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Here's the information on the system:

Buffalo TeraStation Live
Model: HS-DHTGL/R5 2.14
Firmware: 2.14

 

USB backup drive is a new Seagate FreeAgent USB 2.0 1TB drive.

 

Here's what I've done so far:

Installed the USB drive.

Re-formatted USB drive as XFS.

Attempted Backup (Failed)

 

After some contact with Buffalo Tech Support, I performed a forced firmware update.  The firmware update completed successfully.

 

I then attempted to run an Immediate Normal (Copy) Backup to the USB drive.  After some 30-45 minutes, it reports that the backup failed.  This is the error log of that attempt:

 

--- BEGIN BACKUP 2009/06/02 17:28:51 array1/WORK -> HS-GHTGL189@usbdisk1 ---
building file list ...
621331 files to consider
rsync: cannot stat destination "/mnt/usbdisk1/200906021728": Input/output error (5)
rsync error: errors selecting input/output files, dirs (code 3) at main.c(493 [receiver=2.6.8]
rsync: connection unexpectedly closed (8 bytes received so far) [sender]
rsync error: error in rsync protocol data stream (code 12) at io.c(463) [sender=2.6.8]
--- END BACKUP 2009/06/02 18:11:49 array1/WORK -> HS-DHTGL189@usbdisk1 ---
 

I've done some looking on that rsync error, but I haven't been able to find anything that seems to be what I need in relation to a TeraStation.

 

Anyone have any ideas?  I appreciate any help or info you might be able to provide.  Thanks!

   Well if you have already force flashed the firmware on the unit theres not too much more you can do at that end. You could try a different usb cable or usb drive to see if the problem is somehow stemming from the usb drive though.

   

A bit of an update: after some more input from Buffalo Tech Support and some reading, we tried formatting the USB drive as EXT3.  The format failed.

 

Going to see about pulling the drive off of the TeraStation and plugging it into a PC and run some diagnostics on it.  I may find out that there is something wrong with the USB drive itself.  Unfortunately, since the TeraStation is at a remote site from where I normally work, I have to rely on someone on site to do these sorts of things.  Hopefully he'll have time and get a chance to do that.

 

Thanks for the input, Caleb.

I know this might seem simplistic but after force updating the firmware did you initialize the unit? (Web Admin->Maintenance->Initialization->Restore)? Doing so erases the footprints of the previous firmware (even if it was the same version and usually may help in cases such as these.