[shevgenius]

Изучение User Guide дало ответы на некоторые вопросы, в частности:

информация хранится в памяти контроллера

там я в самом вопросе накрутил с формулировкой...

1.6.7 Drive Roaming
Configuration data is saved in both the NVRAM on the RAID controller and on the drives attached to the controller.
This action maintains the integrity of the data on each drive, even if the drives have changed their physical device ID.

Так скорее всего RAID-контроллер определяет замену диска, сверяя конфигурацию на дисках и в NVRAM контроллера.

Сначала удалите старый массив. Новый не даст создать.

Здесь вы правы, но делать это нужно на контроллере с отключенными дисками, чтобы подключив диски с массивом, контроллер подхватил конфигурацию RAID-массива с дисков.

1.6.8 Drive Migration
Drive migration is the transfer of a set of drives in an existing configuration from one controller to another. The drives
must remain on the same channel and must be reinstalled in the same order as in the original configuration. The
controller to which you migrate the drives cannot have an existing configuration.

Смущает, только эта оговорка. Что значит virtual drive (not all of the drives in a drive group)?
Т.е. это физические диски, из которых состоит/размечен virtual drive, который видит ОС, но в этот набор не включены диски hot spare или еще что-то?

NOTE: When you migrate drives, move only the drives that make up the virtual drive

When you migrate drives, move only the drives that make up the virtual drive (not all of the drives in a drive group), so that you do not see an NVRAM mismatch error (providing a configuration is on the destination controller). The NVRAM mismatch error appears only if you move all of the drives to the other controller.

А какой именно рейд то?

заменили один, дождались конца ресинхронизации, заменили второй

Сейчас используется аппаратный RAID10 на четырех дисках, дожидаться четыре ресинхронизации думаю будет дольше, к тому же их нужно делать последовательно,
чем собрать чистый RAID10 и накатить на него бекап.
А если верить User Guide, то вариант извлечь старый RAID-массив и собрав новый надежнее, т.к. всегда останется старый хромающий но еще работающий.
Да и диски старые и новые разных производителей, хоть и объем одинаковый.

6Gb/s MegaRAID® SAS RAID Controllers - User Guide

1.6.7 Drive Roaming

Drive roaming occurs when the drives are changed to different ports on the same controller. When the drives are
placed on different channels, the controller detects the RAID configuration from the configuration data on the drives.
Configuration data is saved in both the NVRAM on the RAID controller and on the drives attached to the controller.
This action maintains the integrity of the data on each drive, even if the drives have changed their physical device ID.

NOTE
If you move a drive that is being rebuilt, the rebuild operation restarts;
it does not resume from the stopping point.

Follow these steps to use the drive roaming feature:
1. Turn off the power to the server and all drives, enclosures, and system components. Disconnect the power cords from the system.
2. Open the host system by following the instructions in the host system technical documentation.
3. Move the drives to different positions on the backplane to change the targets.
4. Determine the SAS target requirements.
5. Perform a safety check.
a. Make sure that the drives are inserted correctly.
b. Close the cabinet of the host system.
6. Reconnect the power cords to the system.
7. Turn on the power to the system.
The controller then detects the RAID configuration from the configuration data on the drives.

1.6.8 Drive Migration

Drive migration is the transfer of a set of drives in an existing configuration from one controller to another.
The drives must remain on the same channel and must be reinstalled in the same order as in the original configuration.
The controller to which you migrate the drives cannot have an existing configuration.

NOTE
Partial configurations, which include individual virtual drives, can be migrated.

NOTE
Drive roaming and drive migration cannot be supported at the same time.

Follow these steps to migrate drives:
1. Make sure that you clear the configuration on the system to which you migrate the drives to prevent a configuration data mismatch between the drives and the NVRAM.
NOTE
When you migrate drives, move only the drives that make up the virtual drive (not all of the drives in a drive group), so that you do not see an NVRAM mismatch error (providing a configuration is on the destination controller). The NVRAM mismatch error appears only if you move all of the drives to the other controller.

2. Turn off power to the server and all drives, enclosures, and system components. Disconnect the power cords from the systems.
3. Open the host system by following the instructions in the host system technical documentation.
4. Either remove the SAS cable connectors from the internal drives, or remove the shielded cables from the external drives that you want to migrate.
a. Make sure that pin 1 on the cable matches pin 1 on the connector.
b. Make sure that the SAS cables conform to all SAS specifications.
5. Remove the drives from the first system, and insert them into the drive bays on the second system.
6. Connect the SAS cables to the drives in the second system.
7. Determine the SAS target requirements.
8. Perform a safety check.
a. Make sure that all of the cables are attached correctly.
b. Make sure that the RAID controller is installed correctly.
c. Close the cabinet of the host system.
9. Reconnect the power cords to the system.
10. Turn on the power to the system.
The controller detects the RAID configuration from the configuration data on the drives.