With the system running and the new disk not inserted, if you insert the new disk (the SS4000 does support hot-swapping disks) can you hear the new disk power up when it is inserted? Does the disk indicator light turn green after about 10 seconds?
If it doesn't power up, that will be a reason for not being recognized. If it does power up and is still not recognized, it could be that the drive itself isn't supported by the SS4000.
You can see a list of supported disk drives for the SS4000 in the Tested Hardware and Operating System List. Unfortunately that list is getting old (February 2008) and many of those drives may no longer be available.
With the system running if I insert the new disk the drive light does not turn green. If it powers up I cannot really tell, being in a server room w/fans and A/C it is hard to tell....I tested the port by moving one of the working disks into it, and yes, it powers up and turns green (then rebuilds the disk because its Raid 5).
I did check the Tested Hardware list, the disk is not specifically on it, however the make, model, p/n lead me to believe that they might fall into the Similar Drive category. I am having a hard time finding disks on the tested list because they seem to be no longer available. I know these disks may not work in the long run, however I would dearly love to have someone tell me how to format the disk so I can be certain that it isn't working BECAUSE the disk won't work, not because its formatted incorrectly.
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You're not going to be able to format the drive independently in the SS4000.
I recommend checking with Seagate to see what tools they have for formatting a disk drive. The Seagate Barracuda Family website has a couple interesting links you might find helpful: The BIOS does not detect or recognize the ATA / SATA hard drive and How Do I Low-Level Format a SATA or ATA (IDE) Hard Drive?
There's also a SeaTools site that may have some of the same information.
Thanks for the advice - I will be reviewing the Barracuda site today, as well as putting out feelers to see if I can lay my hands on some drives that ARE on the Tested Hardware and Operating System List . Between these two I hope to have the SS4000-E running smoothly again soon!