Thanks for responding.
3 x Hitatchi HDS721010KLA330 and 1 x Samsung HD103UJ. I know that mixing vendors is not ideal..
I've been using the 'maximum size' setting with the web GUI and also tried using a full 3 TB setting of 3145728 and smaller sizes such as 3135242, - this fails too, as does trying raid 6.
Have you checked and compared the firware revisions (version on drive vs. the version listed in the
compatibility list)?
Hitachi = KAOA70M
Samsung = 1AA01108
I should warn you, Hitachi is a PITA about firmware. They won't give you a link. You'd have to get it from Highpoint. Not as sure with Samsung's support in this case.
BTW, have you set the truncation?
As you've mixed drives, this would be a good idea to set it at 1G.
SAS controllers are rather picky about SATA drives, as the recovery timings are set differently on consumer models than enterprise (0,0 vs. 7,0 respectively). Some consumer models will work, but the firmware revision will make or break you. If these where WD drives, you can set the values with a utility, but I've never been able to get/find them from other drive makers. They want to force you to buy the RAID models afterall...
As this is such a problem (stability), I've always recommended using enterprise RAID drives when using RAID. Hardware or software based, though with hardware, it's even more important, as the recovery is handled by the RAID card, not the OS. They can be a tad slower, but they're built to be more reliable, and more importantly, stable when used in a RAID environment.
Running in mixed mode (different drives by different manufacturers) may also be the culprit here, but check the firmware revisions first.
If they both happen to be correct (you may need to contact Highpoint, as anything newer usually works as well, but not always), you could try removing the Samsung from the set, and see if it will build with the 3 Hitachi's.
It's just an idea (and a very likely source of the problem),
but check the firmware first.

Assuming all 4 drives have the correct firmware, then see if it's the mixed drive environment (pull the Samsung).
If you're in the position you can return the drives, I'd truly recommend this, and get 4 WD RE3 1TB models (WD1002FBYS). These are enterprise RAID models, and are on the Compatibility List.
Let me know how you get on with this, and good luck.
