MaxAttach NAS 4000 Series OS 2.2 Hard Disk Drive Replacement

MaxAttach NAS 4000 Series MaxAttach NAS 4000 Series OS 2.2 Hard Disk Drive Replacement DOCUMENT OVERVIEW Who Should Use This Instruction Set This MaxAttach NAS 4000 Series by Maxtor HDD Replacement Instruction Set is intended as an important aid in identifying, and successfully replacing a specific failed drive. Document Applicability Use this replacement procedure only for the following systems: MaxAttach NAS 4000 Series Microsoft Windows-Powered O/S version 2.2 WARNING Back up all your user data before using this procedure. Failure to follow the steps in this procedure may result in loss of all user data, locking up the system, or both. Be sure of your failed disk diagnosis before attempting any replacement procedures. Important Warnings The procedure involves replacing a disk drive that is a member of a redundant array of independent disks (RAID), specifically a RAID 5 array which uses spanning and parity writing to provide enhanced data protection features in the case of a SINGLE disk drive failure. WARNING Failure to exactly follow this procedure can lead to the loss of all user data, system re-boot failure, or both. General Recommendations The following recommendations will assist you in diagnosing and replacing the correct failed drive: Read and understand this procedure completely before starting any work. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 1 Part Number: 000001844

Follow the procedure steps exactly. Once the cover is removed from your system, clearly mark all drives with their physical drive number. When viewed from the front of the chassis, the drives have the following physical, logical and RAID 5 definitions: First drive on the left - Primary Slave Drive 1 - PS-D1 Second drive on the left - Secondary Master Drive 2 - SM-D2 Third drive on the left - Primary Master Drive 0 - PM-D0 Fourth drive on the left - Secondary Slave Drive 3 - SS-D3 Use the Identify Disk utility to determine which drive has failed or is missing from the array. Perform all prerequisite steps before physically removing the drive from the chassis. Replacement drives must be the at least the same size as the failed drive. However, during the RAID rebuild process, a larger drive will be automatically re configured to match the smallest drive in the array so that all drives end up being the same size. Make sure the jumpers on the replacement drive match those on the failed drive. Keep the failed drive in a safe place until you have completely restored the system to correct operation and all data is verified as complete. Perform all post installation reconfiguration steps as required. If in doubt, call for technical support. IdentifyDisk.Exe Utility Requirements The IdentifyDisk.Exe utility is used to identify missing physical disks from the system arrays. Running from a DOS shell, it will identify all found and all missing disks. Utility Name: Identify Disk Utility File Name: IdentifyDisk.Exe Available On: Your system located at C:\Drivers http://www.maxtor.com/products/maxattach/downloads/downloads.htm Download to your client administration system and/or to a floppy disk. Disk Replacement Requirements MaxAttach NAS 4000 Series Microsoft Window-Powered O/S Revision 2.2 Replacement hard disk drives should be the same model number or same same or higher drive capacity as the failed drive. Disk Array Configuration Requirements These replacement instructions are only applicable for restoring your MaxAttach NAS 4000 Series to its originally installed configuration of RAID 5 - Striping with Parity Checking (Redundant MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 2 Part Number: 000001844

Array of Independent Disks), and DOES NOT cover other user determined configurations such as JBOD (Just A Bunch of Disks), RAID 0 - Striping, or RAID 1 Mirroring. WARNING If you have re configured your array to another RAID method such as RAID 0, RAID 1, RAID 0+1, or JBOD, stop and do not continue this procedure. Instead, call technical support for additional information as to the best way to proceed. The MaxAttach NAS 4000 Series contains four internal disk drives. To determine the drive size of your MaxAttach NAS 4000 Series, check the model number on the label of one of the installed drives. Make sure the replacement drive has at least the same or higher drive capacity as the failed drive. Make sure the new drive has the jumper settings as the failed drive. Document Conventions All descriptions of drive locations are when viewed from the front of the unit. All mouse clicks are left-clicks unless otherwise specified as right-clicks. Objects of user actions taken by the user are in bold face such as click on the OK button. The names of screens, windows, figures, and dialog boxes are in italics such as the Disk and Volumes Status screen appears. Commands typed in the user, usually in a DOS shell interface, are entered as Courier text as in to find the IdentifyDisk.Exe utility, type dir at the C:\> prompt. IDE Interface Configuration of the drives is displayed in the figure below. The board uses the ATA-100 controller on the south bridge. This model has two IDE connectors along the edge of the motherboard. Effectively, the edge of the motherboard supports data. Each drive gets data from this motherboard connector with two identical sets of data cables. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 3 Part Number: 000001844

POWER SUPPLY FRONT PANEL Figure 1: MaxAttach NAS 4000 Series Hard Disk Drive Interface Configuration From Front Internal Disk Array Architecture The factory default disk drive configuration has the following parameters: There are three logical volumes: C:\, D:\, and E:\. Logical volumes C:\ and D:\ are reserved for the operating system (O/S). Each O/S volume is spread across two physical drives. Each O/S volume resides in a partition separate from the user data. Each O/S volume is configured as a RAID 1 (Redundant Array of Independent Disks type 1 array) mirrored array. Logical volume E:\ is available for user data. The user data volume is spread across a larger partition on all four physical drives. The user data volume is configured as a four drive RAID 5 array which is a multi disk striping with parity check array. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 4 Part Number: 000001844

The figure below shows the arrays. Figure 2: MaxAttach NAS 4000 Series O/S Version 2.2 HDD Internal Disk Array Architecture HDD FAILURE MODES SUMMARY When a disk drive fails on a MaxAttach NAS 4000 Series, the actions of the system BIOS and the operating system (O/S) vary depending on the drive that failed. In general, by following the procedures in this section, you should at least be able to get your system reboot. If the failed drive is the main boot drive, the OS will attempt to switch to another bootable drive. If any of the other drives fails, the O/S will keep the system running and re-bootable and the user data available. In both cases above, the RAID array is said to be in a Degraded where any additional disk failure will lead to user data loss. The table below summarizes drive failure modes and the general necessary actions for recovery. More detailed failure scenarios for each disk are described in the next section. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 5 Part Number: 000001844

Table #1 - Disk Drive Failure Modes System Boot Disk / Remedial Action Required Failed Drive Below Primary Master Drive 0 PM-D0 Primary Slave Drive 1 PS-D1 Secondary Master Drive 2 SM-D2 Secondary Slave Drive 3 SS-D3 Primary Master Drive 0 Fails 1. Three boot attempts from PM-D0. 2. Recovery boot from SM-D2 3. Replace PM-D0 and restore mirror from SM-D2 Primary Slave Drive 1 Fails 1. Normal boot from PM-D0 2. Replace PS-D1 and restore mirror from SS-D3 Secondary Master Drive 2 Fails 1. Normal boot from PM-D0 2. Replace SM-D2 and restore mirror from PM-D0 Secondary Slave Drive 3 Fails 1. Normal boot from PM-D0 2. Replace SS-D3 and restore mirror from PS-D1 For four failure modes above, the general restoration procedure is: 1. Remove the unit from its rack; 2. Replace the failed drive; 3. Identify the new disk with a write signature; 4, Upgrade the new disk to a dynamic disk, 5. Reconnect the new disk to its mirror image; 6. Rebuild the RAID 5 array. For the failure mode below, no physical disk replacement is required. Instead, the O/S partitions on the Master Drives must be re-imaged. Primary Master Drive 0 & Secondary Master Drive 2 O/S Corrupted 1. Three boot attempts from PM-D0 5. Restore O/S to PM-D0 from mirror on SM-D2 3. Recovery boot from PS-D1 2. Three boot attempts from SM-D2 4. Restore O/S to SM-D2 from backup O/S on PS-D1 DETAILED HDD FAILURE MODES Failure Sequence for Primary Master Drive 0 (PM-D0) The BIOSmarks the drive as missing ( bad ). The system will attempt to boot from the Primary Master Drive 0. The BIOS will keep looking for the Primary Master Drive 0 for three tries. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 6 Part Number: 000001844

A Fatal Error ( blue screen of death ) may be encountered during the reboot tries on the Primary Master Drive 0. The error message will probably be INACCESSIBLE BOOT DEVICE. The system will remain locked up for five minutes. It will then attempt to reboot automatically from the Primary Master Drive 0 three times. If this attempt fails, the system will reboot from Secondary Master Drive 2. If a successful boot is obtained, the RAID array is now in critical state and can tolerate the loss of no additional disks without permanent user data loss. The system will continue to boot from the Secondary Master Drive 2. Failure Sequence for Primary Slave Drive 1 (PS-D1) The BIOS marks the drive as missing ( bad ). The BIOS will boot normally starting from the Primary Master Drive 0. If a successful boot is obtained, the RAID array is now in critical state. The loss of another disk drive will lead to permanent user data loss. The system will continue to boot from Primary Master Drive 0. Failure Sequence for Secondary Master Drive 2 (SM-D2) The BIOS marks the drive as missing ( bad ). The BIOS will boot normally starting from the Primary Master Drive 0. If a successful boot is obtained, the RAID array is now in critical state. The loss of another disk drive will lead to permanent user data loss. Failure Sequence for Secondary Slave Drive 3 (SS-D3) The BIOS marks the drive as missing ( bad ). The BIOS will boot normally starting from the Primary Master Drive 0. If a successful boot is obtained, the RAID array is now in critical state. The loss of another disk drive will lead to permanent user data loss. The system will continue to boot from Primary Master Drive 0. IDENTIFY FAILED DRIVE CAUTION Use this procedure if your system is running or you know that it will reboot. If you system will not boot, skip ahead to REBUILD CORRUPTED PRIMARY MASTER DRIVE 0 (PM-D0) and SECONDARY MASTER DRIVE 1 (SM-D2) below on page 34 MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 7 Part Number: 000001844

Identify Drive - Log On 1 Log onto the system. 2 Use an administrator s workstation. Type in the user name and password. Log into the web user interface for the Administration Server Application Figure 3: Logging onto MaxAttach NAS 4000 Series Web User Interface 3 Once the browser appears, navigate to the server. Enter either the server name (if it was modified from the factory default) or the IP address number of the Maxtor appliance into the URL field. For example, use http://ma112581 which are the last six digits of the appliance serial number of 003048112581. The serial number can be any combination of alphanumeric characters. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 8 Part Number: 000001844

Click here to log on Figure 4: Administration Server Application 4 Click on Administer this server appliance. Another logon dialog box will appear. Again type in administrator user name and password. Identify Drive - Run IdentifyDisk.Exe 5 Access the target server through Terminal Services or Web Browser > Maintenance > Terminal Services. 6 Login as Administrator. 7 In Terminal Services, go to Start > Run and type in cmd to enter the DOS Console. Do not use quotes ( ) around the letters. 8 Change the directory to C:\ Type C:\ to change to the C:\ drive. 9 At the C:\> prompt, type IdentifyDisk followed by the <Enter> key to run the utility. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 9 Part Number: 000001844

10 The Identify Disk Utility will display a text screen of information and the status of each drive. Figure 5: IdentifyDisk.Exe DOS Listing Showing All Drives OK 11 A failed drive will be indicated in the display by a Not Ready message. Figure 6: IdentifyDisk.Exe DOS Listing Showing Secondary Master - Drive 2 Not Ready MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 10 Part Number: 000001844

12 If you did not find a failed disk drive after running the IdentifyDisk.Exe utility, your problem is probably not a disk drive failure. Stop. Call customer service. WARNING If you did not find a failed disk drive after running the IdentifyDisk.Exe utility, your problem is not a failed disk drive. Stop this procedure. To continue will risk losing all user data on the drives. Call customer support for your next steps. IDENTIFY CORRECT REPLACEMENT PROCEDURE Once you have determined the failed disk, use the table below to identify the physical location of each disk and the correct replacement procedure. Table #2 - Failed Disk Drive Check List Drives Listed from Left to Right When Viewed from Front Check Failed Drive Logical Name Abbreviation Physical Location Replacement Procedure To Use Primary Slave Drive 1 - PS-D1 First drive from left Go to REPLACE PRIMARY SLAVE DRIVE 1 (PS-D1) or SECONDARY SLAVE DRIVE 3 (SS-D3) on page 28. Secondary Master Drive 2 - SM-D2 Second drive from left Go to REPLACE PRIMARY MASTER DRIVE 0 (PM-D0) or SECONDARY MASTER DRIVE 2 (SM-D2) on page 12. Primary Master Drive 0 - PM-D0 Third drive from left Go to REPLACE PRIMARY MASTER DRIVE 0 (PM-D0) or SECONDARY MASTER DRIVE 2 (SM-D2) on page 12. Secondary Slave Drive3 - SS-D3 Fourth drive from left Go to REPLACE PRIMARY SLAVE DRIVE 1 (PS-D1) or SECONDARY SLAVE DRIVE 3 (SS-D3) on page 28. NOTE The Primary Master Drive 0 and the Secondary Master Drive 2 use the same replacement procedure. The Primary Slave Drive 1 and the Secondary Slave Drive 3 use the same replacement procedure. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 11 Part Number: 000001844

REPLACE PRIMARY MASTER DRIVE 0 (PM-D0) OR SECONDARY MASTER DRIVE 2 (SM-D2) CAUTION Only perform the procedure below if you are replacing the Primary Master Drive 0 or the Secondary Master Drive 2. The Primary Master Drive 0 is the THIRD drive from the left when viewed from the front. The Secondary Master Drive 2 is the SECOND drive from the left when viewed from the front, Prepare for Disk Replacement 1 Back-up your data. Logon to Your System 2 Log onto your system as administrator from an administrator workstation and type in the administrator user name and password. 3 Enter the server name or its IP address number as a URL. The initial server window appears in the browser. 4 Click on Administer this server appliance link. Another logon window appears. 5 Again enter the administrator user name and password. The MaxAttach NAS 4000 Series Home Page appears. PM-D0/SM-D2 - Remove the Mirror 6 Navigate to the Disk Volume Status screen. Click on the Disks and Volumes tab in the primary (top) navigation bar. 7 The Disks and Volumes Page appears. Click on the Disks and Volumes link. 8 Right-click inside the left box of the Missing disk. The failed or missing disk will always be at the bottom of the display. Ignore the drive numbers (e.g. Disk 0, Disk 1, Disk 2) as they have been automatically reassigned when the drive failed. A pop-up menu appears. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 12 Part Number: 000001844

Right Click Here Figure 7:.Accessing the Remove Mirror Menu 9 Select the Remove Mirror option from the pop-up menu. 10 Select the Missing disk. Figure 8: Remove Mirror Dialog Box 11 Click on the Remove Mirror button to remove the missing disk from the menu. NOTE Your MaxAttach NAS 4000 Series can continue operating in this mode until a new hard disk is replaced. However, you may experience some degradation of service. PM-D0/SM-D2 - Shut Down the System 12 Return to the appliance window, and click on the Maintenance tab in the primary (top) navigation bar. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 13 Part Number: 000001844

The Maintenance Page appears. 13 Click on Shutdown in the secondary menu bar or in the Shutdown link on the page. The Shutdown Page appears. 14 Click on the Shutdown link to power down the system. 15 When software has safely shut down, complete the power off procedure. Turn the back panel power rocker switch to OFF or 0. Unplug the power cable. Unplug all communication and network cables. PM-D0/SM-D2 - De-Rack the System 16 De-rack the system, if rack mounted. Undo the rack hardware. Set aside for safekeeping. CAUTION The MaxAttach NAS 4000 Series weighs approximately 25 pounds (11 kilograms). Care must be taken during rack removal to avoid dropping the unit or injuring the repair technician. PM-D0/SM-D2 - Remove the Cover 17 Remove the cover. Undo the two thumb screws from the back of the chassis. A straight blade screwdriver will be required the first time the cover is removed. Back Panel Thumb Screws Figure 9: Back Panel Thumb Screws MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 14 Part Number: 000001844

18 Slide the cover backwards to release the front tongue-and-groove flanges of the cover from the front plate then lift up the back of the cover, as shown in the figure below. CAUTION Always wear a wrist strap to avoid static discharge when working with electronic components. Back Panel Front Panel Figure 10: Lifting the Cover from the Back 19 Identify the hard drive disk numbers. Consult the label on the chassis for drive identification. There are two hard disk drive holders, each holding two of the four drives. ------- Disk 1 -------- Disk 2 -------- Disk 0 -------- Disk 3 ------- Disk Drive Holders (2 each) Disk Drive Mounting Screws (4 per drive) Figure 11: Front View of Disk Drives MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 15 Part Number: 000001844

NOTE You should mark the drive numbers on the disk drive holders to help you eliminate replacement errors. PM-D0/SM-D2 - Remove the Failed Drive 20 Remove the cables. Remove the data cable connector and the power connector from the back of the hard disk drive. NOTE Regardless of configuration, each hard disk drive has the same connector cables. There are two ribbon cables for data (ATA-100) and four sets of wires for HDD power (4-pin, Molex standard). 21 Remove the data cable connector and the power wire connector from the back of the hard disk, as shown below. Disk 1 ----- Disk 2 ------ Disk 0 ------ Disk 3 Data Cable Connector Power Wire Connector Figure 12: Data Ribbon Connector and Power Wire Connector 22 Remove the failed disk drive from the chassis. Remove the front to back ribbon cable. Remove the four screws holding the disk drive cover over the disk drive. Remove the two nuts securing the drive holder to the chassis. It should not be necessary to remove the fan connector cable. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 16 Part Number: 000001844

Disk 1 ---- Disk 2 ---- Disk 0 ---- Disk 3 Remove four screws for each drive Remove Ribbon Cable Remove Nuts Securing Holder to Chassis Figure 13: Disk Drive Holders and Drive Mounting Screws 23 Remove the failed disk drive. Tip the drive holder up and carefully remove the drive. Set the drive safely aside until the replacement process has successfully completed. You should mark the failed drive to easily identify it. Disk 1 ---------- Disk 2 ---------- Disk 0 ---------- Disk 3 Figure 14: Tipping Holder and Sliding Disk Drive Out MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 17 Part Number: 000001844

NOTE Note any drive jumper settings on the removed drive. Change the jumpers on the replacement drive to match the removed drive. WARNING DO NOT DISCARD THE FAILED DRIVE. Clearly mark the failed drive as to its logical identity and physical location in the chassis. Keep it safely stored until the replacement procedure has successfully been completed and your MaxAttach NAS 4000 Series has returned to production. PM-D0/SM-D2 - Install the Replacement Drive 24 Match the replacement drive jumper settings to the failed drive jumper settings. Inspect the failed drive for jumper settings. Change the jumpers on the replacement drive to match. Make sure the replacement drive jumpers match the failed drive jumpers. 25 Replace the failed drive. Tip the holder upward on an angle. Slide a new hard disk drive into the holder. Return the holder with the hard disk drive back into the enclosure. Fasten the four screws holding the disk drive to the holder. See Figure #14 - Tipping Holder and Sliding Disk Drive Out on page 17. 26 Reconnect internal cables. Connect the data cable connector and the power wire connector to the back of the hard disk drive, with the red stripe on right. NOTE The power wire connector is notched to fit in the proper orientation. The data cable connectors are folded to easily place them in the proper orientation. PM-D0/SM-D2 - Prepare System for Reconfiguration 27 Reconnect the unit s network and power cables. 28 Power up the system. 29 The system should reboot. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 18 Part Number: 000001844

Return to your administrator s workstation. PM-D0/SM-D2 - Log Onto Your System 30 Return to your administrator s workstation and log onto your system as administrator. For procedure detail, see Logon to Your System on page 12. PM-D0/SM-D2 - Write Signature and Upgrade Wizard 31 Select Disks and Volumes from the primary (top) menu bar. The Write Signature and Upgrade Disk Wizard appears. Figure 15: Write Signature and Upgrade Disk Wizard - Step 1 - Welcome Screen 32 Click on the Next button on the opening screen. The Select Disk to Upgrade screen appears. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 19 Part Number: 000001844

Figure 16: Write Signature and Upgrade Disk Wizard - Step 2 - Select Disks to Upgrade 33 Select the disk you want to upgrade: If you replaced the Primary Master Drive 0, select Disk 0. If you replaced the Secondary Master Drive 2, select Disk 2. 34 Click on Next. The Completing the Write Signature and Upgrade Disk Wizard screen appears. 35 Verify that you have selected the correct disk to upgrade. If you replaced the Primary Master Drive 0, you must upgrade Disk 0. If you replaced the Secondary Master Drive 2, your must upgrade Disk 2. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 20 Part Number: 000001844

Figure 17: Write Signature and Upgrade Disk Wizard - Step 3 - Completing the Write Signature and Upgrade Disk Wizard Confirmation Screen 36 Click on Finish to start the disk write signature and upgrade process. A write signature will be added to the drive. A write signature is a Windows 2000 procedure to a write a unique random number to the disk so that the O/S can recognize it as part of the dynamic disk pool. The disk will then be upgraded to a dynamic disk. Windows 2000 requires the dynamic disk attribute to create Mirrored, Spanned, Stripped, and/or RAID 5 disk arrays. PM-D0/SM-D2 - Re-Mirror the Drives 37 After the Write Signature and Upgrade process has completed, the Disk Volume Status screen appears. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 21 Part Number: 000001844

Figure 18: Disk Configuration Screen After Write Signature and Upgrade 38 Right-click the remaining mirror volume to reestablish the mirror between the two Master Drives. If you replaced the Primary Master Drive 0, right-click on the Disk 2 mirror. If you replaced the Secondary Master Drive 2, right-click on the Disk 0 mirror. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 22 Part Number: 000001844

A pop-up menu appears. Figure 19: Add Mirror Volume - Step One - Pop-Up Options Menu - Select Add Mirror 39 Select the mirror target, which is the drive you replaced. If you replaced the Primary Master Drive 0, select Disk 0. If you replaced the Secondary Master Drive 2, select Disk 2. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 23 Part Number: 000001844

Figure 20: Add Mirror Volume - Step Two - Add Mirror Dialog Box - Select Replaced Disk 40 Click on the Add Mirror button. A Disk Management dialog box appears. 41 Click OK. Figure 21: Add Mirror - Step Three - Disk Management Dialog Confirmation WARNING Do not change the Boot.ini file. 42 The MaxAttach NAS 4000 Series will automatically regenerate the mirror. This operation may take several minutes to completely add the mirror for the new disk. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 24 Part Number: 000001844

PM-D0/SM-D2 - Cross Check 43 Navigate to the Disk Volume Status screen and click on Disks and Volumes. The Disks and Volumes Page appears. 44 Click on the Disks and Volumes tab. 45 Check for four good disk drives. PM-D0/SM-D2 - Regenerate the RAID 5 Array 46 Navigate to the Disk Volume Status screen. 47 Right-click on any RAID 5 volume. A pop-up menu appears. RAID 5 volumes are indicated with blue stripes. Figure 22: Repair RAID 5 Volume - Step One - Right Click on a RAID 5 Volume - Pop-Up Menu for Repair Volume 48 In the pop-up menu, click on Repair Volume. The Repair RAID-5 Volume dialog box appears. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 25 Part Number: 000001844

Figure 23: Repair RAID-5 Volume - Step Two - Repair RAID Dialog Box 49 Click on the disk to begin to repair the RAID 5 volume. If you replaced the Primary Master Drive 0, select Disk 0. If you replaced the Secondary Master Drive 2, select Disk 2. 50 Click on OK to start the RAID rebuild process. The RAID rebuild process will take between 5 and 7 hours to complete. 51 When the RAID rebuild process is complete, the Disk Status Completion screen will show a successful rebuild with four healthy disks in the RAID 5 array. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 26 Part Number: 000001844

Figure 24: RAID 5 Volume Successfully Repaired 52 Reboot the system. 53 Once your unit fully reboots, logon to the system as normal. For procedure detail, see task steps in Logon to Your System on page 12. The MaxAttach NAS 4000 Series Home Page appears. PM-D0/SM-D2 - Final Check 54 Navigate to Disk Volume Properties. You should see all four drives. You can also rerun the IdentifyDisk.Exe utility. 55 Shut down the system. 56 Disconnect all power, network, and test cables. 57 The replacement procedure for the Primary Master Drive 0 or Secondary Master Drive 2 is complete. 58 Return the MaxAttach NAS 4000 Series to production by concluding with the section titled RETURN THE UNIT TO PRODUCTION on page 36. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 27 Part Number: 000001844

REPLACE PRIMARY SLAVE DRIVE 1 (PS-D1) or SECONDARY SLAVE DRIVE 3 (SS-D3) CAUTION Only perform the procedure below if you are replacing the Primary Slave Drive 1 OR the Secondary Slave Drive 3. The Primary Slave Drive 1 (PS-D1) is the first drive on the left when viewed from the front, The Secondary Slave Drive 3 (SS-D3) is the fourth drive from the left when viewed from the front. PS-D1/SS-D3 - Prepare for Replacement 1 Back-up your data. PS-D1/SS-D3 - Remove the Mirror 2 Log onto your system as administrator. For procedure detail, see task steps in Logon to Your System on page 12. 3 Navigate to the Disk Volume Status screen. For procedure detail, see page 12 - Step #6 - Navigate to the Disk Volume Status screen. 4 Click on the Disks and Volumes link. 5 Right-click inside the box of the Missing disk. See Figure #8 - Remove Mirror Dialog Box on page 13. 6 Select Remove Mirror from the pop-up menu. Then select the disk to be removed. 7 Click on the Remove Mirror button to remove the missing disk from the menu. See Figure #8 - Remove Mirror Dialog Box on page 13. NOTE Your MaxAttach NAS 4000 Series can continue operating in this mode, until a new hard disk is replaced, however, you may experience some degradation of service. Also, your RAID array is now in a critical state where any additional failure will result in the loss of all user data. PS-D1/SS-D3 - Shut Down the System 8 Return to the appliance window, and click on the Maintenance item in the primary (top) navigation bar. The Maintenance Page appears. 9 Click on Shutdown in the secondary menu bar or in the Shutdown link on the page. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 28 Part Number: 000001844

The Shutdown Page appears. 10 Click on the Shutdown link to power down the system. 11 When software has safely shut down, complete the power off procedure. Switch off the hard power switch on the back of the unit and unplug the power cable. Unplug all communication and network cables. PS-D1/SS-D3 - De-Rack the System 12 De-rack the system, if rack mounted. Undo the rack hardware and set aside for safekeeping. CAUTION The MaxAttach NAS 4000 Series weighs approximately 25 pounds - 11 kilograms. Care must be taken during rack removal to avoid dropping the unit or injuring the repair technician. PS-D1/SS-D3 - Remove the Cover 13 Remove the cover. Undo the two thumb screws from the back of the chassis. A straight blade screwdriver will be required the first time the cover is removed. See Figure #9 - Back Panel Thumb Screws on page 14. 14 Identify the hard drive disk numbers. Consult the label on the chassis and mark the drive numbers on the disk drive holders. See Figure #11 - Front View of Disk Drives on page 15. PS-D1/SS-D3 - Remove the Failed Drive 15 Remove the cables. Remove the data cable connector and the power connector from the back of the hard disk drive. See Figure #11 - Front View of Disk Drives on page 15. 16 Remove the failed disk drive from the chassis. Remove the four screws holding the disk drive cover over the disk drive. See Figure #13 - Disk Drive Holders and Drive Mounting Screws on page 17. Remove the two nuts securing the drive holder to the chassis. It should not be necessary to remove the fan connector cable. See Figure #14 - Tipping Holder and Sliding Disk Drive Out on page 17. 17 Remove the failed disk drive. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 29 Part Number: 000001844

Tip the drive holder up and carefully remove the drive Set the drive safely aside until the replacement process has successfully completed. It is suggested you mark the failed drive to easily identify it. NOTE Note any drive jumper settings on the removed drive. Change the jumpers on the replacement drive to match the removed drive. WARNING Do not discard the failed drive. Keep it safely stored until the replacement procedure has successfully been completed and your MaxAttach NAS 4000 Series has returned to production. PS-D1/SS-D3 - Install the Replacement Drive 18 Match the replacement drive jumper settings to the failed drive jumper settings. Inspect the failed drive for jumper settings. Change the jumpers on the replacement drive to match. Make sure the replacement drive jumpers match the failed drive jumpers. 19 Replace the failed drive. Tip the holder upward on an angle. Slide a new hard disk drive into the holder. Return the holder with the hard disk drive back into the enclosure. Fasten the four screws holding the disk drive to the holder. See Figure #14 - Tipping Holder and Sliding Disk Drive Out on page 17. 20 Reconnect internal cables. Connect the data cable connector and the power wire connector to the back of the hard disk drive, with the red stripe on right. NOTE The power wire connector is notched to fit in the proper orientation. The data cable connectors are folded to easily place them in the proper orientation. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 30 Part Number: 000001844

PS-D1/SS-D3 - Restart and Installation Check 21 Connect the external power and network cables to the unit. CAUTION Dangerous voltages exist inside the chassis power supply. Use extreme caution when working around the unit with the cover off. 22 Restart the system by pressing the soft power button on the front panel. It will automatically reboot. WARNING If system will not boot, you may have replaced the wrong drive. Stop and call for support. 23 Logon to the system from a client workstation. For procedure detail, see Logon to Your System on page 12. The MaxAttach NAS 4000 Series appears. PS-D1/SS-D3 - Write Signature and Upgrade Wizard 24 From the main navigation bar, select Disks and Volumes. A Welcome Wizard automatically appears. See Figure #15 - Write Signature and Upgrade Disk Wizard - Step 1 - Welcome Screen on page 19. 25 Click on the Next button. The Select Disks to Upgrade dialog box appears. See Figure #16 - Write Signature and Upgrade Disk Wizard - Step 2 - Select Disks to Upgrade on page 20. 26 Select the disk you want to upgrade: If you replaced the Primary Slave Drive 1, select Disk 1. If you replaced the Secondary Slave Drive 3, select Disk 3. 27 Click on the Next button. The Completing the Write Signature and Upgrade Disk Wizard dialog box appears. See Figure #17 - Write Signature and Upgrade Disk Wizard - Step 3 - Completing the Write Signature and Upgrade Disk Wizard Confirmation Screen on page 21. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 31 Part Number: 000001844

28 Verify that the correct disk is to be upgraded. If you replaced the Primary Slave Drive 1, Disk 1 must be selected. If you replaced the Secondary Slave Drive 3, Disk 3 must be selected. 29 Click on Finish to start the disk write signature an upgrade process. For procedure detail, see page 21 - Step #36 - Click on Finish to start the disk write signature and upgrade process. SM2/SS3 - Rebuild the Array Mirror 30 After the Write Signature and Upgrade process has completed, the Disk Volume Status screen will appear. See Figure #18 - Disk Configuration Screen After Write Signature and Upgrade on page 22. 31 Right-click the one drive without a mirror to reestablish the mirror between the target new drive and its original mirror source drive. A pop-up menu appears. See Figure #19 - Add Mirror Volume - Step One - Pop-Up Options Menu - Select Add Mirror on page 23. 32 Select the Add Mirror menu option. The Add Mirror dialog box appears. See Figure #20 - Add Mirror Volume - Step Two - Add Mirror Dialog Box - Select Replaced Disk on page 24. 33 Select mirror source. If you replaced Primary Slave Drive 1, select mirror source Disk 3. If you replaced Secondary Slave Drive 3, select mirror source Disk 1. 34 Click on the Add Mirror button. A Disk Management dialog box appears. See Figure #21 - Add Mirror - Step Three - Disk Management Dialog Confirmation on page 24. WARNING Do not change the Boot.ini file. 35 Click OK to start the mirror regeneration process. The MaxAttach NAS 4000 Series will automatically regenerate the mirror. This operation may take several minutes to completely add the mirror for the new disk. PS-D1/SS-D3 - Cross Check 36 Navigate to the Disk Volume Status screen and click on Disks and Volumes. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 32 Part Number: 000001844

The Disks and Volumes screen appears. 37 Click on the Disks and Volumes link and check for correct indications of four healthy drives. WARNING If system now shows two failed drives, you may have replaced the wrong drive. Stop and call for support. PS-D1/SS-D3 - Regenerate the RAID 5 Array 38 Navigate to the Disk Volume Status screen. RAID volumes are indicated with blue stripes. 39 Right-click on any RAID 5 volume. The pop-up menu appears. See Figure #22 - Repair RAID 5 Volume - Step One - Right Click on a RAID 5 Volume - Pop-Up Menu for Repair Volume on page 25. 40 In the pop-up menu, click on Repair Volume. The Repair RAID-5 Volume dialog box appears. See Figure #23 - Repair RAID-5 Volume - Step Two - Repair RAID Dialog Box on page 26. 41 Select the newly replaced disk. If you replaced the Primary Slave Drive 1, select Disk 1. If you replaced the Secondary Slave Drive 3, select Disk 3. 42 Click OK to start the RAID 5 rebuild process. The RAID 5 rebuild process will take between five and seven hours to complete. When the process is complete, the Disk Status Completion screen will show a successful RAID 5 array rebuild with four healthy disks. See Figure #24 - RAID 5 Volume Successfully Repaired on page 27. 43 Reboot the system when the RAID 5 array has been successfully regenerated. 44 Logon to the server as normal. For procedure detail, see Logon to Your System on page 12. The MaxAttach NAS 4000 Series Home Page appears. PS-D1/SS-D3 - Final Check 45 Navigate to Disk Volume Properties where you should see all four drives. You can also rerun the IdentifyDisk.Exe utility. 46 Shut down the system and disconnect all power, network, and test cables. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 33 Part Number: 000001844

47 The replacement procedure for the Primary Master Drive 1 or the Secondary Master Drive 2 is complete. 48 Continue with RETURN THE UNIT TO PRODUCTION on page 36. REBUILD CORRUPTED PRIMARY MASTER DRIVE 0 (PM-D0) and SECONDARY MASTER DRIVE 1 (SM-D2) NOTE Use this procedure when your system will not boot from either the Primary Master Drive 0 or from the Secondary Master Drive 2. PM-D0/SM-D2 Corrupted - Symptoms of Corrupted O/S Although not a direct hard disk drive failure, a corrupted O/S on both the Primary Master and the Secondary Master will keep the system from successfully failing over to the back up O/S image stored on the Primary Slave Drive 1 and Secondary Slave Drive 3 unless the system is rebooted at least six times. The symptoms of a corrupted O/S are any of the following: The system will hang up during boot. The administrator will see the blue Fatal Error Screen ( blue screen of death ). The administrator will see a frozen progress bar. NOTE The system will reboot itself after the symptoms above appear for five minutes. PM-D0/SM-D2 Corrupted - Obtaining a Reboot 1 The recovery technique used is to get the automatic fail over capability to eventually boot the system from backup O/S and restore Primary O/S with last good backup Primary O/S image. The last good backup Primary O/S image located on the mirrored backup O/S volume (Primary Slave Drive 1 and Secondary Slave Drive 3). 2 After the recovery is finished, the system will reboot itself from the Primary O/S. NOTE Refer to online help for more detailed instructions. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 34 Part Number: 000001844

3 If the recovery mode is manual or Primary O/S restoration fails, the system will boot from the backup O/S and wait for instruction. PM-D0/SM-D2 Corrupted - Log Onto to the System 4 Log on to the system through Terminal Services or Web Browser. 5 Click on Restore original factory shipped image if you log on using the Web user interface. Click on the Restore Factory Reset desktop icon if you log on using Terminal Services. Figure 25: Restore Factory Reset Desktop Icon for Return to Default Configuration 6 A DOS shell screen appears. Restore Factory Reset desktop icon MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 35 Part Number: 000001844

Figure 26: DOS Shell Window for Return to Default Configuration 7 The recovery of the corrupted O/S disks is automatic from this point on: A Drive C:\ Quick Format message will appear. A good image will be written from the Primary Slave Drive O/S partition on logical drive D:\ to the Secondary Master Drive 2 O/S partition on logical drive D:\. The Secondary Master Drive 2 on logical drive D:\ will mirror its O/S image to the Primary Master Drive 0 on logical drive C:\. The DOS shell window will close. 8 Manually reboot the system to reboot from logical C:\ again. NOTE All previous settings that have been created such as Users, Groups, and Shares will not be available. WARNING If the system will not reboot after following the procedures above, it is likely that your problem is not a failed drive. Call for technical support. RETURN THE UNIT TO PRODUCTION 1 Use this procedure for all disk drives. 2 Replace the cover and tighten the two thumb screws. 3 Return the system to its rack or production location. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 36 Part Number: 000001844

Replace your MaxAttach NAS 4000 Series unit to its rack mounting configuration, if equipped. Connect all communication and network cables to the back panel. Plug the unit into its power source. Make sure the main power switch on the back panel is returned to the ON position. 4 Power the MaxAttach NAS 4000 Series on by pressing the soft power button on the front panel. The system will automatically reboot. 5 The disk drive replacement procedure has been successfully completed. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 37 Part Number: 000001844

2001-2002 Maxtor Corporation. All Rights Reserved. Maxtor is a registered trademark of Maxtor Corporation. MaxAttach and MaxNeighborhood are trademarks of Maxtor Corporation. Other product names, company names and logos are trademarks or registered trademarks of their respective owners. Specifications subject to change without notice. This publication and the content herein may be revised without any obligation to notify any person of such revision. MaxAttach NAS 4000 Series OS 2.2 HDD Replacement 38 Part Number: 000001844