First off: Let the volume build and keep activity low for initial building without rebooting to cut down on build time or use fast initialization! I think you got bumped with the same bug I did when i started playing with the 9650 controller.
My system boots faster than the 3ware can clear and reset the drive itself and often when I did either a hard or soft reset I would get some drives that seemed to be 'locked up' (reset command got queued and flushed but never executed?). Another strange thing I had to do (recommended by 3ware) was to delay staggered spin-up..
what mainboard/chasis/case are you using? latest firmware for mainboard?
what's your firmware revision for your raid controller? latest?
are you using stock sata breakout cables from the 3ware card to the backplane/drives or ones that came with the backplane/chasis?
You should most definitely patch the firmware on your 3ware to the latest revision and do the delay spinup.. And since you only have 5 disks I doubt it will strain your power supply.
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