Readynas X6 Won't Boot

[mjw]

I am trying to see if I can resuscitate an old Readynas X6. I've managed to recover all the data on the drives and now I'm trying to work out why the X6 won't boot. Here's the history so far:

May 27th X6 sends the following email:

Subject: Unexpected enclosure status detected

Disk on channel 1 reports a temperature of 60C / 140F.

Please shutdown the system immediately for service.

I was a very hot day and it's quite possible that the X6 overheated.

May 29th X6 sends the following email:

Subject: RAID event detected (tera)

RAID sync finished on volume C. The volume is now fully redundant.

[Tue May 29 11:57:27 WEST 2012]

Email with the same subject arrived on

Fri Jun 1 02:39:34 WEST 2012
Mon Jun 4 02:59:31 WEST 2012
Tue Jun 5 16:48:13 WEST 2012
Tue Jun 5 10:31:13 WEST 2012
Thu Jun 7 12:31:15 WEST 2012

Looking at the log files there seem to be some phy_irq 8008 error messages that appeared prior to each RAID event:

Jun 5 10:12:57 tera kernel: phy_irq 8008 repeated 1
Jun 5 10:12:57 tera kernel: unlinked
Jun 5 10:13:08 tera kernel: linked, 1000mbps mode
Jun 5 10:13:09 tera kernel: unlinked
Jun 5 10:13:15 tera kernel: linked, 1000mbps mode
Jun 5 10:31:12 tera kernel: nr_disks=4, working_disks=4, while finishing recovery.
Jun 5 10:31:12 tera kernel: SB 1 disk 1 should be DJR_DISK_READY, but not : 1
Jun 5 10:31:12 tera kernel: On 1: nr_disks=4,working_disks=4,finishing recovery.
Jun 5 10:31:12 tera kernel: All drives are ONL on SB1, done recovery.
Jun 5 10:31:12 tera kernel: SB 2 disk 1 should be DJR_DISK_READY, but not : 1
Jun 5 10:31:12 tera kernel: On 2: nr_disks=4,working_disks=4,finishing recovery.
Jun 5 10:31:12 tera kernel: All drives are ONL on SB2, done recovery.
Jun 5 10:31:12 tera kernel: SB 3 disk 1 should be DJR_DISK_READY, but not : 1
Jun 5 10:31:12 tera kernel: On 3: nr_disks=4,working_disks=4,finishing recovery.
Jun 5 10:31:12 tera kernel: All drives are ONL on SB3, done recovery.
Jun 5 10:31:12 tera kernel: SB 4 disk 1 should be DJR_DISK_READY, but not : 1
Jun 5 10:31:12 tera kernel: On 4: nr_disks=4,working_disks=4,finishing recovery.
Jun 5 10:31:12 tera kernel: All drives are ONL on SB4, done recovery.

Jun 6 03:12:28 tera kernel: nfsd: last server has exited
Jun 6 03:12:28 tera kernel: nfsd: unexporting all filesystems
Jun 6 03:12:28 tera kernel: RPC: failed to contact portmap (errno -5).
Jun 6 03:12:28 tera exiting on signal 15
Jun 6 03:24:31 tera syslogd 1.4.1#10: restart.

Jun 7 11:29:22 tera kernel: phy_irq 8008 repeated 1
Jun 7 11:29:22 tera kernel: unlinked
Jun 7 11:29:26 tera kernel: linked, 1000mbps mode

On June 7th the X6 became completely unable to boot and the final log entry shows

Jun 7 19:50:52 tera kernel: phy_irq 8008 repeated 25
Jun 7 19:52:39 tera kernel: phy_irq 8008 repeated 2
Jun 7 19:52:39 tera kernel: unlinked
Jun 7 19:52:43 tera kernel: linked, 1000mbps mode
Jun 7 19:55:56 tera kernel: phy_irq 8008 repeated 25
Jun 7 19:59:14 tera kernel: phy_irq 8008 repeated 2
Jun 7 20:00:53 tera kernel: phy_irq 8008 repeated 4
Jun 7 20:00:53 tera kernel: unlinked
Jun 7 20:00:54 tera kernel: linked, 1000mbps mode
Jun 7 20:03:21 tera kernel: phy_irq 8008 repeated 3
Jun 7 20:04:41 tera kernel: phy_irq 8008 repeated 4

I performed a memory check (successful). I tried USB Boot and TFTP Boot without success. The only thing I haven't yet tried is a factory default.

It seems like it's a hardware problem of some sort. At the moment I am running Seatools on each disk.

[mjw]

I ran Seatools Generic Long test on each disk and all disks passed so the problem is unlikely to be due to the disks.

By searching the forums there seem to by a few other threads with "phy_irq 8008" messages in the logs. The error seems to generally point to the network link going down on the readynas:
viewtopic.php?f=21&t=1201&start=45
viewtopic.php?f=21&t=8867&start=15
viewtopic.php?p=4356#p4356

But in my case, it looks like /var/log/messages doesn't get updated at all so something seems to be stopping the boot process even reaching the point of logging kernel messages.

[mdgm]

Maybe there is a problem with the chassis after all. High temperatures does sound concerning. Have you opened up the unit and looked to see if it's full of dust that needs cleaning out?

[mjw]

No dust problem, but at this point the X6 hardware seems to be the problem. Bought a new NAS.