Ambiguous RAID failure

Early 2008 Mac Pro with Apple RAID card and 4 x 1TB drives installed.
I've had yet another RAID failure on my system (it's happened several times before) but this time the diaganostic is ambiguous and I need to make absolutely sure what's happened before I try to recover from it.
Overnight the RAID Utility log reported that Drive 3 had failed, that Raid Set RS1 was now degraded, and that there was no spare available for rebuild.
When I look now in RAID Utility at the status of the drives and of the array, all four drives show "green" (SMART: Verified and Status: Good), and Raid Set RS1 is "Viable (Degraded)".  But it shows the drives in Bays 2, 3, 4 as "Assigned" to Raid Set RS1, while the drive in Bay is not: it shows as "Roaming".
I'm fairly sure that one of the drives actually is problematic, because I've been having increasingly frequent episodes of freezing and non-responsiveness on the system (spinning beachball).  In the past couple of days it got so bad that it was difficult to do anything at all following a restart; the freeze/beachball happened very soon after.  I remember now that I had exactly this symptom in the past, just prior to a drive failure that RAID Utility reported.
So I guess I need to replace one of the drives, mark it as "Spare" in RAID Utility, and let the array rebuild.
But WHICH drive should I replace?  The log says that Drive 3 failed (I'm assuming that "Drive 3" is the drive in "Bay 3"), but now that drive shows as "good"--as do all four drives.  It's Drive 1 (i.e. the drive in Bay 1) that's been taken out of the array; drives 2, 3, and 4 are in Raid Set RS1.  Is that a red herring?  Is it possible that Drive 1 is bad even though the report was about Drive 3?  (Drive 1 is the only drive that has never been replaced at any time in the four years since I got this system.)
I think/fear that if I replace Drive 3, I'll blow away the array.
So it seems to me that I should rebuild the array by marking Drive 1 as spare (since it's the only drive that's unassigned), wait for it to complete, and then replace Drive 3 and rebuild again.  Or maybe I should just replace Drive 1 pre-emptively.
I don't know, but it takes a full 72 hours for the re-build to complete, a nerve-wracking time because throughout it the system is vulnerable to a second drive failure, so I would prefer not to have to do it multiple times.
Can someone please tell me in detail what the safest/most correct way is to proceed in order to recover from this?
Thanks.

Thanks, but it doesn't seem to be related to swapping/paging or to CPU usage by a runaway process.  The system always seems to have plenty of RAM (18 GB is installed) and neither Activity Monitor nor iStat Menus ever seem to show anything obviously suspicious (nor does "top" when I run that),  No swapping, no processes consuming all the CPU (also, it's an 8-core machine).
What typically happens is that the system will seem fine, but then running a new command, or (e.g.) asking my IMAP client to move some files, provokes a hang: everything locks up, spinning beachball, etc.  Sometimes this is preceded by an obvious degradation in performance, but sometimes not.
It "feels" disk-related and in the past I had similar symptoms preceding a disk failure (as I did before replacing the drive a few days ago).  But I can't see anything relevant in the log files, and in the past, when a disk failed, I didn't see clear evidence of this in the logs until RAID Utility declared the failure--nothing previous to that.
Is there some way to increase the verbosity of the disk-related logging?  If a disk really is problematic, even if the problems are recoverable after retries, you'd think that would be detectable by the system and that it could be logged.
The only other things I can think of trying right now are either: (1) replacing the remaining drives in the RAID Array one by one, starting with the drive in Bay 3 (because of the earlier ambiguity), and/or (2) disconnecting as much as possible from the system and seeing if it becomes more stable in that configuration.  Though I've already mostly done (2) without any obvious improvement,

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    This all sounded like a bad idea to me. And what does the Vendors RAID monitor software say then?  “Disk Really Really FAILED, check for a fire.”
    As I tried to figure out which drive was actually the bad RAID pair I stumbled on a solution.
    First I noted that the OS Disk Utility did NOT show a fault in the RAID. It listed both RAIDS as “Online.’ Thus no rebuilding was needed and it did not begin the rebuild process.
    The Vendors disk monitor software saw some fault, but Mac was still able to read and write to the RAID, both disks in the mirror.  I wrote a folder to the RAID and with various rebooting steps I pulled the “Bad” drive and looked at the “Good” Drive….the folder was there…I put the Bad drive back in and pulled the Good Drive and the folder was there on the “bad” drive.  So it wrote to both drives.  AND THE VENDORS MONITORING SOFTWARE SHOWED THE PREVIOUSLY LABELED ‘BAD’ DRIVE AS ‘GOOD’ AND THE MISSING DRIVE SLOT AS ‘BAD’.
    My stumbled FIX.   I moved a bunch of files off the failed RAID to the new RAID  but before I moved the sparse bundle, a folder of 500 gigs movies and some other really big folders the DISK UTILITY WINDOW (which I still had open) now showed that the RAID had a Defect and began rebuilding the mirror set itself, out of the blue!   I don't know why this happened.  But moving about 1/2 of the data off of it perhaps did something?  Any Ideas?
    This process took a few hours as best I can tell (let it run overnight) and the next day the RAID was fine and the Vendors RAID monitor did not show a fault any longer.
    So, the Vendors RAID monitoring software reporting a “FAILED” drive without any specific error codes to look up.  Perhaps they could have more info for the user on the specific fault?  The support line of the the Vendor said with certainty “the Volume Header is corrupted” and THE ONLY FIX is to completely ZERO THE DRIVE! This was not necessary as it turns out.
    And the stick in the eye to me…..
    “I've also sometimes seen the drives get marked as "failed" by the disk utility due to a shaky connection. In some cases, swapping the ends of the Thunderbolt cable will help with this. Something to try, perhaps, if your problems come back. “
    Ya Right…..
    Mike

    Follow up.
    After going through the Zeroing process and rebuilding the RAID set three times, with various configurations, LaCie finally agreed to repair the unit under warrantee.
    I tried swapping the power supplies and thunderbolt wires, tried taking the drive out of series with the newer big brother of it.  And it still failed after a few days.
    I just wanted to share more of what I learned with regard to rebuilding the RAID sets via the Terminal.  The commands can be typed partially and a help paragraph will come up to give VERY cryptic descriptions of the proper use of the commands.
    First Under terminal you can used the command "diskutil appleRAID list" to list those drives which are in the RAID.  This gives you the ID number for each physical drive. For example:
    AppleRAID sets (1 found)
    ===============================================================================
    Name:                 LaCie RAID 3TB
    Unique ID:            84A93ADF-A7CA-4E5A-B8AE-8B4A8A6960CA
    Type:                 Mirror
    Status:               Online
    Size:                 3.0 TB (3000248991744 Bytes)
    Rebuild:              manual
    Device Node:          disk4
    #  DevNode   UUID                                  Status     Size
    0  disk3s2   D53F6A81-89F1-4FB3-86A9-8808006683C2  Online     3000248991744
    -  disk2s2   E58CA8F5-1D2C-423A-B4BE-FBAA80F85879  Spare      3000248991744
    ===============================================================================
    In my situation with the failed RAID, I had an extra disk in this with the status of Missing/Failed. 
    The command is "diskutil appleRAID remove" and the cryptic help paragraph says:
    Usage:  diskutil appleRAID remove MemberDeviceName|MemberUUID
            RAIDSetVolumePath|RAIDSetDeviceName|RAIDSetUUID
    MemberDeviceName|MemberUUID  is the number listed in the "diskutil appleRAID List" command,  and
    RAIDSetVolumePath|RAIDSetDeviceName|RAIDSetUUID is the Device Node for the RAID which here is /dev/disk4.
    I used this command to remove the third entry (missing/failed), I did not copy the terminal window text on that one, so I cannot show the list of three disks.
    I could not get to remove the disk2s2 disk listed as SPARE, as it gave an error message:
    Michaels-iMac:~ mike_aronis$ diskutil appleraid remove E58CA8F5-1D2C-423A-B4BE-FBAA80F85879 /dev/disk4
    Started RAID operation on disk4 LaCie RAID 3TB
    Removing disk from RAID
    Changing the disk type
    Can't resize the file system on the disk "disk2s2"
    Error: -69827: The partition cannot be resized
    But I was able to remove it using the graphical interface Disk Utility program using the delete key.
    I then rebuilt the RAID set by dragging the second drive back into the RAID set.
    I could not get the command: "diskutil appleRAID update AutoRebuild 1 /dev/disk4" to work, because even though it was trying to execute it HUNG.  I put the two drives into my newer LaCie 2big as my attempt at further trouble shooting the RAID (this was not suggested by LaCie tech), rebuild the RAID and now I am going to leave it setup that way for a few days before I ship it back to just see if the old drives work fine in the new RAID box (thus proving the RAID box is the problem). I tried the AutoRebuild 1 command just now and it gave an error.
    Michaels-iMac:~ mike_aronis$ diskutil appleraid update autorebuild 1 /dev/disk4
    Error updating RAID: Couldn't modify RAID (-69848)
    Michaels-iMac:~ mike_aronis$
    In my haste to rebuild the RAID set for the third or forth time as LaCie led me through the testing this and test that phase, I forgot to click the "Auto Rebuild" option in the Disk Utility program.
    Question for the more experienced:
    As I was working on this issue, I notice that each time I rebooted and did work in the Terminal (with and without the RAID plugged in to the thunderbolt connection) I notice that the list of drives would change and my main boot drive would not stay listed as drive 0!  Some times it would be drive 0, sometimes the RAID would be listed as Drive 0.  It's strange to me...I would have thought the designation for Drive0 and Drive1 would always be my two build in drives (SSD and spinning drive).
    Mike

  • Mac Mini Server HDD raid failure help

    My server has been running for years, perfectly, most of the time. It is set up as a mirrored raid set.
    I noted today that the second HDD is displaying a "failed" red flag in disk utility. I attempted to Rebuild and that failed.
    In the FIRsT aid tab Verify returns errors. "This disk needs to be repaired using the Recovery HD..restart control r....etc."
    There's my problem. No monitor or keyboard. I'm using screen sharing from an imac.
    Is there a way to run the server reboot remotely?
    Is it time to purchase a new server or simply replace the faulty drive?
    Cheers
    Gaz

    Hi Chaz,
    Is it time to purchase a new server or simply replace the faulty drive?
    I think replace the faulty drive is thw answer.

  • Apple-Installed RAID Failure

    When I bought my G5, I ordered it with the dual 250 GB SATA drives in a raid to create a 500 GB drive. Today, it appears that the RAID has failed and the computer will not boot properly. Well, rather it starts up, is fine for about 5 minutes, and then everything shuts down.
    Using disk utility while booting from the (apparently) damaged drive does not reveal any errors because the drives seem to work fine until the crash. However, I installed 10.4.6 on an external drive, and while the RAID is recognized for about a minute after startup, it just quits and I get the device removal warning. After the RAID quits, running disk utility reveals that one of the disks has "Failed" and the other is "Offline."
    I have tried resetting the PRAM and starting up in Safe Mode, but neither succeeded in solving the problem. Is it possible to correct the error without losing data? Is there a way of at least stabilizing it long enough so that I can retrieve important data (because like an idiot, I didn't backup)?

    Well I went into an Apple Store, and the only advice that they were able to give me was to try Prosoft's Data Rescue II, although none of the Geniuses had ever used it so they really didn't know if it would work.
    As it turns out, if the controller is stable enough, Data Rescue can actually recover data from it. So I got myself a 500 GB external hard drive and ran drive clone (which simply copies the data from one drive to another) and the program didn't show any errors! There is the slight problem that the 500 GB drive that I got was about 1.4 gigs short of the internals, but I'll be pretty darn happy if I can keep 99.6% of my data!
    Unfortunately the clone drive isn't mounting, but I assume that's either because the drive was not formatted, or because of that missing 1.4 GB. However, I do have a large internal drive that I can restore to from the clone drive, so I'm hoping everything will work out.

  • WAE 674 RAID Failure

    I replaced the disk in Slot 3, which was defective.  After replacement, the disk showed "Online" in show disk detail within 15 mins of replacement.  This seemed odd, it usually requires more than 1 hour to rebuild a disk.   However, the RAID-5 status showed "Critical".
    When I execute a "disk logical shutdown", reload, then attempt to execute "disk recreate-raid" I get this returned:
    Failed to remove RAID Logical drive. (1,2)
    Controllers found: 1
    A selected physical drive is not available for use.
    Command aborted.
    Failed to create RAID Logical drive. (1,2)
    Please, verify the disk does not contain mounted file system that remain in use.
    Execute the command "(config)#disk logical shutdown" and reload the device before the array is recreated.
    ====================================================================================================
    show disks tech-support>
    Physical Device information
          Device #0
             Device is a Hard drive
             State                         : Ready
             Supported                     : Yes
             Transfer Speed                : SAS 3.0 Gb/s
             Reported Channel,Device       : 0,0
             Vendor                        : IBM-ESXS
             Model                         : ST3300656SS
             Firmware                      : BA49
             Serial number                 : 3QP2B8BF
             World-wide name               : 5000C50016999C98
             Size                          : 286102 MB
             Write Cache                   : Disabled (write-through)
             FRU                           : 43X0805
             PFA                           : No
          Device #1
             Device is a Hard drive
             State                         : Ready
             Supported                     : Yes
             Transfer Speed                : SAS 3.0 Gb/s
             Reported Channel,Device       : 0,2
             Vendor                        : IBM-ESXS
             Model                         : ST3300656SS
             Firmware                      : BA49
             Serial number                 : 3QP2B712
             World-wide name               : 5000C50016990110
             Size                          : 286102 MB
             Write Cache                   : Disabled (write-through)
             FRU                           : 43X0805
             PFA                           : No
          Device #2
             Device is a Hard drive
             State                         : Ready
             Supported                     : Yes
             Transfer Speed                : SAS 3.0 Gb/s
             Reported Channel,Device       : 0,3
             Vendor                        : IBM-ESXS
             Model                         : VPBPA300C3EST1 N
             Firmware                      : A529
             Serial number                 : JLVVUBVC
             World-wide name               : 5000CCA00930C3BB
             Size                          : 286102 MB
             Write Cache                   : Disabled (write-through)
             FRU                           : 43X0805
             PFA                           : No Physical Device information

    Hi James,
    The problem, I believe is here:
    RAID Physical disk information:
      disk00: Ready                      3QP2B8BF    286102 MB
      disk02: Ready                      JLVVUBVC    286102 MB
      disk03: Ready                      3QP2B712    286102 MB
    If you check the output, it says disk01 is missing. One thing we should try is - remove disk03 and put it in place of disk01.
    Further, the disks should be in "online" state, not "Ready" state. This may be hardware problem with RAID controller.
    Anyway, here is the last option we can apply:
    Use the system recovery process, if you can. The steps you may want to perform are step 7: Rebuild RAID. And then Step 8: Install .bin image.
    Let us know how it goes.
    Thanks.

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