62
(STDOUT) Sector size (logical/physical): 512B/4096B
(STDOUT) BIOS cylinder,head,sector geometry: 30401,255,63. Each cylinder is 8225kB.
(STDOUT) Partition Table: msdos
(STDOUT)
(STDOUT) Number  Start  End          Type  File system  Flags
(STDOUT)         0,1,0  30401,80,62        Free Space
(STDOUT)
   Finding all volume groups
 No volume groups found
(CMD) mdadm --examine --scan --verbose -c partitions 1> /tmp/gsj3jrxR5F 2> /tmp/moaRQi73fd
Executing: mdadm --examine --scan --verbose -c partitions
Current disk layout
$VAR1 = {
         '/dev/sda' => {
                         'bios_heads' => '255',
                         'disklabel' => 'msdos',
                         'partitions' => {},
                         'bios_cylinders' => '30401',
                         'size' => '250059350016',
                         'sector_size' => '512',
                         'begin_byte' => 0,
                         'end_byte' => '250059350015',
                         'bios_sectors_per_track' => '63'
                       }
       };
Current LVM layout
$VAR1 = {};
Current RAID layout
$VAR1 = {};
Current device tree
$VAR1 = {
         '/dev/sda' => undef
       };
Desired disk layout
$VAR1 = {
         'PHY_/dev/sda' => {
                             'opts_all' => {},
                             'preserveparts' => 0,
                             'align_at' => 4096,
                             'disklabel' => 'msdos',
                             'partitions' => {
                                               '6' => {
                                                        'encrypt' => 0,
'start_byte' => '68720533504', 'filesystem' => 'swap', 'mountpoint' => 'none', 'mount_options' => 'rw', 'end_byte' => '70531510271',
                                                        'size' => {
'resize' => 0, 'always_format' => 0, 'range' => '1810976768-1810976768', 'preserve' => 0, 'eff_size' => 1810976768, 'extended' => 0
                                                                  }
                                                      },
                                               '1' => {
'start_byte' => 1051648, 'end_byte' => '250059350015',
                                                        'size' => {
'resize' => 0, 'always_format' => 0, 'preserve' => 0, 'eff_size' => '250058292224', 'extended' => 1
                                                                  }
                                                      },
                                               '7' => {
'journal_dev' => undef,
                                                        'encrypt' => 0,
'start_byte' => '70531514368', 'createopts' => '-m 5 -j', 'mountpoint' => '/home', 'mount_options' => 'rw,relatime',
                                                        'size' => {
'resize' => 0, 'always_format' => 0, 'range' => '179527835648-179527835648', Use of uninitialized value in string eq at /usr/share/fai/setup-storage//Commands.pm line 1142.
                                       'preserve' => 0,
'eff_size' => '179527835648', 'extended' => 0
                                                                  },
'filesystem' => 'ext3', 'end_byte' => '250059350015'
                                                      },
                                               '5' => {
'journal_dev' => undef,
                                                        'encrypt' => 0,
'start_byte' => 1052672, 'createopts' => '-b 2048', 'mountpoint' => '/', 'mount_options' => 'rw',
                                                        'size' => {
'resize' => 0, 'always_format' => 0, 'range' => '68719476736-68719476736', 'preserve' => 0, 'eff_size' => '68719476736', 'extended' => 0
                                                                  },
'filesystem' => 'ext3', 'end_byte' => '68720529407'
                                                      }
                                             },
                             'fstabkey' => 'device',
                             'bootable' => -1,
                             'virtual' => 0
                           }
       };
Desired device tree
$VAR1 = {
         '/dev/sda' => [
                         '/dev/sda1',
                         '/dev/sda5',
                         '/dev/sda6',
                         '/dev/sda7'
                       ]
       };
/ FS create_options: -b 2048
/home FS create_options: -m 5 -j
Trying to add CMD: true
PRE:
POST: exist_/dev/sda
Trying to add CMD: true
PRE: exist_/dev/sda
POST: cleared1_/dev/sda
Trying to add CMD: parted -s /dev/sda mklabel msdos
PRE: cleared1_/dev/sda
POST: cleared2_/dev/sda
Trying to add CMD: parted -s /dev/sda mkpart extended "" 1051648B 250059350015B
PRE: cleared2_/dev/sda
POST: prep2_/dev/sda1
Trying to add CMD: true
PRE: prep2_/dev/sda1
POST: exist_/dev/sda1
Trying to add CMD: parted -s /dev/sda mkpart logical "ext3" 1052672B 68720529407B
PRE: cleared2_/dev/sda,exist_/dev/sda1
POST: prep2_/dev/sda5
Trying to add CMD: true
PRE: prep2_/dev/sda5
POST: exist_/dev/sda5
Trying to add CMD: parted -s /dev/sda mkpart logical "linux-swap" 68720533504B 70531510271B
PRE: cleared2_/dev/sda,exist_/dev/sda5
POST: prep2_/dev/sda6
Trying to add CMD: true
PRE: prep2_/dev/sda6
POST: exist_/dev/sda6
Trying to add CMD: parted -s /dev/sda mkpart logical "ext3" 70531514368B 250059350015B
PRE: cleared2_/dev/sda,exist_/dev/sda6
POST: prep2_/dev/sda7
Trying to add CMD: true
PRE: prep2_/dev/sda7
POST: exist_/dev/sda7
Trying to add CMD: mkfs.ext3 -b 2048 /dev/sda5
PRE: exist_/dev/sda5
POST: has_fs_/dev/sda5
Trying to add CMD: mkswap  /dev/sda6
PRE: exist_/dev/sda6
POST: has_fs_/dev/sda6
Trying to add CMD: mkfs.ext3 -m 5 -j /dev/sda7
PRE: exist_/dev/sda7
POST: has_fs_/dev/sda7
Trying to add CMD: true
PRE: cleared2_/dev/sda,exist_/dev/sda7
POST: pt_complete_/dev/sda
1:true
pre:
post: exist_/dev/sda
2:true
pre: exist_/dev/sda
post: cleared1_/dev/sda
3:parted -s /dev/sda mklabel msdos
pre: cleared1_/dev/sda
post: cleared2_/dev/sda
4:parted -s /dev/sda mkpart extended "" 1051648B 250059350015B
pre: cleared2_/dev/sda
post: prep2_/dev/sda1
5:true
pre: prep2_/dev/sda1
post: exist_/dev/sda1
6:parted -s /dev/sda mkpart logical "ext3" 1052672B 68720529407B
pre: cleared2_/dev/sda,exist_/dev/sda1
post: prep2_/dev/sda5
7:true
pre: prep2_/dev/sda5
post: exist_/dev/sda5
8:parted -s /dev/sda mkpart logical "linux-swap" 68720533504B 70531510271B
pre: cleared2_/dev/sda,exist_/dev/sda5
post: prep2_/dev/sda6
9:true
pre: prep2_/dev/sda6
post: exist_/dev/sda6
10:parted -s /dev/sda mkpart logical "ext3" 70531514368B 250059350015B
pre: cleared2_/dev/sda,exist_/dev/sda6
post: prep2_/dev/sda7
11:true
pre: prep2_/dev/sda7
post: exist_/dev/sda7
12:mkfs.ext3 -b 2048 /dev/sda5
pre: exist_/dev/sda5
post: has_fs_/dev/sda5
13:mkswap  /dev/sda6
pre: exist_/dev/sda6
post: has_fs_/dev/sda6
14:mkfs.ext3 -m 5 -j /dev/sda7
pre: exist_/dev/sda7
post: has_fs_/dev/sda7
15:true
pre: cleared2_/dev/sda,exist_/dev/sda7
post: pt_complete_/dev/sda
(CMD) parted -s /dev/sda mklabel msdos 1> /tmp/jrRQqi82MR 2> /tmp/3T4TzL_av0
Executing: parted -s /dev/sda mklabel msdos
(CMD) parted -s /dev/sda mkpart extended "" 1051648B 250059350015B 1> /tmp/LFOEHEm0Dk 2> /tmp/Qm6sqWyNX4
Executing: parted -s /dev/sda mkpart extended "" 1051648B 250059350015B
(STDOUT) Warning: The resulting partition is not properly aligned for best performance. (CMD) parted -s /dev/sda mkpart logical "ext3" 1052672B 68720529407B 1> /tmp/YnbUF9XTo9 2> /tmp/WFak2ZtTZv
Executing: parted -s /dev/sda mkpart logical "ext3" 1052672B 68720529407B
(STDOUT) Warning: The resulting partition is not properly aligned for best performance. (CMD) parted -s /dev/sda mkpart logical "linux-swap" 68720533504B 70531510271B 1> /tmp/zGV33bIEb8 2> /tmp/EH_2G9u0df Executing: parted -s /dev/sda mkpart logical "linux-swap" 68720533504B 70531510271B (STDOUT) Warning: The resulting partition is not properly aligned for best performance. (CMD) parted -s /dev/sda mkpart logical "ext3" 70531514368B 250059350015B 1> /tmp/EAQ6ud68Oq 2> /tmp/AWZ0VTWNBe Executing: parted -s /dev/sda mkpart logical "ext3" 70531514368B 250059350015B (STDOUT) Warning: The resulting partition is not properly aligned for best performance.
(CMD) mkfs.ext3 -b 2048 /dev/sda5 1> /tmp/2n_6E0ucWV 2> /tmp/wvKGl9nATE
Executing: mkfs.ext3 -b 2048 /dev/sda5
Command had non-zero exit code
(STDERR) mke2fs 1.41.12 (17-May-2010)
(STDERR) mkfs.ext3: Invalid argument while setting blocksize; too small for device
(STDERR)

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