FreeBSD 5.2.1-Release-p3 & SATA problem

[Jeff Doolittle]

I've seen a couple posting searching the FreeBSD question, stable, and 
current mailing list so this is probably just a "me too" posting....

The following is a snippet from "dmesg" as of the last reboot:

----------------------------------------
Copyright (c) 1992-2004 The FreeBSD Project.
Copyright (c) 1979, 1980, 1983, 1986, 1988, 1989, 1991, 1992, 1993, 1994
        The Regents of the University of California. All rights reserved.
FreeBSD 5.2.1-RELEASE-p3 #1: Sat Mar 20 14:53:35 EST 2004
    root at saturn.kingsquarry.net:/usr/obj/usr/src/sys/SATURN
Preloaded elf kernel "/boot/kernel/kernel" at 0xc089d000.
Preloaded elf module "/boot/kernel/vinum.ko" at 0xc089d21c.
Preloaded elf module "/boot/kernel/acpi.ko" at 0xc089d2c8.
ACPI APIC Table: <A M I  OEMAPIC >
Timecounter "i8254" frequency 1193182 Hz quality 0
CPU: Intel(R) Pentium(R) 4 CPU 2.40GHz (2398.86-MHz 686-class CPU)
  Origin = "GenuineIntel"  Id = 0xf25  Stepping = 5
  
Features=0xbfebfbff<FPU,VME,DE,PSE,TSC,MSR,PAE,MCE,CX8,APIC,SEP,MTRR,PGE,MCA,C
MOV,PAT,PSE36,CLFLUSH,DTS,ACPI,MMX,FXSR,SSE,SSE2,SS,HTT,TM,PBE>
  Hyperthreading: 2 logical CPUs
real memory  = 536018944 (511 MB)
avail memory = 511012864 (487 MB)
FreeBSD/SMP: Multiprocessor System Detected: 2 CPUs
 cpu0 (BSP): APIC ID:  0
 cpu1 (AP): APIC ID:  1
ioapic0 <Version 2.0> irqs 0-23 on motherboard
Pentium Pro MTRR support enabled
......
atapci0: <Promise PDC20378 SATA150 controller> port 
0xd880-0xd8ff,0xdfa0-0xdfaf,
0xdf00-0xdf3f mem 0xfeac0000-0xfeadffff,0xfeafe000-0xfeafefff irq 23 at 
device 4
.0 on pci3
atapci0: [MPSAFE]
ata2: at 0xfeafe000 on atapci0
ata2: [MPSAFE]
ata3: at 0xfeafe000 on atapci0
ata3: [MPSAFE]
ata4: at 0xfeafe000 on atapci0
ata4: [MPSAFE]
isab0: <PCI-ISA bridge> at device 31.0 on pci0
isa0: <ISA bus> on isab0
atapci1: <Intel ICH5 UDMA100 controller> port 
0xfc00-0xfc0f,0-0x3,0-0x7,0-0x3,0-
0x7 at device 31.1 on pci0
ata0: at 0x1f0 irq 14 on atapci1
ata0: [MPSAFE]
ata1: at 0x170 irq 15 on atapci1
ata1: [MPSAFE]
atapci2: <Intel ICH5 SATA150 controller> port 
0xef90-0xef9f,0xefa8-0xefab,0xefa0
-0xefa7,0xefac-0xefaf,0xefe0-0xefe7 irq 18 at device 31.2 on pci0
atapci2: [MPSAFE]
ata5: at 0xefe0 on atapci2
ata5: [MPSAFE]
ata6: at 0xefa0 on atapci2
ata6: [MPSAFE]
......
GEOM: create disk ad0 dp=0xc49d3460
ad0: 19092MB <ST320413A> [38792/16/63] at ata0-master UDMA100
acd0: CDRW <48X12X50 CD-RW 1.04 20021101> at ata1-master PIO4
GEOM: create disk ad4 dp=0xc49d3060
ad4: 190782MB <WDC WD2000JD-00FYB0> [387621/16/63] at ata2-master UDMA100
GEOM: create disk ad6 dp=0xc49d2760
ad6: 190782MB <WDC WD2000JD-00FYB0> [387621/16/63] at ata3-master UDMA100
em0: Link is up 100 Mbps Full Duplex
GEOM: create disk ad10 dp=0xc49d2060
ad10: 190782MB <WDC WD2000JD-00FYB0> [387621/16/63] at ata5-master UDMA100
GEOM: create disk ad12 dp=0xc49d2660
ad12: 190782MB <WDC WD2000JD-00FYB0> [387621/16/63] at ata6-master UDMA100
GEOM: create disk ar0 dp=0xc48c6de0
ar0: 381564MB <ATA RAID0 array> [48642/255/63] status: READY subdisks:
 disk0 READY on ad4 at ata2-master
 disk1 READY on ad6 at ata3-master
GEOM: create disk ar1 dp=0xc48c1de0
ar1: 381564MB <ATA RAID0 array> [48642/255/63] status: READY subdisks:
 disk0 READY on ad10 at ata5-master
 disk1 READY on ad12 at ata6-master
----------------------------------------

Note:  vinum is not being used even though it's loaded.

The Promise SATA drives are configured as RAID0 through the controller 
and work perfectly, even dumped my entire file server (~120gb) without a 
problem.
The Intel SATA drives are configured as RAID0 through "atacontrol" and 
is unable to handle a dump of my file server OR and rsync from the local 
Promise RAID0 array.

All failures I experience are the same, a complete system hang with 
either ad10 or ad12 and a message like the following:

Instance #1
ad10: TIMEOUT_WRITE_DMA retrying (2 retries left) LBA=191

Instance #2
ad12: TIMEOUT_WRITE_DMA retrying (2 retries left) LBA=66491231

Once the error occurs the machine is frozen and requires a reset in 
person and I have also observed the IDE h/d light on the case is on 
solid.  All attempts to disable Hyper-Threading result in the machine 
not shutting down properly when a reboot is performed.

The situation occurs with both a generic and custom kernel.  Finally, 
the BIOS was updated to v1016 from ASUS prior to FreeBSD being installed.

Is there a bug report already filed for this issue or has it been 
corrected in a "current" release?

       Thanks.
          Jeff

ps:  In all my years of using FreeBSD since v2.2.7 this is the first 
problem I've ever encountered, yes I know v5 isn't "production quality" 
but its been serving me well since the v5.1 and this is the machine 
which will be replacing a v4.9 on Intel P2 hardware.