Let me start by saying that I have no detailed experience of RAID 5 arrays.
We have a 3 Disc, single volume, RAID 5 array operating an SBS 2008 Server. The RAID controller is Intel Matrix Manager accessed via Intel Matrix 8.9, Storage Controller.
The Port 2 disc was reported as failed and subsequently I replaced it. However, although the new disc was a 500gb Seagate Barracuda, as per Ports 0 & 1, it was a newer version as the original ST3500418AS are no longer available.
The RAID controller recognised the new disc and I took the option to include it in the volume. However, it was only after the 'rebuild' had started that I noticed that the physical sector size of the new disc was 3024 bytes and not 512 bytes per the other 2 discs. I let the 'rebuild' process run to completion and the new disk was added into the array at Port 2.
All appeared well until I tried to reboot the server, it would not boot, simply cycling round and round past the Intel boot screen and appearing to start to load but after 2 minutes or so it rebooted.
I refitted the original failed disc and the file server rebooted, per normal, but of course with a degraded array.
I contacted the tech support desk of the well known UK retailer of the disk and was advised to reformat the disk on a separate PC to 512bytes and then re-introduce it to the RAID 5 array.
I did as advised but the file server would not boot with the new disc simply connected to the array port, never mind being introduced to the array, I never got that far. I am now again running in a degraded state with the old disc in place whilst trying to find a solution.
The 'techie' further advised that my only option would be to rebuild the array, but this is with the inferred loss of data and I do not really want to do that.
Any advice would be most welcome. I attach screen dumps of the array as currently seen via the Matrix Storage Controller.