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HP Proliant DL385 G2 drive hot swap.  Pulled new drive from server before rebuild completed now get an orange light after put back in even with new drive.

Posted on 2011-02-22
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Last Modified: 2012-05-11
We have an HP Proliant DL385 G2 with two logical drives setup.  We had a orange light on one of the drives (Logical drive 1...2 drives with Raid 1+0 setup) so we hot swapped the drive.  Right after I put the drive in I realized that I needed to get the serial number off of the drive so I pulled the drive before any lights started flashing (not smart in hind sight).  I then put the drive back in about a minute later and got a orange light.  We looked in the array configuration utility and could see that the drive was showing as failed.  We decided to put a new drive in to see if that would fix the issue but got an orange light with that drive as well.  I noticed a blue light on the other drive in the array so we went back to the Array Configuration Utility and could see that the array was in "Interim Recovery Mode"  and the new drive was showing as failed.  We are thinking that a server reboot or a firmware update might resolve this issue, but we want to limit the damage for the day and decided to look for help.  Anyone know what the best course of action would be?  Thanks in advanced!
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Question by:briankehoe
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Author Comment

by:briankehoe
ID: 34956456
By the way, the Controller Card is a Smart Array P800.
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andyalder earned 500 total points
ID: 34958723
Reboot normally gets them out of interim recovery mode, do it with the disk bay empty that had the failed disk in. You may also want to erase the replacement disks by putting them in a test server and running system erase from smartstart - erases the metadata and wipes the test machines disks and configuration.
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Author Comment

by:briankehoe
ID: 34973244
Rebooting did not resolve the issue but it did lead to the solution that worked.  We ended up shutting the Server completely down for another reason and when it came back online it began the rebuild.  

We had tried the restart without the drive in, which did clear the "Interim Recovery Mode" notice, but the drive still showed as failed after we put it back in.  

We actually left the same drive in when we shut the server completely down.

So it looks like for our case at least that a complete shut down did the trick.  Not sure if Meta Data was actually an issue on the drive that had a successful rebuild as it was not the same drive that caused the initial problem (i.e. we tried two other new drives thinking we might have messed up the first one and the last one we used worked after a complete shutdown).  Sorry for the lengthy explanation but I just don't want to mislead anyone else that might have a similar issue.

I am giving full credit to the answer above and listing this comment as an assisted solution so that people will read both as they both brought us to the solution and will both be necessary for the next person.  Thank you andyalder for your help.
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Author Closing Comment

by:briankehoe
ID: 34973264
Explained in last comment.
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Expert Comment

by:andyalder
ID: 34975442
Yeah sorry, my bad terminology. Shouldn't have said rebooting since that isn't the same as power cycling. The controller wouldn't even know if a soft reboot took place, it has to go through POST and let you do do the F1/F2 bit.
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