device not ready error

Okay guys, so to break it down, I had a drive that was part of a RAID solution. (this was handed off to me so not sure which config) I was able to pull the drive and quick format. I downloaded and ran Recuva. It runs for about an hour and a half and then I see all the files that I should be able to recover. All excellent condition. I then try to choose a drive to recover to and regardless of the drive I choose whether it be the 2nd drivebay on the dock, or local to c:/ It errors out. I receive place holders in the results that are all 1k. Smaller files seem to recover 'ok', like some smaller txt files, but it seems anything larger it won't recover and I get the drive is not ready. I've read through the possible solutions people have mentioned i.e disabling hibernation, sleep, or any of those possibilities and that isn't the issue. Hell, i've been on the pc the whole time it's running so no way anything is going to sleep, but nothing. The drive may have an issue with a block or sector down the line, but if the scan can complete and I get the file structure and the file name, would think it should be able to recover it. Any ideas? I don't have another PC to try this out on at the moment, although I don't think it would do any good. Is there a way to actively recover the files as they're being scanned? I've looked through options and can't find anything. I do IT work for a living, and normally can figure things out, but for some reason on this one i'm stumped. Please let me know if you have any suggestions beyond power that may be able to help. thank you.