init: F3 unlock project — ESP32-C3 bridge + procedure for CLAR200 Exos X18

2026-06-14 21:12:56 -04:00
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+# Handoff — 2026-06-14 — clar200-unlock bootstrap
+
+## Context
+
+Started from a `tank` (pve173, 549 TB ZFS) degradation diagnosis. mirror-35 is a
+3-way mirror running on effectively ONE healthy disk:
+- `4450364206979169854` (ZL2PNZ99) — **UNAVAIL / dead**
+- `wwn-0x5000c500c3663b1d-part1` (/dev/sde) — **healthy** (0 pending/realloc)
+- `wwn-0x5000c500c37f4eff` (/dev/sdg) — **failing**: 30,536 pending sectors,
+  11,032 reallocated, 18 ZFS read errors
+
+mirror-35 holds **3.68 TB** of real data (25.3% full) — it is a live stripe
+member, not empty. Plus **ex-mirror-38** (`wwn-0x5000c500c382f4ac-part1`) is a
+bare single-disk vdev. Both need **14.6 TB+** replacement disks, of which there
+are **none free** on pve173 (all 14.6 T disks already in tank; spares are 10.9 T,
+too small).
+
+Seth re-added an EMC-locked 16 TB drive (SN **ZRS015V7**) hoping to use it. It's
+the same CLAR200-locked Exos X18 that a prior session failed to unlock. This
+project is the unlock attempt.
+
+## What I confirmed this session (re: the drive)
+
+- Drive is on **pve173**, dual-pathed: `/dev/sg121` (7:0:43:0) and `/dev/sg122`
+  (8:0:11:0), model `SS160520 CLAR200`, fake serial `Maxtor 5A320J0…RAMB1TV0`.
+- New HBA (pve173 SAS2116, vs pve197 before) → **same lock** ⇒ not the controller.
+- SCSI **target/bus reset** (`sg_reset -t`) → drive returns in same state.
+- `sg_senddiag --test` → Illegal request. READ CAPACITY → Hardware Error.
+- ⇒ Confirmed firmware-level lock below the SCSI layer. No host fix exists.
+  Prior `EMC_CLAR200_DRIVE_FIX_NOTES.md` conclusion stands; I closed the two
+  doors it left open (HBA + reset).
+
+## What I built
+
+Project `~/bin/clar200-unlock` + Gitea repo. ESP32-C3 (already on steel141
+`/dev/ttyACM0`, MAC 58:8c:81:ac:f0:4c) as a 3.3 V USB-serial bridge to the F3
+terminal. Firmware (`firmware/clar200_bridge.ino`, live `~N` baud menu), flash
+script, full `PROCEDURE.md`, and `docs/f3-command-reference.md` (honest about
+Exos-vs-7200.11 uncertainty).
+
+## Next steps (ordered)
+
+1. `cd ~/bin/clar200-unlock/firmware && ./flash.sh /dev/ttyACM0` — installs
+   arduino-cli + esp32 core (first run), builds, uploads. **Not done yet.**
+2. Bench-test bridge: `screen /dev/ttyACM0 115200`, jumper GPIO4↔GPIO5, confirm echo.
+3. Bench the drive (pull from pve173 JBOD, standalone power). **Needs an
+   SFF-8482→SATA-power adapter / SAS dock — confirm Seth has one.**
+4. Multimeter the F3 pinout (PROCEDURE §3), wire, get boot banner + `F3 T>`.
+5. Map format command via `?`, format to 512, verify with `sg_readcap`/`smartctl`.
+6. If healthy → `zpool replace tank 4450364206979169854 <newdisk>` for mirror-35
+   (replace before detach), then re-mirror ex-mirror-38. Repeat for ZR511KWK.
+
+## Open questions / decisions pending
+
+- RMA to ServerPartDeals vs. attempt F3 first? Leaning F3 first (cable free).
+- Does Seth have standalone SAS power + jumper wires + multimeter on the bench?
+- tank mirror-35: the dying sdg is still attached as a (poor) 2nd copy — leave it
+  until a real replacement resilvers; **don't detach early.**
+
+## Also worth doing
+
+Minor CKSUM counts on mirror-10/18/19/20/30; no scrub since the tank migration.
+Worth a `zpool scrub tank` AFTER mirror-35 is on healthy disks (not before — a
+scrub hammers the dying sdg).