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 Low Cost Offsite Backups Made Easy!
Author: charles
Last Post by: charles
Last Posted: 9/8/2009 13:37
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Low Cost Offsite Backups Made Easy! 

 
Author
Topic

charles

 

Location: United States

Registered:  9/8/2009

Posts: 9

How To Create a Removable Disk Backup System using Hot-Swap Drives


I recently created a removable SATA drive backup solution for a customer. The project involved about $860.00 worth of parts, along with some free software from Microsoft. It replaced a dead Ultrium 1/8 tape autoloader. A replacement drive was going to cost about $4,050; or the customer could try to get HP to repair the old one for about $2,500. Plus, the enterprise backup software the customer was using was no longer under support contract. Replacing that contract would have cost another $2,700.

Replacing Tape System
New Tape Drive$4,050 eaQty 1$4,050
Backup Software$2,7001$2,700
Total Cost $6,750

Alternate Plan
1.5 TB Drives$1501$750
Drive Rack $251$25
Drive Trays$154$60
Ship/Handling/etc  $45

Total  $855

Savings  

$5,895

 

Parts:

  • Kingwin KF-812-BK SATA drive rack
  • Kingwin drive tray for above with single fan (four of these)
  • Seagate 1.5 Terabyte Serial ATA Hard Drive (five of these)


I used Robocopy to perform the backups on a daily basis (more on that later).

The trays are made of aluminum so they are quite sturdy and have good heat transfer, an important option in modern hard drives. The rack has a rear fan for cooling, and the slide-out trays have one fan. One fan in front and one in back is loud enough that I wouldn't go with a two-fan model unless the rack was going in a server room somewhere. According to user reviews, the rack sometimes causes spontaneous reboots when you hot-swap the drives. I did not have this problem, so I suspect it happens in machines with inadequate power supplies; your mileage may vary.

The Kingwin rack and trays do not come with any documentation, instructions, or anything. Their website also has nothing. This led me to make a mistake in my first installation attempt. I'll get to that later. The trays have rubber shock absorbers, so they should be reasonably portable. Modern drives are self-parking, so the drives should be quite stable when ported around. The trays use a 64-pin Din Connector to bridge between the rack/chassis and the pull-out trays. This works well; there are no exposed pins or wires for static electricity to zap the drives.

The drive powers up as long as the front lock is locked. Removing the drive requires unlocking the drive, which releases it from the rack and powers it down. The key does not stay in the rack--it pushes out, so you can't just leave the key in the rack perpetually.

 

 

(continued...)

 



(Last edit: 9/8/2009)

charles

 

Location: United States

Registered: 9/8/2009

Posts: 9

Part 2: Hardware Installation


Inserting the drive into the tray was a bit of a squeeze. I made a mistake here, by sliding the drive in enough to connect the wires, then trying to attach the screws from below the tray. WRONG! On the second tray, I found an easier method. The drive attaches to a metal plate that sits on rubber pads and has a single screw holding it to the tray. I removed the screw to get that plate out of the tray. That's certainly an easier way to go about installing the drive (see the Drive in tray image below). The plate has four holes to mount it to the drive. The tray has holes that line up with the plate, so you can get to the screws through the bottom of the tray, but it's a pain to line up the screws. I ended up using tweezers on the first tray. I'm glad I found the better method the second time around. The cables are short, and the lid is a tight fit over the drive, but it does fit. I repeated the process for all five drives, and then stuck a piece of tape on the tray lid with a number so I would know which drive was which.

 

I'm unsure how helpful the rubber shock absorber pads are, though, as tight as the lid fits over the top. In theory, that pad cuts noise from drive vibration. But the lid basically touches the drive, so I doubt there's much dampening going on here.

 

Next I shut down my PC and unplugged it. I opened up the PC and inserted the rack into an open 5.25" bay. It is a long piece, so the fit is pretty tight against the cables coming out of the power supply. But it did fit. Routing the power and Serial ATA cables around was a bit awkward as well. I had to carefully route the SATA cable behind the power supply cables. I also had to find an open 5-pin power cable and get it into the rack while it was half-in and half-out, as there was not enough room to maneuver between the rack and the computer power supply.

After that, I closed up the PC and inserted the tray into the rack. This, too, was a tight squeeze. Buyer reviews had warned me this might happen and that it should clear up after the tray has been pulled out a few times. No worries, it locks in tight enough to work. I powered up Windows, which saw the new drive. I was able to work with it just like an internal SATA drive. I assigned it to D:, and got busy designing a backup strategy to use that drive.

The vendor was out of single-fan trays, so I ended up with two that have double fans in the front; those fans are noisy. I wish it was quiet enough not to notice. That, plus the lack of clear documentation are my only two complaints. And the documentation really isn't a big deal. It might have saved me a few minutes of having to think through the process and doing it the hard way on the first tray, though.

The tray / rack assembly only carries a one-year warranty. But for $25, it's not that big a deal to replace it if there are problems. Since there's no documentation, I'm not sure how you would go about claiming anything on the warranty anyway! the drives are under Seagate warranty for five years, so I don't have anything to worry about there.

 

(continued...)

charles

 

Location: United States

Registered: 9/8/2009

Posts: 9

Part 3: Backing up Network Files to the New Drive


Rather than spend thousands of dollars for a backup software that's difficult to learn and hard to maintain, the customer requested something available for free or in the public domain.  RoboCopy is a free tool available here from Microsoft for general use.

Note that by default Robocopy does not copy files that are the same (size and date) between source and destination.

Every other day, the customer powers off the PC and changes out the drive.  The other four drives are then stored offsite.

 

Here is the script used to pull files from remote servers and copy them to the removable hard drive. 

 

@echo off
rem .
rem .     Make sure destination directories exist by trying to make them This way a new drive will get the folders it needs.
call c:\rcopy\makedirs.bat
c:
cd\rcopy
rem .            Get Day of Week
set dow=%DATE:~0,3%
set date1=%DATE%
set tm1=%TIME%
if %dow%==Sun goto C
if %dow%==Mon goto A
if %dow%==Tue goto B
if %dow%==Wed goto C
if %dow%==Thu goto A
if %dow%==Fri goto B
if %dow%==Sat goto C
set dow2=SetA
goto end
:A
set dow2=SetA
Goto End
:B
set dow2=SetB
Goto End
:C
set dow2=SetC
Goto End
:End
rem .                   Get destination drive label so we'll know which drive is getting the data.
echo %date1% >> %dow%.txt
vol d: >> %dow%.txt
echo %dow2% >> %dow%.txt
echo ----- >> %dow%.txt
rem .            Set file destination.
set dest=d:\bvc\%dow2%\
rem .
rem .            Set up robocopy parameters
rem             -xf        exclude filetypes
set xfil=/XF *.mpg *.mpeg *.mpe *.mp3 *.m1v *.mov *.wmv *.asf *.avi *.wma *.mid thumbs.db desktop.ini folder.dat *.m4a
rem .            -xd        exclude directories
set xdir=/XD Recycler DfsrPrivate OfficeXP Office2003 Acrobat9 OracleClient iTunes
rem .            -log        Output log
set log=/Log:%dest%rCopyLog
rem .            -sec         copies security
rem .            -secfix     applies security
rem .            -a+:a         applies archive attribute
rem .            -mir        mirrors directory tree
rem.         (all subdirs, even empty, deletes dest files that no longer exist
rem .            -r:        retry attempts
rem .            -w:        wait between retries
rem .            -v        output includes skipped files
rem .            -np        turns off percentage complete
set switch=/SEC /SECFIX /A+:A /MIR /R:3 /W:5 /NP %xfil% %xdir%
rem .            run the Backups...
c:\rcopy\robocopy %1 %dest%%2 %switch% %log%.%2.txt

 

So what is this script doing?

  1. Gets the day of the week
  2. From that, decides whether to save data as backup SetA, SetB, or SetC (3 copies allowed per drive)
  3. It then build the switches for robocopy
  4. Finally, it copies some data from the source (%1 variable) to the new destination (%2 variable)

Logs should be reviewed daily to make sure the scripts ran and had no errors. The log often will often conttain "Extra File" or "Extra Folder" in the logs. This typically means a file was deleted in the destination because it did not exist in the source. It also should have a fairly high "skip" count after the first run. These are files that did not need to be copied as they had not changed since the last backup. In fact, the majority of files should be in this category.

 

(continued...)



(Last edit: 9/8/2009 13:31)

charles

 

Location: United States

Registered: 9/8/2009

Posts: 9

Part 4: Analysis


The system outlined above is not perfect.  It is louder than the original PC.  It does not provide fail-over options should that PC shut down.  It does not work in parallel.  It does not have a graphical interface for searching backed up files nor robust logs.

It can be slow.  One day, it kept hitting files that were in use, which caused a second delay each time, and ended up running for 10 hours before it completed!  But most of the time it's done within one to two hours, which is not bad for a 250 - 300 Gb data set.

It's a disk drive, so there's no proprietary hardware required to read the data; just a working PC with the appropriate drive controller, which any modern PC will have.

Hard drives are fragile. These drives get carried around, dropped into car seats and everything else.  They probably will not last as long as a comparable non-portable drive.

The original plan was to rotate the drives once per week, taking a drive home each Friday.  If there's a catastrophic power surge that wipes out both my PC and the servers, then the customer could lose up to a week's data that way.  The computer in this case gets power from the a UPS, so that's not entirely impossible, though unlikely.  Based on that, the customer was encouraged to rotate drives at least every other day.

Pulling the drives can really confuse Windows.  While some motherboards can handle hot-swapping drives, the PC used here was not able to recognize the new drive when hot-swapping occured.  The user was instructed to shut the PC down before trading out the drives.

Overall, though, the customer was quite pleased with this method of backing up data.  They get more space that's faster to search through and has next to no learning curve.  There was no need to buy special software or expensive tapes on a regular basis.  They do not have to figure out how to make the special software do what it is supposed to do, or pay thousands for database plug-ins and various other options that should be part of any backup solution.

Based on the six months this has been in place, we see no reason to revert to tape systems in the near future.  For this customer at least, tape backup is dead.