Yes, you have to check every recovered file to see if it valid. Color markings are "estimation" only, prone to errors. You may find this explanation helpful - http://www.z-a-recovery.com/man-validation.htm
Also, if you email me couple of samples which are "red" but actually OK, I'll check if we can fix the code to assign colors correctly.
I find it surprising that something is accessible but ZAR does not see it. Is it possible that there is another copy of the same data buried somewhere in the folder tree?
If you fiddle with the disk configuration (i.e. add/remove good disks), or even add/remove memory cards (they are also a part of disk configuration), ZAR senses this and it is announced on load. However, if all the array members are found OK, then it is OK to use the save file.