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You should boot from a USB2 port if possible. USB3 ports seem to lose connection for some. No need for USB3 speed (port or flash drive) for this purpose anyway since it is mostly just accessed at boot to unpack the OS archives into RAM (OS runs in RAM) or to save settings you make so they can be reapplied at boot.

Cache-only shares will go beyond the mimimum. Or writes directly to cache will go beyond minimum. The purpose is to allow cache-prefer or cache-yes shares to overflow to the array so they don't go beyond minimum accidentally. Each of your user shares also has a minimum free setting. If a disk has less than minimum, Unraid will choose another disk when deciding which disk to write a file to. Note that in any case, once Unraid has decided which disk to write a file to, it will try to write the whole file to that disk, even if it runs out of space. It has no way to know in advance how large a file will become. The usual recommendation is to set minimum to larger than the largest file you expect to write to the user share (or to cache in the case of cache minimum).

cache-yes and cache-prefer shares will overflow to the array when cache gets below minimum, cache-only shares have no choice but to go to cache until it runs out of space.

What happens if you boot in SAFE mode?

One thing to consider is that mover can't move open files (such as seeds). One of the reason I send torrents directly to the array. I have them on a share that only includes a single disk. But if you want to put torrents on cache, you should use a cache-prefer share so they can overflow to the array after cache gets less than Cache Minimum Free (Global Share Settings)

syslog Seems odd there are so many various outgoing connections from your server. Are you booting in GUI mode and using the browser on the server to access the internet?

My guess. You had a number of shares set cache-only for some reason (though some of those have files on the array). Do you really need all of those to stay on cache? No idea what you are using those for since their names have been anonymized. You have a pretty large cache so it should be pretty hard to fill it up. Are you trying to seed torrents from it or something? I always send torrents directly to the array.

You are loading a lot of packages from Nerdpack? Why?

OK, that looks good. Run mover again and when it finishes post new diagnostics.

mv /mnt/user0/system /mnt/user0/system1 mv /mnt/user0/domains /mnt/user0/domains1 ls -lah /mnt/user

Tools - Diagnostics, attach complete diagnostics zip file to your NEXT post. But, all of those remote addresses makes me wonder if you have put your server on the internet and are being attacked by bots. Your server should only be accessible from your LAN or through a VPN. Have you put it in the DMZ of your router or something? Nevermind, I misread. Those are outgoing connections.

The things in /mnt/cache are on cache obviously. The things in /mnt/user0 are the user shares excluding cache, in other words, on your array. As you can see, there are duplicates. You need to delete one or the other. Probably the cache versions are the ones to keep since I think those would be the ones that were being used. You can just rename the ones on the array for now and that will get them out of the way so the cache versions can be moved. Do you know how to rename those?

Are you trying to access your server from outside your LAN?

Can you ping your server?

Go to Tools - Diagnostics and attach the complete diagnostics zip file to your NEXT post.

I'm sure Squid can fill in the details, but I think it is just checking to make sure you don't have any addons (plugins or dockers) that were determined to be problematic after you installed them, and checking your Unraid version in case there is some critical reason you shouldn't be using that version.

Have you done memtest?

Almost everyone you will encounter on the forum are fellow users like yourself, even the moderators.

domains and system shares still have files on cache. Probably these are duplicates of files on the array, since mover won't overwrite existing files. From the command line, what do you get with these? ls -lah /mnt/cache/system ls -lah /mnt/user0/system ls -lah /mnt/cache/domains ls -lah /mnt/user0/domains

Yes, you might consider fewer, larger disks to give similar capacity as those 4TB disks. That will make it easier to expand. 8TB seems lowest price per TB at the moment.

Does it work for even a little while when you first boot? If so, get us the diagnostics instead of just the syslog. Tools - Diagnostics, attach complete diagnostics zip file to your NEXT post.

Your docker settings are stored on flash, and you can get them going again just as they were using the Previous Apps feature on the Apps page. But, you may not need to even do that much. Since this is just a drive replacement, with shrinking the array, you might just do it the "standard" way, one disk at a time. Replace parity first since it needs to be largest and let it rebuild. Then proceed with replacing / rebuilding whichever disk needs replacing the most (SMART report), or whichever disk has the most contents. Repeat until you have all the new disks in. Then move the data from the remaining disks using unBALANCE plugin, Krusader, or whatever you prefer. When those are empty, New Config without them and rebuild parity. That method has the advantage of keeping your server going throughout the whole process. And you have parity protection through all of it except for the rebuilding parity steps, and that isn't much risk if you keep the original disks until finished.

That would do it alright. Your screenshot said 50GB Minimum Free, but I guess you must have changed that after you had the problem, but without telling us 😉

Correct

Is this a replacement for a file that already exists?