Hey, kyo83. Did you ever find an answer to your questions? I'm in a similar situation where my current RAID storage is almost full and I'm looking for a way to add additional drive to increase total storage without interrupting what is already in place. Same as you, I've had no luck from my Google searches so far.
Hey guys, I'm in the same situation for my most important client. I have found nothing, and Adaptec says they do not support it, and will not answer whether it is possible or not. I'm not going to bother posting this until I'm done, so I'm typing in real time.
The array currently has four 500GB SSDs in a RAID 10. I am trying to add two more 500GB SSDs.
First, I captured multiple good backups with verifies. Next, I opened up the server and switched controllers. One thing, they said that you cannot move RAID 10 between controllers, that is BS, I just moved from a single channel 6405 to dual channel 6805E controller and it was seamless.
The bad part comes now, I added the additional drives into the array controller and initialized them. I'm logging into the server now and will see if it provides options to do anything useful with the existing array.
OK had some problems with the Adaptec manager, anfter a full uninstall, reboot, install, reboot cycle, I was able to open it up. I right clicked on the array and selected expand. On the right pane, I checked off the two new drives and clicked apply. It's doing it's thing now, lets see what happens.
OK now the array shows six members, and shows as configuring.
Well, shut the server down, put it back in the rack, restarted. Still shows as reconfiguring, still shows old capacity, but I will imagine it will have to finish reconfiguring before it will allow access to the new capacity.
I will call this a tentative victory right now. This applies to the controllers I am using and to Windows 2008R2 Enterprise. Be cautious and make sure you have VERIFIED backups before you try on your own. Best of luck, I will try to remember to post here once it hits 100%, it's 4% now after 30 minutes runtime, thats um.... 12.5 hours at the present rate, so it would be tomorrow some time.