1. Either RAID-5 with hot spare or RAID-6 should be fine for <= 8 drives. Any decent RAID controller should support hot-sparing (regardless of RAID level).
2. Get a RAID controller with on-board BBU. I'd still recommend a UPS to provide for graceful shutdown, but if it's only on or the other, I'd go with the on-board BBU.
That said, a UPS only needs to keep the system up long enough for it to shut down properly. For what you're looking at, a UPS hold-up time of a couple minutes should be sufficient, which can be had pretty cheap. (However, a UPS won't save you in the event of an unexpected shutdown/crash/etc., which is why an on-board BBU is still desirable.)
3. If the RAID controller fails, you'll need a similar (possibly identical) model, and at minimum one from the same vendor. (I keep a spare because of that.) The vendor should be able to tell you what combination will work. Some also offer an advanced replacement option. (They ship you a replacement immediately on notification of a failure, and you send the old/defective unit back to them later.)
4. Any decent controller will support on-line capacity expansion (OCE). However, it can take quite a bit of time for large arrays... but unless you're able to backup everything and reload it, it's better than nothing.
5. The Areca controller you list has all of the required features. (Caveat: I haven't used Areca, but they appear to be competitive).
6. You'd be better off using RAID-qualified disks, such as the WD and Seagate enterprise drives or you're likely to suffer spurious dropouts/rebuilds. The RAID controller vendor should have a qualification list for both drives and backplanes (the latter shouldn't matter since the case is direct-connect, not really a backplane).
7. The performance limits aren't likely to be the drives, but the OS, network stack, protocol handlers, and network. With 4x RAID-6, the drives may be a limiting factor for writes, but not reads unless you're doing a lot of random IO; when you get to >= 6x drives, they'll likely outstrip the other factors. If you're planning on growing the array in the future, I'd go for lower power and more efficient drives such as the WD-RE3/4-GP's.
8. As for the OS... whatever you're most comfortable with, as you're likely going to be getting intimate with it. If you can make good use of Windows Server's other features, and your primary requirement is CIFS/SMB support, by all means... If you're looking for something that's more of a pure SAN/NAS and are a bit more adventurous, you might look at OpenFiler and FreeNAS, or Solaris w/ZFS (great performance, eliminates the need for a RAID card but you give up OCE).
9. Quite a few case options out there that can hold 8+ drives. The case you list is OK; primarily depends on whether you prefer pedestal or rack-mount.
You might also want to read this thread:
http://www.tomshardware.com/forum/250101-32-raid-works-...