What RAID level is this, RAID0? (Sorry if I missed it in the post.)
I'd:
- check the cabling first, replace it
- reset the controller CMOS to defaults
- check the drives individually (bench each one, bench a couple in RAID0)
- try to get a replacement controller and see what happens.
From the look of it, cabling is the first suspect, the controller - number two.
Alex Gerulaitis
Systems Engineer
DV411 - Los Angeles, CA