Did you set SCSI ID's, and you're sure that the replacement drive has a SCSI ID that doesn't conflict with anything else on the SCSI bus? Verify SCSI ID's.
Another possibility, depending on where/how you obtained your replacement drive, it may have data on it and may have been a member of a different RAID-set in a prior life. If this is the case, your RAID controller would detect this and that's could cause this confusion.
You don't need to go into Smart Start, just go into the ROM based ACU, or launch into Windows (assuming windows) and go into the ACU GUI.
You should see your original array with its 2 remaining original members in a degraded state, and you may see a second array with a single member being the replacement drive, either in a degraded or failed state. If this is the case, then delete the array containing only the replacement drive (careful to delete the right one, and by the way, how are your system backups?). Once you save these settings, the replacement drive is erased of its prior membership, and it should be assumulated into your original array.