Unmountable on new drive/won't format

unRAID OS Version: 6.0-beta14b

Description: Drive replacement unmountable, format option doesn't appear to do anything

How to reproduce: Complicated and might not be repeatable, so this is what actually happened:

An empty drive in the array failed and rather than wait for an RMA replacement, I decided to do a New Config.  At this point, there is no valid parity.

While that was rebuilding, another drive failed with read errors... 

I went to a local store and picked up a replacement drive and ran it through pre-clear.  As I wanted to add that drive to the array to copy the files from the failing drive (reiserfschk showed all was fine but SMART long test failed at 30%), I added it in place of the failed drive. 

unRAID indicated I was doing a drive replacement and I had to confirm that I wanted to bring the array online.  Once this was done, the drive was listed as unmountable, like the failed drive.  In the GUI, it said the drive was unformatted.  I checked to authorize the format and clicked to started it.

Expected results: Drive should be formatted and added to the array

Actual results:  After a second or two after giving the go ahead to the format, the screen refreshes but nothing changes: The drive is still unmountable and unformatted, do I want to format it, etc. 

I stopped the array and changed the drive type to XFS, repeated the steps, same results.

Other information:

syslog attached. Yes, I know there are plugins running, Nerd Tools and Emby Server (this is not installed/configured). I really only meant to provide this as a ''this is weird" alert versus what is expected here, an easily repeatable error, because I'm not sure it is.  Hopefully there is something in the log that will help improve the product.

FYI: Original on-going post regarding the two drive failure: http://lime-technology.com/forum/index.php?topic=39214.0 if more detail is required

I'm thinking I need to use New Config again to get things back on track in the meantime.

Update: I stopped the array and used New Config.  After re-assigning all of the drives in the same positions, I restarted the array.  It then came up that the drive was still unmountable and yet started a parity rebuild anyway.  I stopped the parity rebuild and used the format function.  This time it actually worked and started formatting the drive.

...Donovan

syslog.zip