is the USB corrupt all of a sudden? initially it said RAID failure on the BIOS but now it just starts to load then screen goes blank.. no bios issues.

I have also created a new usb and that loads ok but it doesnt have my configuration, i copied over the config folder to the new usb from my old usb but it still just does the same thing?

Try copying the config files one or a few at a time to see if you can find culprit, or copy just the essential, like the key, array and pool assignments, docker user templates and if it still works configure the rest.