Upgrade hardware. Start again or port over?

So I have a Pi4 in an argon M.2 case. The fan has stopped working and as far as I understand the argon script is bust for a certain combo of hardware. Many have been able to get it running again via I2C scripts but I’ve been trying for days with no luck.
This brings me to changing out my hardware. Thinking either a thin client or mini PC. That side isn’t important. What I would like help with is deciding the best setup route. I don’t have tons of time to dedicate so that may influence what I do.
I see 2 main options: backup my current configuration and port it into a new install on a new system; or, setup a fresh system and setup all the devices and automations from scratch.
I need to do some homework on the whole system as I currently have 3 zigbee controllers (conbee, hue and aqara). I need to tidy that up with the aim to have all my devices on the conbee ideally. Or get everything on one of the other hubs (aqara?) and remove the conbee stick.
Can I set up a second home assistant server in the same house and slowly transfer everything over? Then turn off the Pi and repurpose it. Is that realistic or does having 2 instances of HA cause issues?

There is no easy answer. Everything depends on your current setup - if you believe that everything is OK - you can try migration, otherwise - start from scratch and transfer things one by one.

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Yes, you can have have as many Home Assistant servers as you want, so perfectly feasible to set-up a second and migrate things over.

You mention you have 3 zigbee controllers and I would presume you are also running a WiFi access point. This implies that you will have some interference in the 2.4Ghz spectrum since at least 2 of those will have some overlap. You should prioritize reducing this to a single controller - going with the Conbee and either ZHA or Zigbee2Mqtt.

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Yes you can. Your conbee will be the biggest problem (you will have to move all your Zigbee devices over at once)

I only have a small handful of ZigBee devices on it so should be relatively easy. Once they are ported I can concentrate on changing the hue and aqara stuff to the conbee.
Thanks to others for the clarity about multiple home assistant instances running.

Also you can thing for a Network based Zigbee Hub. At the moment I’m with SLZB-06M< but saw few days ago that they have also “combo” device for Zigbee + zWave (not certified yet), and I’m really thinking to replace it as it’s very useful to have independent hub.

+1 vote for switching to a Network zigbee coordinator if you’re starting from scratch. Avoids the hassle of setting up USB passthrough and dealing with interference.

I’m guessing you’re referring to this model. If so, I’m assuming they’re expecting you to provide regular feedback on the ZWave performance as part of the discounted price.
Great if you’ve only got a couple of Zwave products already, but not so great if you’re just starting out or already have a large Zwave network.
If you’re starting out, any negative experience will leave a bad impression on Zwave performance in general.
If you have a large network, then you have to create 2 separate Zwave networks or face the risk of moving all your devices to an untested product.

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The separate ZigBee controller sounds like a good idea. Is this something an aqara hub can do? I have an M2 hub currently. It’s far more stable than any other similar hub I’ve used.
If an aqara hub is not the correct solution, what (hardware wise) would the setup look like? Assuming a home assistant server tucked away somewhere on ethernet. Then a ZigBee hub/controller sitting centrally in the house talking to everything and feeding back to home assistant. If this is the case then it would greatly simplify my setup and would be very easy to implement.

This post The Ultimate Guide to Integrating Aqara with Home Assistant - Developer Hub - Aqara Forum and especially where it mentions getting a SkyConnect (ZBT-1) tells me that it is better to just go with a separate Zigbee coordinator like something from https://smlight.tech/

Aqara is part of the Works with Home Assistant partner program, but only for matter enabled devices. You could potentially keep the Aqara M2 and use it as a Matter hub.

Thanks. Did some parallel digging and seems a separate coordinater is better with the aim to drop all my current ZigBee hubs.

So I now have my new machine to start the HA new home project. It’s ethernet only and comes pre-installed with Linux mint. I like LM so that’s fine by me. I just need to find a home for it and also decide weather to install HAOS native or in a VM. I’m planning on repurposing the Pi4 as a mini computer for tinkering or serving some other things. So I’m kinda leaning to HAOS on the Lenovo box. i3 with 16gb is probably overkill but it was a good price.

Assuming I can get my head around installing HAOS on this specific device, am I right in thinking it’s essentially a headless setup so no need to keep a screen nearby? That would free up my mobile screen for the pi.

Edit: I ordered a slzb-06 ZigBee coordinator (yet to arrive) so planning on sitting the new machine in a hidden spot. Then the coordinator can sit centrally. Is this all good if they are on different nodes of a mesh network or do they need to be on the same node or even the ‘master mesh commander’?

Haos and Proxmox (if you go that way) are both intended to be headless. Put the machine where it makes sense you’re gonna be accessing it over your network.

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As you have said the i3 with 16Gb is probably overkill, so best to look at using a VM - this way you could use the hardware for additional VM’s.

I would also advise going with Proxmox and HA in a VM. I’d also suggest you look at using LXC’s for running any software add-ons as opposed to just installing the HA Add-ons.