OK, here it is "How to put a drive Online". a drive goes Offline when it's damaged OR it's been replaced with a drive from another array and the controller thinks it belongs in your array. So, the way to make it available is to take it out of the array. Using option 3 ‘Reset Hard Drives to Non-RAID’ in the ROM setup. Scarey! the last thing I would have thought of but, it lets you remove individual drives from an array in addition to removing the array it self.