Linux – Reboot server while HP SmartArray P410i array transformation

So long as you go from one HP controller to another that was made at the same time or more recently and has an up to date ROMPaq applied the array will move over just fine. Simply move the disks to the 380, they don't even need to be in the same drive slots as they store their array information on each disk.

One word of warning though, don't try to 'pre-configure' the 380's array controller, just stick the disks in and let it get on with it. It'll probably throw up quite a few messages when it boots but just leave it alone for at least 30 minutes, you may need to do a full reboot 2/3 times after this to stop the various messages.

If you let me know the exact controller details for the 350 and the 380 I'll see if I can add any more meat to the bone ok.

You do not have an online option. Online array/logical drive expansion with Smart Array controllers is only available with a battery or flash-backed cache unit. The online features leverage the cache unit heavily during online operations.

See the Smart Array P410 Quickspecs.

Management Features 
Online array expansion (with BBWC/FBWC upgrade)
Online Advanced Capacity Expansion (with BBWC/FBWC and Smart Array Advanced Pack upgrade)
Online logical drive extension (with BBWC/FBWC upgrade)
Online RAID level migration (with BBWC/FBWC upgrade)
Online strip size migration (with BBWC/FBWC upgrade)

In general, it's a good idea to have a BBWC/FBWC unit for HP RAID controllers. It'll certainly improve the write performance on your RAID5 array. See this advisory. Look for HP parts #534916-B21 or #462969-B21.

In order to initiate the expansion of your existing array offline, you can download the HP SmartStart CD image (or use the one that came with the server) and boot into the Array Configuration Utility (ACU) to make the appropriate changes to your array. Follow the array expansion instructions listed in the ACU manual.