I had a failed data disk.  I purchased a new replacement disk, ran 3 successful preclear cycles, swapped disks.  Now I am getting a red ball and "disk wrong" instead of an expected blue ball.

 

detailed sequence of my steps:

 

1.  data disk failed.

2.  powered down unRAID Server and purchased new replacement disk.

3.  with unRAID Server powered down, I unplugged all existing disks in the 5-in-3 hot swap bays (pulled out an inch) to keep them from spinning during the preclear cycles for the new disk.

4.  plugged in new data disk to 5-in-3 bay (new data disk was only disk connected to motherboard).

5.  powered up unRAID Server and ran 3 successful preclear cycles on new data disk.

6.  powered down unRAID Server and plugged in (re-seated) all disks, with new data disk in place of the previously failed disk.

7.  powered up unRAID server.  I expected to be able to select the new data disk (as Disk 1) and get a blue ball.

 

Screenshots and syslog attached.  What would be the next step?

syslog-2015-06-21_b.zip

I think you missed a step?

 

At this point the way forward would be:

• Stop the array and unassign the problem disk
  
• Start the array again.  It should now say the disk is missing
  
• Stop the array and assign the disk again.    This time you should be told that starting the array will start a rebuild onto the replacement disk
  
• Start the array and the rebuild should start.  When it completes you will be back in a protected state.  You should still be able to access its contents even while the rebuild is in progress as unRAID will be emulating it from the combination of the other disks plus parity
  

My guess is that for some reason unRAID never realised the disk was being replaced (because you never forced the 'missing' state) which is why it is now complaining about the wrong disk.

Thanks itimpi.

 

After reading your response and more thought of my sequences,  I believe I never did "un-assign" the failed data disk before stopping the array and initiating a clean shutdown.  I tried reinserting the failed data disk but all I get is a lot of beeping from the disk, unRAID is unable to see the failed data disk even when its plugged into a hot swap bay, the failed disk is totally dead.

 

Like you said, I think the problem is unRAID never was told the failed data disk was being taken out of the array.

 

With Disk 1 (failed data disk slot) unassigned, I saw this message on the Array Status page (screenshot attached) "Start will disable the missing disk then bring the array online.  The disks data will be available, but the array will be unprotected; install a new data disk as soon as possible."

 

I clicked "yes I want to do this" check box and started the array.  The missing (failed) data disk was then disabled (forced the "missing" state).  I was able to then stop the array, assign the new data disk (with a blue ball) and start the array to begin the data disk rebuild process.

 

Thank you for your assistance!!