usb, raid 5, and error 24

[jbol]

I am trying to setup openfiler (which is a redhat based distribution that
creates a NAS) on a 2 gig usb with 4 * 1 TB drives in raid 5 running off of
an sil sa3114 based sata controller.
If I remove the sata card so there is only the usb (sda1) I set grub to
'root (hd0,0)' openfiler starts ok.
If I insert the sata card the usb becomes sde1 so I have to set grub to
'root (hd4,0)' and I get grub error 24 - block outside of partition - it
does find grub.conf so (hd4,0) must be correct.
My head hurts!!  - any help please
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