Problem with creating array

> it does detect it on controller initiation.

Even when the drive is not spinning, it will identify itself (manufacturer, capacity) when queried. So, it's possible that it "checks-in", but files/directories on it cannot be read.

Depending on the RAID setup you have for your server. Best thing to do is search for "Dell Open Manage" software for your server and install it https://www.dell.com/support/home/us/en/04/drivers/driversdetails?driverId=R108443&osCode=WNET&productCode=poweredge-4400. Once installed it will give you all the information about your hardware. you should b able to rebuild RAID with same size drive if previous drive is bad, RAID will build automatically and take a long time to complete,

You will not be able to increase the hdd size of a raid array, it's size is set. If you need more storage, you can add additional drives ( either in raid or standalone ) and use the new drive(s) for storage, but the original array will remain unchanged. The other option is to back up all of your data, install new drives and create a new array.

Did you experience a power event? Go to BIOS (F2), and make sure that RAID is Enabled. If RAID got turned off (power event, BIOS reset), then it will give you that message. If RAID is already enabled, then you may need to repair your operating system. If something else happened (drive failures, drives removed, etc.), then the array may be completely gone. Call Data Recovery services if it is critical you retreive the data.

Have you used SCSI drives? I think it should have 80 pins. What was the SIZE of the HDD? You must have the EXACT SAME SIZE for all the Available Hard Drives. Its RAID. You must install (2 or 3 or what ever the number) hard drives with exact the same capacity. IF you have used/ are using 40 GB then you have to use the exact same size. You cannot CHANGE the Size. Then the Raid Array will Fail. If you are using RAID 5 or any similar technology then No Chance.
And you must Launch the "Rebuild Array".
If you have errors while Rebuilding: I would suggest updating the firmware on the remaining drives as there may be an issue with SCSI timeout errors that caused your disk to fall off its array.
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Yes and No..

The standard machine only allows SCSI, (no IDE or SATA or SAS connectors...

However SCSI drives are not cheap.. so

To overcome the power issue (you will notice there are no 4 pin molex connectors, or sata power connectors). However there is a 4 pin molex socket on the SCSI backplane. You can use one of those molex adaptor cables (one connector to many) to get power, from the molex you can use a 4 pin to SATA power connector.

Next step is to decide the drive you want to use. I personally use SCSI, SATA, SAS and IDE in mine (overkill I know).

Cheapness says use IDE or SATA. You can get a pci IDE/SATA controller card on ebay dirt cheap (PCI cards are compatible with the large PCIX slots), they dont take the entire "socket" up but they work (be carefull here, there is one 5v pci socket on these machines, and 6 pcix sockets, the pcix sockets will accept 3.3v pci cards (look at the notches).

Next you have to mount them, with a bit of jiggery pokery you can feed the IDE/SATA cables past the SCSI backplane into the hot swap bay. (If you dont have any empty caddy's pick them up off ebay), just remember you cant just pull em out like you can with the SCSI's!) - or use one of the 5 1/2 media bays.

Plud the other ends into the appropriate controller card (as installed in the PCI bus).

Load up the OS, install drivers (if needed - these should come with the pci card(s), use the disk manager to initialise/first format the drives etc.

All done.

I have done this myself running a 2600, with 2X U320 72gb SCSI (on Raid) 1 x IDE CD/DVDRW in Media bay, DAT 27 SCSI (channel B) in the second media bay. 2x 146gb SAS on a DELL SAS pcix card (in 2 of the hot swap bays) and an old 160gb IDE HDD (Funilly enough theres a bit towards the back of the two fans on the SCSI backplane that if you press the 3 1/2 drive against seems to fit perfectly in this place and stay there! (I think thats fluke to be honest).

All done :)

What is your configuration is it Raid or Scsi?If its Raid you may need to re-create the Raid Array.Enter the Raid Array if this is the case make sure the drives are all on line.If its Scsi you may need to check the boot Drive.You may need to provide some more information in order for me to help you.

Its called the JBOD RAID option - just a bunch of discs.

I don't know of any system that makes a RAID array an operational imperative, I would say the answer to your question is yes.

RTFM.

if you are using raid go into the perc hardware utlity as it boots,try formating the drive there.maybe this will work.If you are using the dell open manage software you can probably format it there in windows.If you are not using raid enter the scsi utlity and do a format there.
Good luck

I think you need to provide heaps more info, like what operating system etc.. Have you tried to change the interface to another port eg if IDE, then move the cable to the secondary or if sata test the drive with another cable/port.. Have you tested the drive in another computer? OK, if it's scsi, then does the drive need a termination? Most scsi drives need a dongle or a terminator to allow them to be recognised.