We have an old HP ProLiant storage server (Windows 2003) with an HP P800 RAID controller. Recently it has started having an issue with the drive in Box 1: Bay 3. It seemed like a regular old failed disk, which happens occasionally since the server is old, so I swapped the disk with a brand new spare and the array will not rebuild (same error persists).

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Thinking I had a junk spare disk, I tried another brand new one, but had the same problem. The error in HP Array Configuration Utility is Code 274 1 TB SATA Drive at Port 3I: Box 1: Bay 3 is bad or missing. To correct this problem, check the data and power connections to the physical drive. The diagnostic LED on the drive in question is on, so the drive has power. The LED is blinking, alternating blue and orange.

The status of the array is (Interim Recovery) Logical Drive 3 (7.3 TB, RAID 6 (ADG)) It has been in Interim Recovery for about a week now and won't do anything else. Unfortunately this server is no longer covered by our HP maintenance contract because HP decided to end support for this model. I have really limited experience with RAID and do not want to do anything to compromise the data on this logical volume - very critical server. What should my next step be? Is it 'safe' to shut down the server, let all the disks spin down, and start it back up to see if the array rebuild will at least start?

Or is the RAID controller shot. Lots of information in report, nothing that stands out other than it failed. Is the new drive identical to the others in the array?

If so, have you tried to simply re-seat the drive? Do you have another drive to try, that one might be bad also. Or your assumption that the bay is bad will have serious consequences. Hopefully fully backed up elsewhere. And yes, I would think a reboot would be a safe option to see if it kicks into the rebuild. Wait until the end of the day though as someone else might disagree. I have 3 spare drives, in addition to the original drive that 'failed' and started this fiasco in the first place.

I have actually tried all 3 spare drives, but it seems like the array isn't even attempting to rebuild once the new drive is present. Each drive I have installed, I've also tried re-seating. The new drive is not identical to the others in the array, but it's identical to the original 'failed' drive. It's a GB1000EAFJL. However, this drive is not identical to the others in the array. Some are different models (they are just a mixmatch of whatever HP sent us as replacements throughout the years for warranty service replacements). The data is fully backed up and the backups are tested good.

Ok here's something weird. I just inserted the original 'failed' disk and the array immediately began rebuilding. It doesn't even attempt to rebuild when any of the 3 spares are inserted. ALL of the spares are genuine HP GB1000EAFJL disks and they were factory sealed in the anti-static package until now. They all spin up when connected to an external power supply.

Pretty weird. An array rebuild usually takes about 1.5 days so I'm not sure if it will actually complete, but the fact that it started this time MIGHT be a good sign? Interesting - so here is a quick update even though I did not get back on here to read the responses about the firmware before I continued to mess around. Rebuilding the array onto the original failed disk did complete, however, it still reported the disk as bad.

I popped in spare #1 and closely watched the ACU. It actually started the rebuild, but stopped after about a minute and reported the disk as failed. Didn't even reach 1%. Repeated the same procedure with spare #2 - same thing. It does attempt to rebuild, but fails very quickly. What I did just now was grabbed a random known good 1 TB SATA 'desktop' type HDD, swapped it into the HP tray, and placed it into the server.

Wasn't really sure what this was going to do but it says 'rebuilding' and hasn't failed yet, but also has not passed 1%. Once this either succeeds or fails, I will try to upgrade the firmware of the spare HP disks. So, andyalder, we also have an old version of the ADU? I'll have to see if I can find the latest version to download.

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