The first thing you need to do is make sure you have a good backup of the data. Have you ran the Array Diagnostics Utility? ACU isn't the same. What is the unused disk in bay 5? Was the drive you are trying to install in bay 1 removed from another array? If so was the array deleted using ACU on the other system before moving the drive? THe array information is written on each disk and if the replacement disk has conflicting array data it can cause problems
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