It seems to be stable for a longer period, but it has borked out now.

As stated the issue seems way more frequent (if not only occuring) when using md raid (and from what I saw from posts also when using xfs).

The array here has failed now with these messages:

[458706.767334] mvsas 0000:02:00.0: Phy5 : No sig fis
[458706.767344] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2022:phy5 Attached Device
[458706.767384] ata8: translated ATA stat/err 0x01/04 to SCSI SK/ASC/ASCQ 0xb/00/00
[458706.767438] ata8.00: device reported invalid CHS sector 0
[458706.767442] ata8: status=0x01 { Error }
[458706.767447] ata8: error=0x04 { DriveStatusError }
[458706.767456] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2081:port 5 ctrl sts=0x199800.
[458706.767462] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2083:Port 5 irq sts = 0x1081
[458706.767470] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2109:phy5 Unplug Notice
[458706.767525] sd 7:0:0:0: [sdf] Result: hostbyte=DID_OK driverbyte=DRIVER_SENSE
[458706.767534] sd 7:0:0:0: [sdf] Sense Key : Aborted Command [current] [descriptor]
[458706.767543] Descriptor sense data with sense descriptors (in hex):
[458706.767547]         
[458706.767551] RAID1 conf printout:
[458706.767556] 72 0b 00 00 00 00 00 0c 00 0a 80 00 00 00 00 00 
[458706.767573]         00 00 00 00 
[458706.767581] sd 7:0:0:0: [sdf] 
[458706.767585]  --- wd:1 rd:2
[458706.767588] Add. Sense: No additional sense information
[458706.767594] sd 7:0:0:0: [sdf] CDB: 
[458706.767598]  disk 0, wo:0, o:1, dev:sde
[458706.767602]  disk 1, wo:1, o:0, dev:sdf
[458706.767605] Read(10): 28 00 06 7d 80 00 00 02 00 00
[458706.767623] end_request: I/O error, dev sdf, sector 108888064
[458706.767660] md/raid1:md4: sdf: rescheduling sector 108888064
[458706.767694] md/raid1:md4: sdf: rescheduling sector 108888312
[458706.767722] md/raid1:md4: sdf: rescheduling sector 108888560
[458706.805557] md/raid1:md4: redirecting sector 108888064 to other mirror: sde
[458706.811953] md/raid1:md4: redirecting sector 108888312 to other mirror: sde
[458706.813419] md/raid1:md4: redirecting sector 108888560 to other mirror: sde
[458706.813465] RAID1 conf printout:
[458706.813470]  --- wd:1 rd:2
[458706.813475]  disk 0, wo:0, o:1, dev:sde
[458706.813481]  disk 1, wo:1, o:0, dev:sdf
[458706.879176] RAID1 conf printout:
[458706.879182]  --- wd:1 rd:2
[458706.879186]  disk 0, wo:0, o:1, dev:sde
[458708.815481] mvsas 0000:02:00.0: Phy5 : No sig fis
[458708.815488] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2022:phy5 Attached Device
[458708.815523] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2081:port 5 ctrl sts=0x89800.
[458708.815526] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2083:Port 5 irq sts = 0x1001
[458708.815533] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2109:phy5 Unplug Notice
[458708.815561] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2081:port 5 ctrl sts=0x199800.
[458708.815564] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2083:Port 5 irq sts = 0x81
[458710.855410] mvsas 0000:02:00.0: Phy5 : No sig fis
[458710.855417] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2022:phy5 Attached Device
[458710.855459] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2081:port 5 ctrl sts=0x89800.
[458710.855462] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2083:Port 5 irq sts = 0x1001
[458710.855468] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2109:phy5 Unplug Notice
[458710.855489] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2081:port 5 ctrl sts=0x199800.
[458710.855492] /build/buildd/linux-2.6.35/drivers/scsi/mvsas/mv_sas.c 2083:Port 5 irq sts = 0x81
[458712.904463] mvsas 0000:02:00.0: Phy5 : No sig fis


The last part about attaching the device repeats a lot. The disk is accessible now though (w/o reboot), so could probably just re-add it to the array.

To be sure I have stopped the array for now and am running badblocks -svw against the disks on the mvsas controller. This has been running for about 12 hours now without any errors in the logs.