I've never encountered that error myself, so I'm not at all sure this 
suggestion will work, but I did run into something similar and the answer was 
to install Windows on the drive and then pop the drive back in my server.  
Prior to that, OpenSolaris/ZFS "remembered" the disk and wouldn't let me use it 
until it appeared sufficiently different.  I also had tried different tools to 
zero the disk.
BTW, it's always a good idea to have a spare disk of the same model on hand.
-- 
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