I am having problems with the RAID array that holds all my media.  It is a
RAID 5 array with 8 1 TB drives, hosted on an Areca 1220 controller.  I have
about 6.2 TB of music, movies, TV shows, and photos on there.

On Friday I got a message that the drive on channel 3 had failed and the
array was degraded.  I got a replacement drive today, powered off the
machine, inserted the replacement drive, and powered up.  I went into the
RAID management software, set the new drive as a hot spare, and it started
rebuilding.  I watched it get to about 9% done and then went away and did
something else.

Coming back, I saw that the RAID management software now listed channel 3 as
failed again (the new drive).  Puzzled, I popped the old "failed" drive into
my other machine and it spun right up.  I was able to format it and see it
in windows no problem.

I powered off the machine, re-attached the old drive, and powered it back
on.  During boot, the RAID card BIOS says that no RAID array is detected.
 Now is where I start to get scared.  I power off, put the old drive back
in, and power on.  Now it detects the array, still in degraded state, but
says that Channel 4 is the bad drive.  I did not change any cables around.

Advice on what to do?  I really, REALLY do not want to lose this array and
all my data.  It would take me a long time to recover it all.  At this point
I am concerned that maybe the RAID card itself is bad, or maybe some bad
cables, or a bad power supply who knows.  But with a RAID 5 array that
already has a bad drive, I am hesitant to start troubleshooting that might
cause another drive to fail and I lose everything.

I guess an option would be to build a completely new system using another
storage architecture, like unRAID, which is what I was planning to do in
another year.  That's really the only way I can think to get my data to
safety.  But I don't want to spend that money/time now if I can at all help
it.

---
Brian

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