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Rebuilding RAID 5

Ayman Altounji
Valued Contributor

Rebuilding RAID 5

Smart-2DH server with 5 18.2GB RAID5 disks

One disk failed and we replaced with another 18.2GB.
Controller starts rebuilding logical drive. The drive on-line light blinks and the activity light flashes.
After about 2 hours the process stops. The on-line light is off, but the activity light flashes occassionally.
The status of the controller is "Waiting for Rebuild"

According to the NT Event Log:
(1) Physical drive status changes to 2 (OK)
(2) Array status changes to 7 (Rebuilding)
(3) About 2 hrs later, Array error is: The device \Device\ScsiPort0, did not respond with the timeout period. We get this 3 times.
(4) Array status changes to 6 (Ready for Rebuild)

Difference between old drives and new drive:
Total Blocks: Old = 35566000, New = 35565080
Physical Drive Flags: Old = 0x4d, 0x25, 0x00, New = 0x4d, 0x25, 0x80

The last failure reason on the new disk is: 0x1B (Hot plug request sense failed).

Does anyone have any suggestions? We have tried several different disks and always end up with the same results. We are about to try to upgrade the firmware on the controller and the disks.