What is the best way to copy ~2 million files on Windows 2003?

I've recently purchased a duplicate NAS for the sole purpose of mirroring the current one (for redundancy's sake).  They each have a 10TB capacity (they are Netgear ReadyNAS Pros).  The one with all the files on it has 1.8 million files in 64,357 folders taking up 6.42TB of space.  I have tried over the previous two weeks to copy the files over to the new NAS with little success.

First tool i tried was SecondCopy, this crashed a few minutes into the copy, with no error.  Second tool was TeraCopy, this too would just fail about 2-3% into the transfer, no error given (just stopped transferring).  Third tool i tried was the built in rysnc tool on the readynas, it too failed, with a completely non descriptive error in the log.  After that, the fourth tool I've tried is DSynchronize, which seems to work, except about 2 hours into a transfer it starts reporting that files are locked on the source drive, and it too stops in the middle of the job.

Is there a tool that is designed for copying so many files on Windows?  I've even tried moving one folder (at the top level) at a time, but even that seems to fail.
Andrew_BellaAsked:
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PcGod718Commented:
my guess is youre either running into memory errors or the folder structure is too deep.  
try using

http://www.xxcopy.com/index.htm
http://technet.microsoft.com/en-gb/magazine/2009.04.utilityspotlight.aspx

they are both reportedly much faster than robocopy while just as stable

you can also look into downloading a Tape backup software like backup exec.  Get the 30 day demo (they are fully functioning) and do a disk to disk backup.
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xclsysCommented:
use an offline clone hadrive software to copy the files
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Andrew_BellaAuthor Commented:
The volume spans across 6 HDs as a RAID array and taking it down would probably not work out for the users (and it would take too long to do it after hours).

Does synctoy use a different method than Windows copy (forgot to mention i gave that a shot too)?
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Lee W, MVPTechnology and Business Process AdvisorCommented:
Curious... any reason you have used Robocopy or XCOPY?
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dax_badCommented:
What about Rsync ?

It's an opensource remote sync server tool that can sync the master NAS to the Mirror on the fly.

http://en.wikipedia.org/wiki/Rsync
http://www.samba.org/rsync/

For setting up in windows

http://www.gaztronics.net/rsync.php

Cheers
/Daniel
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TristanIT ManagerCommented:
Thats a lot of files.
Not surprising that  the low end tools would wipe out trying to enumerate millions of files.
If i were in your position I would do one of two things.
1) break up the file copy into manageable chunks (start with a 100000 files ata a time)
2) Use an enterprise level backup suite like Symantec Backup Exec or CA's Arcserve in to backup to either LTO tape or disk storage, then restore from that media to your target device.
3) Use the copy feature in CA Arcserve to copy the data across (very robust process which is designed to handle these kinds of numbers).
4) Use a copy of Doubletake Backup which has the best sync solution around and would rip through this challenge.
Note that you can download fully functional trial versions of those backup software suites and hire out an LTO tape drive on a short term basis.
In retropsect I am leaning towards the trial version of CA and use the copy function or the Doubletake trial software, both of which I have used in similar scenarios.
 
 
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Andrew_BellaAuthor Commented:
I'm not out of the woods yet (it'll take many days for the copy to complete) but RichCopy has been performing great so far (48 hours into the copy now)!

If that fails, I'm going to need to go the route of a tape backup application.  

Thanks everyone!
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