Summary
-------
Alright, I've upgraded the firmware on this card to the most recent release (814D from 2006.06.26), and re-run the tests *without* success. If you have this card, you should avoiding using bioctl to set unused drives to hotspares at this time.

Specifics
---------
Bad news:
* I've re-run my test sequence *without* success after having upgraded
  the firmware to 814D.
* The LSI boot menu still has no option to reset a drive to "Unused"
  from "Hot spare"

Good news:
* There is an option in LSI WebBIOS boot menu, to reset a drive to
  "Unusued".  [This may have been there before - I never tried the
  WebBIOS boot menu.]

Bad news:
* I managed to corrupt my array while playing with the bioctl hot-spared
  drive in the WebBIOS.  [Both the normal boot menu, and the WebBIOS
  boot menu think everything is good, but OpenBSD fails to boot with the
  following output:

    Using drive 0, partition 3.
    Loading...
    ERR M
  ]  This may have been my fault, but I'm out of time to keep rebuilding
  and retesting.

Other
-----
I'm going to push this box into production shortly. None of this stuff is show stopping (I can live with the occasional after-hours reboot now that I understand the behaviour). I should also note that bioctl from this snapshot very conveniently displays the percentage complete of an array that is rebuilding. :)

If anyone would like me to run some tests before I push this into production, please contact me soon...

Matthew


>   Problem summary (problems with bioctl -H on a SATA 300-8x)
>   ===============
>   To summarize (I've included the full test case below) - I can now use
>   bioctl -H to set an "Unused" drive to "Hot spare".  However, despite
>   showing as hot spare in *both* bioctl and the LSI boot menu, when I
>   fail a drive in my RAID array, the "hot spare" fails to behave as such
>   (it will not be integrated into the degraded RAID array).
> > It gets worse - once a drive has been set as a hot spare through > bioctl,
>   it can never be changed back to unused, nor can it be properly set as a
>   hotspare through the LSI boot menu.  Essentially that slot is now
>   unusable.  The only solution that I have found is to "Clear
>   configuration" from the LSI boot menu (which then requires reinstall of
>   the contents of the drives).

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