Have you got any further with this. I am having the same issue with a TS-XEL backing up to Freecom 640GB Toughdrives. Exactly the same setup as I have used previously with TS-XLs is crashing at random points in the backup. Different source files and different target drives, reporting different sectors as not writable. Both Toughdrives have been externally formatted and fully verified, reformated both XFS and EXT3 on the TS immediately prior to backup but always the same result. The TS-XEL arrived with 1.2 firmware and had the problem so I upgraded to the latest 1.32 version a couple of days ago but still all the same. A typical backup log entry ends:
rsync: writefd_unbuffered failed to write 4092 bytes [sender]: Broken pipe (32)
rsync: write failed on "/mnt/usbdisk1/201006241340/backupsrv01/Small Business Server Backup (05).bkf": Input/output error (5)
rsync error: error in file IO (code 11) at receiver.c(298) [receiver=3.0.3]
rsync: connection unexpectedly closed (31 bytes received so far) [sender]
rsync error: error in rsync protocol data stream (code 12) at io.c(635) [sender=3.0.3]
-------- END BACKUP 2010/06/24 18:59:00 array1/backupsrv01 -> XXXXXXXX@usbdisk1 --------
Accompanied by a plethora of email notifications of the form:
DISK Error Notification
HDD error occurred
Disk(s) the error occurred:UnknownDisk(sde)
(sde) WRITE sector:1032561727 count:14
Disk writing error
Some data may not be recoverable.
Immediate change of disk is recommended.
?
[TeraStationInformation]
TeraStationName: XXXXXXXX (TS-XEL)
Time: 2010/06/24 18:59:35
After which the TS needs rebooting or the USB drive removing in order to get it to reconnect. I can't use Kitonne's external copy program work around as this hardware is being put in to take the backup load off the server and network...
This is a new client and it isn't doing my credibility much good that a backup and storage solution that I assured them was simple and proven is still not fit to commission after a week.
I would reject the hardware and order a TS-XL as used previously but I see that they are using the same firmware version so I am a bit worried about shelling out another £650 and still having problems. I'm also concerned about the length of time and apparent lack of response from Buffalo about these issues that you have already raised.
I thought you might like to know that the 1.32 firmware appears to have the same problems before you get your hopes up too much.