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I have to update the firmware on my Array controller (HP Smart Array 410 512 BBWC). Is it best that I take both of my DSS down when I do this? I'm worried there will be problems with replication if the firmware is different on on controller than the other.
I think you will be ok (never tested with the HP though only on the 3Ware and LSI), I would failover to the Secondary first then update via the BIOS on that Pri. controller then bring it back up and Sync back from the Sec then Failback to the Pri then work on the Sec. The Volume Replication is only concerned with connection and volume status from the Array, if the firmware is not effecting the volumes in size or other modifications then you are good to go.
Good question!