Frozen system even with Raid 5

Hello.

We are right now having a 360 TB Raid-system with 3-Ware controllers. Unfortunately there are 2 ways a disk can fail: A complete sudden fail, which results in a immediate shutdown of the disk, causing the array to continue in degraded mode (raid5), and the soft-fail, which results in a complete hang of the system, the system always prints errors of timeout sending command, card was resetted. A hard-remove of the drive clears the problem, but I dont think thats supposed to be that way, is it? The warnings below keep printed for hours, until the drive is removed. In this time the IOs hang.

Oct 10 23:41:19 kernel: [2850624.586613] sd 0:0:4:0: WARNING: (0x06:0x002C): Command (0x28) timed out, resetting card.
Oct 10 23:41:33 kernel: [2850638.425847] 3w-9xxx: scsi0: AEN: INFO (0x04:0x005E): Cache synchronized after power fail:unit=0.
Oct 10 23:41:33 kernel: [2850638.545663] 3w-9xxx: scsi0: AEN: INFO (0x04:0x005E): Cache synchronized after power fail:unit=1.
Oct 10 23:41:33 kernel: [2850638.665481] 3w-9xxx: scsi0: AEN: INFO (0x04:0x005E): Cache synchronized after power fail:unit=2.
Oct 10 23:41:33 kernel: [2850638.785296] 3w-9xxx: scsi0: AEN: INFO (0x04:0x005E): Cache synchronized after power fail:unit=3.
Oct 10 23:41:33 kernel: [2850638.905123] 3w-9xxx: scsi0: AEN: INFO (0x04:0x005E): Cache synchronized after power fail:unit=4.
Oct 10 23:41:33 kernel: [2850639.024934] 3w-9xxx: scsi0: AEN: INFO (0x04:0x005E): Cache synchronized after power fail:unit=5.
Oct 10 23:41:33 kernel: [2850639.144759] 3w-9xxx: scsi0: AEN: INFO (0x04:0x005E): Cache synchronized after power fail:unit=6.
Oct 10 23:41:34 kernel: [2850639.264575] 3w-9xxx: scsi0: AEN: INFO (0x04:0x005E): Cache synchronized after power fail:unit=7.

Linux 2.6.17.11 vanilla.

Regards,
Chris

Christian,

Make sure you are running the latest 3ware firmware. After that, contact 3ware/AMCC support if you still see any issues.

-Adam