We have a poweredge r510 with a perc6 and a raid 5 array configured with 5 500 gig sata hard drives. One of the drives failed a few days ago so we ordered a replacement for it. Typically when I've replaced failed hard drives in the past i just pop in the new one and it does a back ground rebuild, by the morning we ahve a good array again. in this case though at some point during the rebuiled it appearantly fails and the new drive goes into an offline state. things i have tried so far (after retrying the rebuild incase of a random error)
1. moving the drive to another slot and seeing if i could assign it as a hotspare. I tried going to through openmanage and it says the new disk is foreign when i move it to another slot, i tried clearing the foreign config in openmanage but that wouldn't work
2. next i booted up into the controller bios and tried clearing the config from there, which seems to have worked but i can't use the disk as a hotspare from there either.
3. next i thought i would try the replace option (still in the controller bios) so i put the old one back in and left the new one in one of the previously unoccupied slots, then i tried going to the old drive and selecting replace, but for some reason it shows the old drive as a good unused drive (not part of the array), and its saying the new one is offline, and this status follows it around from slot to slot
so at this point its kind of odd, the old drive is able to be used as a hotspare or be used as a replacement, but I can't use the new one as a replacement or hotspare and it constantly goes offline, any help is greatly appreciated, thank you.