Is your HDD, in fact, a Seagate? What version?
I ask because you may have heard that back in early 2009, Seagate released a firmware update to address the Barracuda 7200.11 HDDs which were shipped with defective firmware.
Seagate has a support page that discusses firmware updates. I would add that the issue generally caused the BIOS to be unable to ID the drive but who knows.
Also when the HDD is missing, what does Disk Management report? (issues can cause a drive to be not reported in Explorer/My Computer but it will show up in Disk Management - usually reported as being "unhealthy")
I would also add that if a HDD connection is faulty (cables, port, etc.) it will not show up in the BIOS.
So, the TS priority is this: boot - is the HDD reported by the BIOS POST; after you boot, is the HDD reported in Disk Management; finally, is the HDD reported in Explorer. If the HDD is ALWAYS present after you boot, then I think it reasonable to stop questioning the physical connections (the connection is not going to reconnect when you boot).
Monk
Thanks to all for all the great ideas and comments. Monk you raise some good questions that I meant to expand on originally so I am glad you asked...
The drive is a Seagate. During preboot (bios message) it always shows all drives including this one, even after a reboot when the issue had just occurred.
A few nights ago I flashed the drive firmware to the very latest (it was a few revs out of date) and verified the new firmware install was successful. However the issue has occurred since then so that did not resolve it.
When the HDD disappears from Windows Explorer from what I remember it still does show up in Disk Manager. However it is marked differently - can't recall if it says unhealthy or unformatted / raw etc but definitely is not in the normal status.
Every time after I reboot it is fine and comes back and Windows Explorer shows it and all files are intact. I can then use the drive just fine. Then suddenly at some point it just disappears.
I have seen it disappear when in the middle of using it. For instance yesterday I was doing a lot of file access of the drive and then eventually it just disappeared and the program using the drive reported an error as a result.
The time before that I was copying a large file over my network to the drive - it would make it just a portion of the way through, then the file copy operation would get stuck at x% and not move. Then I would try looking at the drive properties in Windows Explorer but it would be real slow to response. Then shortly thereafter the drive would disappear. Sometimes the drive just disappears on its own without me doing anything in Windows Explorer or file copy operations etc.
Regarding this:
If the HDD is ALWAYS present after you boot, then I think it reasonable to stop questioning the physical connections (the connection is not going to reconnect when you boot).
I sort of agree. What if it is a split second disconnect due to a faulty cable or connection? Just enough to disconnect and cause Windows to lose track of it, but then its fine and after a reboot therefore the BIOS sees it. I suppose this is possible?
Could it be an issue with an inadequate power supply?
It just dawned on me that perhaps the power supply is somehow related. Now that I think about it, it seems this issue started shortly after I added a 3rd drive to the system.
I have a 550W power supply. My understanding from the PC manufacturer is that the computer is built with this power to support all the components it shipped with plus one future drive (for a total of 2). Now that I have 3 drives I wonder if this could be causing it?
I thought about this at the time I added the 3rd drive - as to whether the existing power supply would be enough. I figured I would just try it and see how it went. And seemed to be fine originally as things seemed to work. But reflecting back perhaps this is the root cause. I should add that the 3rd drive is mostly dormant.
Also I didn't think adding the 3rd drive would really use enough power to put my system over the limits. I say this because the 3rd drive by my rough calculations only uses maybe 10-15 watts. So I figure with 550w available how likely is another 10-15 watts going to be to push me over. But with hindsight maybe it is.
Do you think this could be the cause? Is there anyway to gauge how close I am to overrunning the power supply, short of just upgrading it to see if the issue goes away? I don't mind spending the extra $ to pick up a better power supply, but at the same time I'd rather not bother if the existing one is adequate, and right now its just a theory?
What do you guys think? Thanks!