Hi Robert,

I don't know about

that the HBA driver loads the firmware onto the drives?

I've updated HP drives firmware and fixed strange problems. Didn't know they were Hitachi drives.
  I've tried the harddrive vendor (Hitachi), but they don't
release firmware updates.

I reduced the size of the array to 4x2Tb RAID10 (4Tb redundant).
Perhaps I'll try a smaller size to see if I have the same problem.
The easiest way to replicate the problem is to run hdparm -t /dev/sda
I get about 400kB/s on the problem RAID.

Suggest doing a small raid 5 array (10gb) with 3 drives. Does this work?

Could be a faulty drive or the large size has a bug. If it does not work as a small array it won't work as a large one.
Ben

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