I am also having the same issue with a 1TB Seagate drive.
This has been going on for months now and I've just been ignoring it, even though I've had a constant Critical Error for the last 6 months telling me that "Volume with name DATA has failed. Please check hard drives and try to run Repair to fix errors for disk Seagate ST31000340AS SCSI Disk Device."
Originally I think the problem occurred when I put the 1TB drive in a shelf on my Sonnet D5P eSATA enclosure (pre PP1); turns out that enclosure does not support 1TB drives (my bad; now I have 5 750GB Seagate drives in it working just fine). Since I couldn't add it to the pool I moved it inside the server (Dell PowerEdge SC440) on the Drive 1 channel of the primary SATA controller and have been using it as a server backup drive (since PP1) with no problems whatsoever. I've recently replaced this backup medium with two 500GB USB drives inside a fireproof safe (yes, paranoid), so I've once again been trying to add this disk to the storage pool . . . with no luck. I've spent many hours on this--reformatting it, moving it to other PC's, other enclosures, etc.; I know the drive is fine . . . but the Home Server just won't take it. I have two others of the identical drive (but 6 months newer) installed in an Icy Dock MB561S-4S eSata enclosure and they were ingested to the pool with no problems and work fine (of course I did try the problem drive in the Icy Dock, to no avail). The error message I get when I try to add the drive is:
The hard drive was not formatted
The hard drive was not formatted because it is being used by another program or service. Restart your home server and add the drive again.
Of course I've reformatted, rebooted, etc., countless times. There is no way the drive is being used by another process. For kicks I changed the name of the volume from "DATA" to "STX 1TBA" at one point, and now, in addition to the months-old critical error message noted above for volume DATA, I have another identical critical error for volume "STX 1TBA." (I have a total of 10 other drives in the system with volume name DATA that all work fine; the server is not nor has exhibited any actual errors apart from the normal occasional-but-rare file inconsistency here and there). I have 2.4TB of free space on the server right now.
To further complicate matters, when I physically remove the drive from the server (it is out now), it still shows up in the "Server Storage" tab of the Home Server Console under "Non Storage Hard Drives" with status "Missing;" the good news is the two critical errors referencing non-existant volume failures are gone, replaced by one critical error saying:
Seagate ST31000340AS SCSI Disk Device has failed. Ensure it is connected. If this problem continues, add a new hard drive and then remove the failed hard drive from your server storage using the console.
When I try to remove the drive in the Server Storage tab, I get the error message: "File conflicts prevented the hard drive removal." Again, it was freshly formatted (the long, multi-hour way) immediately prior; there can be no file conflicts.
Sorry for the long post; I'm at wits end and would greatly appreciate any help. I can gladly just write off that drive and get on with my life, but I'd really love to see the calming green on my Network Status again!
I'm happy to provide any more information if someone would find it helpful! Thanks
