If it helps to clarify a screenshot of the Array Management tool showing the Disk group with the issue

The Failed disk on slot 14, we were able to clone it with a lengthy ddrescue run.
The new clone has been reinserted on slot 14.
We need to make the array to accept the new clone as replacement.
Is it possible to import the new clone on slot 14 without touching its data?

The disk on slot 15 was a spare set to physically replace 16 after we got a Failed for 16, the rebuild on 15 failed.
After inspection the disk on slot 16 seemed fine, it's back on the Array and is seen as Optimal but Unnasigned.
Can we switch back 15 to 16 without touching the data on 16 neither ? is the same original disk which was part of the array reinserted.

Hello arielzn,

The drive that you replaced was it on the support matrix for an MD3220?  Here is the link to the support matrix. https://dell.to/3o7nrYu  if it is not then you will need to get a drive that matches the support matrix.  What is the current version of firmware that is on your controllers?

Thanks for your answer.

Yes, it is correctly supported, the replaced cloned drive is now:

0, 14    838.363 GB Physical Disk SAS 6 Gbps ST900MM0006 LS06

And we have it recognized as:

   Physical Disk at Enclosure 0, Slot 14
    
      Status:                  Optimal
                                                                                
      Mode:                    Unassigned
      Raw capacity:            838.363 GB
      Usable capacity:         837.863 GB
      World-wide identifier:   (edited)
      Associated disk group:   None

Just in case, the failed removed but good enough for the ddrescue dump was:

0, 14   838.363 GB Physical Disk SAS 6 Gbps WD9001BKHG D1S4

For the firmware details I get:

CONTROLLERS------------------------------ 
Number of RAID controller modules: 2 

RAID Controller Module in Enclosure 0, Slot 0 

Status: Online 

Current configuration
Firmware version: 07.80.41.60 
Appware version: 07.80.41.60 
Bootware version: 07.80.41.60 
NVSRAM version: N26X0-780890-001 
Model name: 2660 
Board ID: 2660 
Submodel ID: 136
Product ID: MD32xx

The same for the other on Slot 1

Hello arielzn,

Looking at your firmware it is way out of date and is most likely causing your issue.  You should be able to assign the drive back to your virtual disk.  If that doesn’t work, then you can try to revive the disk group and that should bring the virtual disk back online.  Here are the steps that need to be done when reviving a diskgroup.

1. Disable Hot Spares
2. Fail all disks that are part of the disk group.

you will want to use the following command via SMCLI:

set physicalDisk [0,14] operationalState=failed;

For all other drives repeat previous command but change the drive slot.

3. You want to revive the disk group. Here is the command for that.

revive diskGroup disk group name;

Once all the steps are done the disk group should come back online and you should have access to your virtual disk again.

My point was, how to assgin it back, asking to take the same order  its clone had on the array:

physicalDisks=(0,19 0,11 0,12 0,13 0,14 0,9 0,15 0,17 0,18 0,22 0,20)

Hello.

To try first just to assign the drive [0, 14] back to disk group 1, how should I proceed precisely ?

Hello arielzn,

All you have to do is to add the drive back to the diskgroup first and then make sure it is added to the virtual disk.  If you are using disk pools, then you will need to add the drive to the pool.  Here is the link to the administrator guide, & chapter 7 is disk groups, & chapter 8 is disk pools. https://dell.to/31tYsEV

Ok, as explained on the guide I don't see the option " Storage → Disk Group→ Add Physical Disks (Capacity) " available, probably due to the failed state. I do see it for the other Optimal RAID.

The only approach available to assign back the new 14, is by a replace physical disk:

By going for this replacement , the current data on the cloned disk [0, 14] won't be modified ?

Hello arielzn,

The disk 0,14 will be modified so that it can be added back to the virtual disk.  The only way it would not be modified is if when the drive failed you powered off your MD3220.  Since yours has been up and running the data that you cloned is stale and will not be current to what the virtual disk has.

Thanks for all your answers so far.

Trying to add it back on the group didn't work , an Error due to the already failed state of VDs on the disk group.

Going for the second option, after failing all disks in the Disk Group, trying the revive I hit :

# SMcli -n 
 
   -c "revive diskGroup ["1"];"
  
Unable to force disk group "1" to optimal at line 1.
  
Error 29 - This operation cannot complete because there was a security authentication failure on a parameter in the command sent to the RAID controller module.
  
Please retry the operation. If this message persists, contact your Technical Support Representative.
  

  
The command at line 1 that caused the error is:
  
revive diskGroup [1];
  
Script execution halted due to error.
  
SMcli failed.
 

Any other parameter I should add for SMcli ?

Hello arielzn,

Try to reboot your controllers and then try the command again.

In case if you simply want to recover the data, it would easier to reconstruct raid virtually and backup it to a separate location .