Degraded Dell RAID 5 on perc 6/i

I have a degraded RAID due to a failed disk.  It is not hot swappable.  I shut down.  Pulled the bad drive.  Plugged in a drive from a previous RAID and rebooted.  I have cleared the foreign config on the new drive, but when I try to make it a global hot spare, I get the following message:
Physical Disk 0:3: This Physical disk is not suitable to protect all current or potential virtual disks on this controller. Possible reasons include: Insufficient physical disk space, unsupported mix of SAS and SATA type physical disks, unsupported mix of SSD and HDD type physical disks, unsupported mix of 512Bytes and 4KBytes sector size physical disks, unsupported mix of PI capable and incapable type disks and non-SED drive assigned as a GHS when encryption virtual disk is present. Continue with assigning as a global hot spare?

Physical Disk 0:2 and 1:4 are the same.  Physical Disk 0:3 is the one that I have installed.  The only difference I can see from the other two is the other two are Revision KA05 and the new one is Revision KA02.  Below is what the drives show for specs.  Am I ok to go ahead and configure for a global hot spare or do I need to do something else?

ID 0:2
Status OK
Name Physical Disk 0:2
State Online
Bus Protocol SATA
Media HDD
Revision KA05
T10 PI Capable No
Capacity 465.25GB
Used RAID Disk Space 465.25GB
Available RAID Disk Space 0.00GB
Hot Spare No
Vendor ID DELL
Product ID ST3500514NS
Serial No. 9WJ0KQW7
Part Number TH08VNWV2123309I00B0A0
Sector Size 512B
SAS Address 1221000002000000
Non-RAID HDD Disk Cache Policy Not Applicable
 
    Physical Disk 0:3 Ready Available TasksAssign Global Hot SpareClear ... Execute SATA HDD KA02 No
 
ID 0:3
Status OK
Name Physical Disk 0:3
State Ready
Bus Protocol SATA
Media HDD
Revision KA02
T10 PI Capable No
Capacity 465.25GB
Used RAID Disk Space 0.00GB
Available RAID Disk Space 465.25GB
Hot Spare No
Vendor ID DELL
Product ID ST3500514NS
Serial No. 9WJ015FG
Part Number TH08VNWV2123301P00KWA0
Sector Size 512B
SAS Address 1221000003000000
Non-RAID HDD Disk Cache Policy Not Applicable
Jonathan AgerAsked:
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Seth SimmonsSr. Systems AdministratorCommented:
upgrade the firmware
if those existing drives are KA05, even that is very old
KA09 is dated 2013
should look at KA0A - though you might need to go to KA09 (or KA08) first; sometimes you can't just jump that much and need to do other versions in between first (scroll to bottom under 'previous versions')

Seagate SATA ST32000644NS, ST31000524NS and ST3500514NS firmware version KA0A
https://www.dell.com/support/home/us/en/19/drivers/driversdetails?driverId=5KN73
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Jonathan AgerAuthor Commented:
when I checked out the link which you provided, it says that the firmware will not upgrade on a raid that is in a degraded state.  That is where I am currently stuck.  I can upgrade the firmware once the raid has rebuilt but I cant get it to start rebuilding at this stage.

Still not sure what to do. :-(
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Seth SimmonsSr. Systems AdministratorCommented:
ahh yes...forgot about that
i assume you don't have another drive to replace it with?
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DavidPresidentCommented:
Look, those drives are ancient, and the "NEW" one is more ancient.  
You really need to do a full backup and replace all the drives.

 I would not be surprised if rebuilding the array put so much stress on the surviving disks that you would have a catastrophic 100% data loss.

Do yourself a favor and just back it up now, then build a new array with replacement drives.  The disks you have were never designed to last this long.
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Jonathan AgerAuthor Commented:
I ended up rebooting the system and going into the RAID config manager and adding the drive as a global hot spare.  As soon as I did that, the RAID rebuilt it self.  It took about an hour and a half to finish.  No other failures!  Replacement of the whole system has been scheduled to update it to the newest version of hardware.  Thanks for all of your help!
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DavidPresidentCommented:
force close
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