RAID5 drive failure, rebuilt OK, now windows wont even boot recovery console, hangs examining disk
Posted on 2008-11-06
got a video editing system here which suffered a RAID5 drive failure along with a serious software crash (the avid software hung and completely locked out) at the same time
it's an adaptec 2820SA raid card with 6 SATA disks forming a 5-disk array with a hotspare
i came to the machine in a powered-off state, powered it up and loaded the RAID BIOS, at which point it began rebuilding the array onto the hot spare. after several hours it completed and gave the RAID status as "optimal". i've double and triple checked the RAID config and it's correct - it used to consist of drives 0,1,2,3,4 as the array and 5 as the spare. it now consists of 0,1,5,3,4 as the array, with drive 2 failed.
after the rebuild completed, we rebooted, windows begins to load but after the XP logo appears all disk activity stops. the moving bar underneath the logo keeps moving, but nothing happens. it's been left in this state for about 15 minutes with no progress.
the same is true in safe mode, all (i think) the drivers load, it gets to agp440.sys anyway, and that's the end of all disk activity.
so i've tried to boot to recovery console off a windows CD, given it the RAID driver off a floppy (wont even recognize it without that), and it gets as far as "examining 1525579MB disk 0 at id 0 on bus 4 on aac..." and hangs here
where to go from here ? format/reinstall is not simply a last resort, it is absolutely not an option. there must be a way to get windows to recognize this disk, after all RAID 5 is supposed to protect us against drive failure !