vSAN Disk group reported warning as Unhealthy for the vSAN Capacity Disk

Products

• VMware vSAN

Issue/Introduction

Symptoms:

• One or more disks have failed in a vSAN cluster and requires replacement.
• Below error is  reported in vCenter UI under Cluster>Configure>Disk Management
  
  

Environment

VMware vSAN 

Cause

vmkernel.log:
2025-05-27T19:36:30.372Z cpu15:2097793)HPP: HppResetDeviceLogThrottling:1205: last error status from device naa.############## repeated 5 times
2025-05-27T19:36:33.331Z cpu30:2097989)WARNING: HPP: HppThrottleLogForDevice:1136: Cmd 0x2a (0x45be88e81d08, 7391424) to dev "naa.##############" on path "vmhba0:C0:T6:L0" Failed:
2025-05-27T19:36:33.331Z cpu30:2097989)ScsiDeviceIO: 4167: Cmd(0x45be88e81d08) 0x2a, CmdSN 0x1 from world 7391424 to dev "naa.##############" failed H:0x0 D:0x2 P:0x0 Valid sense data: 0x4 0x5d 0xba
2025-05-27T19:36:43.334Z cpu10:2097989)ScsiDeviceIO: 4167: Cmd(0x45be9cecf448) 0x2a, CmdSN 0x1 from world 7391424 to dev "naa.##############" failed H:0x0 D:0x2 P:0x0 Valid sense data: 0x4 0x5d 0xba

• [0x4]   is  HARDWARE ERROR, the device has gone bad and needs to be replaced 

Resolution

Before replacing a failed disk in a vSAN cluster, ensure the following: 

• Disk must be certified for use with vSAN per the vSAN Compatibility Guide
  • Cache disk replacements must be certified for cache use.
  • Disk must be certified for vSAN configuration in use (hybrid/all-flash).
• Disk capacity should ideally be the same as the one being replaced. 
  • If the same size is not available, the next size up is acceptable.
• Disk performance and endurance classes must be the same or higher when compared to the original disk.

See Identifying specific disk failure in a vSAN deduplication cluster for more information.
See How to manually remove and recreate a vSAN disk group using esxcli for more information.

When replacing a failed capacity tier disk without Deduplication and Compression make sure to remove the failed disk from the disk group prior to pulling the disk from the host. See Replace a Capacity Device in vSAN Cluster for more details.

When replacing a failed cache tier disk or a capacity tier disk with Deduplication and Compression the entire disk group needs to be removed from vSAN prior to replacing the failed disk. See Replace a Flash Caching Device on a Host in vSAN Cluster & Add or Remove Disks with Deduplication and Compression Enabled for more details.