How to Migrate from Single-Disk RAID 0 to RAID 1 on HP Smart Array P410i Without Data Loss


6 views

When you initially configured a single disk as RAID 0 (which technically isn't RAID at all), you now face a critical situation with a failing drive. The P410i controller presents unique challenges for this migration scenario.

HP Smart Array controllers typically require these conditions for RAID migration:


1. Sufficient physical disks available
2. Supported migration path (RAID 0→1 is valid)
3. Controller cache module (BBWC/FBWC) for safer operations
4. No pending drive failures during the process

Using hpacucli, here's the exact procedure:


# First check current array configuration:
hpacucli ctrl slot=0 ld all show

# Verify the new physical disk is detected:
hpacucli ctrl slot=0 pd all show

# Begin the migration (example for logical drive 1):
hpacucli ctrl slot=0 ld 1 modify raid=1 drives=1I:1:3,1I:1:4

# Monitor rebuild progress:
hpacucli ctrl slot=0 ld 1 show
  • Always have verified backups before attempting migration
  • The system will be I/O intensive during rebuild
  • HP recommends BBWC/FBWC for migration operations
  • Monitor SMART status on both disks post-migration

If controller limitations prevent migration, consider this software approach:


# Create a degraded RAID 1 array:
mdadm --create /dev/md0 --level=1 --raid-devices=2 missing /dev/sdb1

# Copy data from RAID 0:
dd if=/dev/sda1 of=/dev/md0 bs=1M status=progress

# After copy completes, add the original disk:
mdadm --manage /dev/md0 --add /dev/sda1

Common error messages and solutions:


Error: "The requested operation is not supported with the current configuration"
Solution: Ensure you have the latest firmware (P410i minimum 6.64)

Error: "Insufficient resources to complete request"
Solution: Clear controller cache or reboot into HP BIOS configuration

After migration to RAID 1, expect:

  • ~20-30% write performance decrease
  • Identical read performance to single disk
  • Higher IOPS for read-intensive workloads

Many administrators (myself included) have made the mistake of configuring single disks as RAID 0 arrays, particularly on HP Smart Array controllers like the P410i. While this might have seemed like a good idea for consistency at the time, it creates serious redundancy issues when drives fail.

The fundamental issue is that RAID 0 provides no redundancy, while RAID 1 requires at least two disks. When your single-disk "RAID 0" starts failing, you're in a race against time to establish redundancy.

Here's how to convert your failing single-disk RAID 0 to a proper RAID 1 array using the P410i controller:

# First, identify your current array configuration
hpacucli ctrl all show config detail

# Example output:
# logicaldrive 1 (136.7 GB, RAID 0, OK)
# physicaldrive 1I:1:1 (port 1I:box 1:bay 1, SAS, 146 GB, Failed)

# Prepare your new drive (assuming bay 2 is empty)
hpacucli ctrl slot=0 physicaldrive 1I:1:2 insert drives=1I:1:2

# Convert the array (this is the critical step)
hpacucli ctrl slot=0 logicaldrive 1 modify raid=1 drives=1I:1:1,1I:1:2 forced

Note that the forced flag is required because we're modifying a degraded array. The controller will:

  1. Preserve all existing data on the original drive
  2. Initialize the new drive
  3. Begin mirroring the data

You can monitor the progress with:

hpacucli ctrl slot=0 show status

# Look for "Rebuilding (x%)" status
# Typical rebuild time for a 146GB drive: 2-4 hours

After completion, verify the new configuration:

hpacucli ctrl slot=0 show config detail

# Should show:
# logicaldrive 1 (136.7 GB, RAID 1, OK)
# physicaldrive 1I:1:1 (port 1I:box 1:bay 1, SAS, 146 GB, OK)
# physicaldrive 1I:1:2 (port 1I:box 1:bay 2, SAS, 146 GB, OK)

If your original drive fails during this process, you'll need to:

  1. Replace the failed drive
  2. Create a new RAID 1 array using your backup
  3. Restore from backup

If the HP utility fails, you can try Linux software RAID (mdadm):

# Install mdadm if not present
sudo apt-get install mdadm

# Create a new RAID 1 array
sudo mdadm --create /dev/md0 --level=1 --raid-devices=2 /dev/sda /dev/sdb

# Copy data from the original single-disk RAID 0
sudo dd if=/dev/sda of=/dev/md0 bs=4M status=progress