I have a 3ware 9650SE RAID controller with a RAID 5 array containing 15 Seagate ST31000340NS disks. After noticing ECC errors in the Port 10 drive I replaced it with a spare and began a RAID rebuild. Part way through the rebuild the Port 5 disk failed completely, which rendered the array inoperable because the new disk in Port 10 was incomplete. The array remained in use during the rebuild until the failure of the Port 5 disk. I hoped to recover the data by putting back the original Port 10 disk, but the RAID controller did not add it back to the array. Instead, it was listed as "available". My question is, how can I force the controller to recognise the original Port 10 disk in its original location? There is no "add disk" option in the 3dm2 interface.
* EXTRA INFO * Thanks for all the comments and suggestions relating to my original posting. I should have mentioned before that the array was mounted read-only during the rebuild. I don't know if that makes any difference to the chances of forcing the controller to accept the original disk back. There isn't a backup by the way. Whatever happens, I have certainly learned my lesson re. RAID5.
Best Answer
I believe you are out of luck. This is one of the dangers of RAID5. Since the array was in use, all the other disks are now out of sync with the original port 10 disk.
updated: Regarding the update read-only mounting...Whether or not this works is really going to be an implementation detail of the 3ware. Even if you mounted read-only, the raid controller could have updated some metadata on the disks and decided this configuration is not recoverable. That's what I would expect.