hang on startup when 2nd HDD added

Some drives have a 'Slave Present' jumper that needs to be set. Have you checked your ( Master ) drive fot that?

'Cable Select' needs a marked IDE cable (with a hole in one of the wires), Are you using a correct cable?

you can follow these steps to make sure first
http://www.helpwithpcs.com/upgrading/install-hard-drive.htm

Disconnect the CD-ROM and try attaching the HDD alone.

Check if it boots fine ?

Another best method, disconnect all the drives from IDE channel and connect only the new HDD. Start and try accessing BIOS to see if HDD is detected. If still hangs -> the HDD is malfunctioning.

I have used a certain motherboard which will take an abnormally long amount of time to boot when a new hard drive is added. Its IDE detection scheme is apparently not very efficient, but it does boot after a while (3-5 minutes). Maybe yours is experiencing a similar symptom.

Your motherboard ay be incompatible with the new HDD.

Consult your M/B Manual ow vendor web site for compatibility issues.

Update your M/B BIOS maysolve the problem.

Give the IBM time at the start screen. It takes time to detect hard disk not compatible iwith its normal detection routine. After that enter the BIOS when it gives u the option. This might take as long as 10 minutes and then set the hard disk to manual.

You might wanna update ur BIOS to the latest version as this might easily fix ur problem.

CHances are that the hard disk might not be compatible with ur board due to drive geometry but these issues get fixed with a BIOS update in most cases so give it a shot. If this doesnt work u mgiht have to change the hard disk or maybe the manufacturer. Try getting the same manufacturer HDD as the original disk for max compatibility.

Dan

Does it hang since the first time you pluged it? or from the second time.

It seems strange that a new system would give you these problems. Nevertheless, components can be bad, even if they are new.

Make sure that the Master drive's jumper settings are correct. Some of them have a special setting for "Master with Slave Attached", as well as a "Single" setting.

I once had a weird error like this when the jumper settings on the CD/ROM drive were wrong. It was set as "Slave", when it was the only drive on that IDE channel. Make sure it is set to "Master". You might have to remove the CD/ROM drive to see what the settings need to be. But a lot of times the settings are listed on the back of the drive. I think they are as follows:

M S C
A  L S

You read them vertically:

M
A

is "Master".

S
L

is "Slave".

C
S

is "Cable Select".

If your CD/ROM is set to "Slave", that may be the problem. Your BIOS should tell you what it thinks the CD/ROM is set to, but check the jumper settings just to be sure.

Also try swapping the IDE cable with a new one, or a known good one. Make sure it is the new ASA66 type, with 80 wires, not the old 40-wire IDE cables.

Also, try swapping the power supply with a known good one, or a new one. Jonybrv was onto this when he/she suggested you disconnect the CD/ROM drive. That would lessen the load on the system, and possibly allow it to boot. But I would still try a new power supply. I can't tell you how many times a power supply has been the problem, when everything else seems OK. You always get weird behavior and unexplained errors when the PSU is going. Your symptoms seem to fall into this category.

You could also try disconnecting the CD/ROM drive and connecting the second hard drive on that IDE cable. It should recognize the hard drive now. If it doesn't, then the hard drive is bad, regardless of what you said about it's being a known good drive.

How about splitting points equally among all the experts? Very frustrating to not get even one response from the asker. All suggestions by the experts were good, in my opinion.