hdd with 2.6.8-16sarge7:

-------

hdd: ST340823A, ATA DISK drive
ide1 at 0x170-0x177,0x376 on irq 15
hdd: max request size: 128KiB
hdd: Host Protected Area detected.
        current capacity is 78165360 sectors (40020 MB)
        native  capacity is 78165361 sectors (40020 MB)
hdd: 78165360 sectors (40020 MB) w/1024KiB Cache, CHS=65535/16/63, UDMA(33)
 /dev/ide/host0/bus1/target1/lun0: p1 p2 p3

--------

Badblocks read-only and non-destructive write return no error, filesystems are
fsck clean:

---------
# /etc/init.d/lvm start
Setting up LVM Volume Groups...
  Reading all physical volumes.  This may take a while...
  Found volume group "spare" using metadata type lvm2
  2 logical volume(s) in volume group "spare" now active
# fsck.ext3 -f /dev/mapper/spare-home
e2fsck 1.40-WIP (14-Nov-2006)
Pass 1: Checking inodes, blocks, and sizes
Pass 2: Checking directory structure
Pass 3: Checking directory connectivity
Pass 4: Checking reference counts
Pass 5: Checking group summary information
/dev/mapper/spare-home: 68784/524288 files (1.8% non-contiguous), 
767457/1048576 blocks
# fsck.ext3 -f /dev/mapper/spare-media
e2fsck 1.40-WIP (14-Nov-2006)
Pass 1: Checking inodes, blocks, and sizes
Pass 2: Checking directory structure
Pass 3: Checking directory connectivity
Pass 4: Checking reference counts
Pass 5: Checking group summary information
/dev/mapper/spare-media: 31748/3538944 files (2.0% non-contiguous), 
6045677/7077888 blocks
-------------

Contains three partitions used by lvm:

----------
  22    64   39082680 hdd
  22    65    9831748 hdd1
  22    66   16073032 hdd2
  22    67   13173300 hdd3
 254     0   28311552 dm-0
 254     1    4194304 dm-1

# pvdisplay
  --- Physical volume ---
  PV Name               /dev/hdd1
  VG Name               spare
  PV Size               9.38 GB / not usable 0
  Allocatable           yes (but full)
  PE Size (KByte)       4096
  Total PE              2400
  Free PE               0
  Allocated PE          2400
  PV UUID               YwheMf-s0pv-97XS-sAOB-oGSk-WcHA-ZEo8Ag

  --- Physical volume ---
  PV Name               /dev/hdd3
  VG Name               spare
  PV Size               12.56 GB / not usable 0
  Allocatable           yes (but full)
  PE Size (KByte)       4096
  Total PE              3216
  Free PE               0
  Allocated PE          3216
  PV UUID               b9Xviu-XSOP-9lz4-4gcY-tE9W-fqxA-k2amBh

  --- Physical volume ---
  PV Name               /dev/hdd2
  VG Name               spare
  PV Size               15.32 GB / not usable 0
  Allocatable           yes
  PE Size (KByte)       4096
  Total PE              3923
  Free PE               1603
  Allocated PE          2320
  PV UUID               TEN6QM-MVlA-LDlO-Moiu-O7mU-VTfZ-pinLz6
------------

With 2.6.18.dfsg.1-12etch2 and 2.6.22-2snapshot.9178 on etch kernel 
complains a lot about read errors and lvm code fails to scan the drive 
for physical volumes after that. I suppose initial ide drive scan fails 
and the drive is disabled since. Boot time logs go past so fast, that I can't 
catch them. 'hdd=noprobe hdd=65535,16,63' boot options don't help.

--------------
# hdparm -i /dev/hdd

/dev/hdd:

 Model=ST340823A, FwRev=3.07, SerialNo=7EF1EYYG
 Config={ HardSect NotMFM HdSw>15uSec Fixed DTR>10Mbs RotSpdTol>.5% }
 RawCHS=16383/16/63, TrkSize=0, SectSize=0, ECCbytes=0
 BuffType=unknown, BuffSize=1024kB, MaxMultSect=16, MultSect=off
 CurCHS=16383/16/63, CurSects=16514064, LBA=yes, LBAsects=78165360
 IORDY=on/off, tPIO={min:240,w/IORDY:120}, tDMA={min:120,rec:120}
 PIO modes:  pio0 pio1 pio2 pio3 pio4
 DMA modes:  mdma0 mdma1 mdma2
 UDMA modes: udma0 udma1 *udma2 udma3 udma4 udma5 udma3 udma4 udma5
 AdvancedPM=no WriteCache=enabled
 Drive conforms to: Unspecified:  ATA/ATAPI-1 ATA/ATAPI-2 ATA/ATAPI-3 
ATA/ATAPI-4

 * signifies the current active mode
-----------------

All operations like fdisk fail after boot like this:

-------------
end_request: I/O error, dev hdd, sector 0
printk: 33 messages suppressed.
Buffer I/O error on device hdd, logical block 0
end_request: I/O error, dev hdd, sector 1
Buffer I/O error on device hdd, logical block 1
end_request: I/O error, dev hdd, sector 2
Buffer I/O error on device hdd, logical block 2
end_request: I/O error, dev hdd, sector 3
Buffer I/O error on device hdd, logical block 3
end_request: I/O error, dev hdd, sector 4
Buffer I/O error on device hdd, logical block 4
end_request: I/O error, dev hdd, sector 5
Buffer I/O error on device hdd, logical block 5
end_request: I/O error, dev hdd, sector 6
Buffer I/O error on device hdd, logical block 6
end_request: I/O error, dev hdd, sector 7
Buffer I/O error on device hdd, logical block 7
end_request: I/O error, dev hdd, sector 8
Buffer I/O error on device hdd, logical block 8
end_request: I/O error, dev hdd, sector 9
Buffer I/O error on device hdd, logical block 9
end_request: I/O error, dev hdd, sector 10
end_request: I/O error, dev hdd, sector 11
end_request: I/O error, dev hdd, sector 12
end_request: I/O error, dev hdd, sector 13
end_request: I/O error, dev hdd, sector 14
end_request: I/O error, dev hdd, sector 15
end_request: I/O error, dev hdd, sector 16
end_request: I/O error, dev hdd, sector 17
end_request: I/O error, dev hdd, sector 18
end_request: I/O error, dev hdd, sector 19
end_request: I/O error, dev hdd, sector 20
end_request: I/O error, dev hdd, sector 21
end_request: I/O error, dev hdd, sector 22
end_request: I/O error, dev hdd, sector 23
end_request: I/O error, dev hdd, sector 24
end_request: I/O error, dev hdd, sector 25
end_request: I/O error, dev hdd, sector 26
end_request: I/O error, dev hdd, sector 27
end_request: I/O error, dev hdd, sector 28
end_request: I/O error, dev hdd, sector 29
end_request: I/O error, dev hdd, sector 30
end_request: I/O error, dev hdd, sector 31
end_request: I/O error, dev hdd, sector 0
end_request: I/O error, dev hdd, sector 1
end_request: I/O error, dev hdd, sector 2
end_request: I/O error, dev hdd, sector 3
end_request: I/O error, dev hdd, sector 4
end_request: I/O error, dev hdd, sector 5
end_request: I/O error, dev hdd, sector 6
end_request: I/O error, dev hdd, sector 7

# /etc/init.d/lvm restart

Shutting down LVM Volume Groups...
  /dev/hdd: read failed after 0 of 2048 at 0: Input/output error
  /dev/hdd1: read failed after 0 of 2048 at 0: Input/output error
  /dev/hdd2: read failed after 0 of 2048 at 0: Input/output error
  /dev/hdd3: read failed after 0 of 4096 at 0: Input/output error
  No volume groups found
Setting up LVM Volume Groups...
  Reading all physical volumes.  This may take a while...
  /dev/hdd: read failed after 0 of 512 at 0: Input/output error
  /dev/hdd: read failed after 0 of 512 at 40020541440: Input/output error
  /dev/hdd: read failed after 0 of 2048 at 0: Input/output error
  /dev/hdd1: read failed after 0 of 512 at 10067640320: Input/output error
  /dev/hdd1: read failed after 0 of 2048 at 0: Input/output error
  /dev/hdd2: read failed after 0 of 512 at 16458711040: Input/output error
  /dev/hdd2: read failed after 0 of 2048 at 0: Input/output error
  /dev/hdd3: read failed after 0 of 4096 at 13489340416: Input/output error
  /dev/hdd3: read failed after 0 of 4096 at 0: Input/output error
  No volume groups found
  No volume groups found
  /dev/hdd: read failed after 0 of 2048 at 0: Input/output error
  /dev/hdd1: read failed after 0 of 2048 at 0: Input/output error
  /dev/hdd2: read failed after 0 of 2048 at 0: Input/output error
  /dev/hdd3: read failed after 0 of 4096 at 0: Input/output error
  No volume groups found

# hdparm -z /dev/hdd

/dev/hdd:
 BLKRRPART failed: Input/output error

# dmesg

ldm_validate_partition_table(): Disk read failed.
end_request: I/O error, dev hdd, sector 0
end_request: I/O error, dev hdd, sector 1
end_request: I/O error, dev hdd, sector 2
end_request: I/O error, dev hdd, sector 3
end_request: I/O error, dev hdd, sector 4
end_request: I/O error, dev hdd, sector 5
end_request: I/O error, dev hdd, sector 6
end_request: I/O error, dev hdd, sector 7
end_request: I/O error, dev hdd, sector 0
end_request: I/O error, dev hdd, sector 1
end_request: I/O error, dev hdd, sector 2
end_request: I/O error, dev hdd, sector 3
end_request: I/O error, dev hdd, sector 4
end_request: I/O error, dev hdd, sector 5
end_request: I/O error, dev hdd, sector 6
end_request: I/O error, dev hdd, sector 7
end_request: I/O error, dev hdd, sector 0
end_request: I/O error, dev hdd, sector 1
end_request: I/O error, dev hdd, sector 2
end_request: I/O error, dev hdd, sector 3
end_request: I/O error, dev hdd, sector 4
end_request: I/O error, dev hdd, sector 5
end_request: I/O error, dev hdd, sector 6
end_request: I/O error, dev hdd, sector 7
end_request: I/O error, dev hdd, sector 0
end_request: I/O error, dev hdd, sector 1
end_request: I/O error, dev hdd, sector 2
end_request: I/O error, dev hdd, sector 3
end_request: I/O error, dev hdd, sector 4
end_request: I/O error, dev hdd, sector 5
end_request: I/O error, dev hdd, sector 6
end_request: I/O error, dev hdd, sector 7
Dev hdd: unable to read RDB block 0
end_request: I/O error, dev hdd, sector 0
end_request: I/O error, dev hdd, sector 1
end_request: I/O error, dev hdd, sector 2
end_request: I/O error, dev hdd, sector 3
end_request: I/O error, dev hdd, sector 4
end_request: I/O error, dev hdd, sector 5
end_request: I/O error, dev hdd, sector 6
end_request: I/O error, dev hdd, sector 7
end_request: I/O error, dev hdd, sector 0
end_request: I/O error, dev hdd, sector 1
end_request: I/O error, dev hdd, sector 2
end_request: I/O error, dev hdd, sector 3
end_request: I/O error, dev hdd, sector 4
end_request: I/O error, dev hdd, sector 5
end_request: I/O error, dev hdd, sector 6
end_request: I/O error, dev hdd, sector 7
end_request: I/O error, dev hdd, sector 24
end_request: I/O error, dev hdd, sector 25
end_request: I/O error, dev hdd, sector 26
end_request: I/O error, dev hdd, sector 27
end_request: I/O error, dev hdd, sector 28
end_request: I/O error, dev hdd, sector 29
end_request: I/O error, dev hdd, sector 30
end_request: I/O error, dev hdd, sector 31
end_request: I/O error, dev hdd, sector 24
end_request: I/O error, dev hdd, sector 25
end_request: I/O error, dev hdd, sector 26
end_request: I/O error, dev hdd, sector 27
end_request: I/O error, dev hdd, sector 28
end_request: I/O error, dev hdd, sector 29
end_request: I/O error, dev hdd, sector 30
end_request: I/O error, dev hdd, sector 31
end_request: I/O error, dev hdd, sector 0
end_request: I/O error, dev hdd, sector 1
end_request: I/O error, dev hdd, sector 2
end_request: I/O error, dev hdd, sector 3
end_request: I/O error, dev hdd, sector 4
end_request: I/O error, dev hdd, sector 5
end_request: I/O error, dev hdd, sector 6
end_request: I/O error, dev hdd, sector 7
 unable to read partition table

# cat /proc/ide/hdd/cache
1024
# cat /proc/ide/hdd/capacity
78165361
# cat /proc/ide/hdd/driver
ide-disk version 1.18
# cat /proc/ide/hdd/geometry
physical     16383/16/63
logical      65535/16/63
# cat /proc/ide/hdd/media
disk
# cat /proc/ide/hdd/model
ST340823A
# cat /proc/ide/hdd/settings
name                    value           min             max             mode
----                    -----           ---             ---             ----
acoustic                0               0               254             rw
address                 0               0               2               rw
bios_cyl                65535           0               65535           rw
bios_head               16              0               255             rw
bios_sect               63              0               63              rw
bswap                   0               0               1               r
current_speed           66              0               70              rw
failures                2               0               65535           rw
init_speed              66              0               70              rw
io_32bit                0               0               3               rw
keepsettings            0               0               1               rw
lun                     0               0               7               rw
max_failures            1               0               65535           rw
multcount               0               0               16              rw
nice1                   1               0               1               rw
nowerr                  0               0               1               rw
number                  3               0               3               rw
pio_mode                write-only      0               255             w
unmaskirq               0               0               1               rw
using_dma               0               0               1               rw
wcache                  1               0               1               rw
-----------------

Booting back to sarge kernel and all is fine...

-Mikko


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