Can't rebuild my RAID5 array!

[SilverMK3]

I recently had one of the 320GB Seagate 7200.10 drives fail in my RAID 5 Array. After RMA'ing the drive I left the server turned off until the replacement drive arrived today.

I put in the new drive and fired up the server again only to be greeted with the following message when I fire up the HighPoint RAID Management console: "The following arrays can not be used, do you want to delete them?: CORTEX_TERABYTE". Obviously I click "NO" - but now I can't do anything other than look at the disabled array.

Here's what I get when I go to Array Management and click on the array:

ARRAY INFORMATION

Name:     CORTEX_TERABYTE
Type:     RAID 5
Capacity:     959.93GB
Status:     Disabled
Cache Policy:     Write Back

Here's what I get when I go click on on the first disk in the array:

PHYSICAL DEVICE INFORMATION

Model:     ST3320620AS
Type:     Hard Disk
Location:     Controller 1, Channel 1
Revision:     3.AAC
Capacity:     319.98 GB
Total Free:     0.00 GB
Max Free:     0.00 GB
Status:     Critical
Transfer Mode:     SATA300
Read Ahead:     Enabled
Write Cache:     Enabled
NCQ:     Disabled

The other disks (Channel 3 and Channel 4) report the same information, except their Status is "Normal".


According to the manual, I should expect the Array to be in the status Broken and be able to click on Add Disk and Rebuild from there... Unfortunately those options are grayed out. I can only Unplug or Delete the array.

Help!!

Here's the log file from the console:

14/12/2006 5:46:00 PM   Disk 'ST3320620AS' at Controller1-Channel2 failed.   
14/12/2006 9:42:55 PM   Disk 'ST3320620AS' at Controller1-Channel2 failed.   
16/12/2006 6:07:05 PM   Disk 'ST3320620AS' at Controller1-Channel2 failed.   
16/12/2006 6:07:05 PM   Array 'CORTEX_TERABYTE' verifying failed.   
18/12/2006 7:44:43 PM   Disk 'ST3320620AS' at Controller1-Channel2 failed.   
18/12/2006 7:44:43 PM   Array 'CORTEX_TERABYTE' rebuilding failed.

 

[ZeroH]

it says rebuilding failed.. so it sounds like it tried to start the rebuild process but failed due to disk 2 being bad. is disk 2 the new disk or another bad one?

and disk1 says it's in critical status so that's probably bad too.. so you may have 2 bad drives there.

 

[SilverMK3]

Thanks for the quick reply.
Disk 2 is the on that died. It was removed, RMA'd and replaced but I can't add it back into the array.
I'm not sure why Disk 1 is set to Critical, there's no explanation of what that means in the RocketRaid manual or management console... Its keeping me from rebuilding the array whether I'm using 3 disks or 4.

 

[mwarps]

it looks like either this new disk is also bad, or the controller itself has failed, since the controller1-channel2 thing is broken again, two days later.

 

[SilverMK3]

Hey,
Disk 2 originally failed last Thursday (14th), but it recovered and rebuilt itself.
It failed again Saturday (16th) and turned itself off but I was gone for the weekend. When I turned it back on on Monday (18th) it rebuilt itself yet again but failed while it was doing this. After running the SeaTools diagnostics and confirming the drive was dead I RMA'd it and left the server turned off until I got the replacement back today. And now I can't seem to rebuild it at all anymore.

 

[ZeroH]

i'd run seatools on disk1 to make sure it's not bad.. it sounds like it is though.