An old Windows 2003 server is running on a 4 disks (each250GB) RAID 5 array, attached to a 3Ware 9500S-4LP unit. This morning I got two alarms from the controller:

- 0x04:0x0025 Cache flush failed; some data lost: unit=0
- 0x04:0x000A Drive error detected: unit=0, port=1

I'd like to replace the drive, however I miss the correct procedure. Should I simply turn off the machine, replace the faulty drive and reboot? Will the controller rebuild the array automatically?


Method 1)

  1. Tell the controller to remove the drive.
  2. Remove the drive from the server.
  3. Put in the new drive.
  4. Tell the controller to rescan.
  5. Flag the new drive as a host spare.

Once flagged as the host spare, the card should automatically take it to replace it the old drive and sync it, rebuilding the array.

Take a look at the User Guide or the CLI guide.

Method 2)

Pull the old drive and put in the new one. The raid card should detect the change and rebuild raid with the new drive.

  • Can this techcnique be used to enlarge the array? For example, as it may be worth it to use larger disks at this time, say I could use a new 500GB disk, I could replace the disks one by one (once the rebuild has completed per each drive). Once the 4 disks have been replaced, can the controller be instructed to enlarge the array (currently 650GB out of 4x250GB) – Riccardo Mar 5 '13 at 10:22
  • BTW in the user manual I see that as for RAID 5 "Requires a minimum of three drives". This would mean that the array should be working seamlessly with 3 drives, simply removing the defective one? Of course this would mean lowering reliability – Riccardo Mar 5 '13 at 13:00
  • Yes the 3BM interface states that the unit is degraded and that a drive is "NOT IN USE". It states that the unit will work however no more being fault tolerant. It is not clear how to remove the faulty drive...from the 3BM interface it is possible to delete the unit, not possible to remove a drive – Riccardo Mar 5 '13 at 14:48
  • I think I will unplug the broken drive and replace with a new one. Will try to install a larger drive – Riccardo Mar 5 '13 at 15:25
  • I have added the new drive. During rebuild, another drive is throwing ECC errors! OMG! Collapsing? – Riccardo Mar 6 '13 at 13:46

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