FWIW: I have read about some of the pitfalls that people have encountered with the drive replacement and expansion process on the PR4100 and I wanted to share what I ran into with respect to the drive replacement and volume expansion process. My goal was to replace the original drives in my PR4100 with larger drives and to NOT lose my data and to end up with the volume being as large as it could be (using all of the available space of the new drives).
First let me mention what I did:
I went from 4X4TB drives to 4X10TB drives on a PR4100 with upgraded ram (16 instead of the stock 4) . The ram upgrade was painless. I did read somewhere that a user had difficulty removing the cover to the unit , and so did I for a few seconds. It is a little harder to get off than one might think . Don’t know if I actually needed that additional ram or not … and probably never will.
As for the drives : I started from the left to the right. I took out the original 4TB drive from the bay on the left and replaced it with a new 10 TB drive. All went well for a few hours, but then I ran into a problem when the drive in bay 3 (call that drive 3) indicated that it was bad (with a red light on the front of the PR4100 ) . At that point I powered down the unit, let it cool down, took out the new drive that was in slot (bay) 1, and put the original drive back into slot 1. Thankfully drive 3 had come back to life so that drive 1 (the original drive) was able to be rebuilt and at that point the unit showed as operating properly. I did a fast disk check and all showed good. I suspect that drive 3 was near failure and had perhaps overheated ? Not sure . Anyway, I then proceeded to replace drive 3 with a new 10TB drive . That process went well, and then I continued with drive 1, drive 2, and drive 4. All showed good on on the home screen, but after replacing all four drives, the total capacity was still as it was originally.
So the next thing needed was to expand the size of the volume . I have read that others ran into a problem with that task, and here is a solution that is (was) hiding in plain sight from a lot of people (myself included) .
In the process of expanding the volume size those who have run into a problem probably missed the following : There is another screen that one encounters along the expansion drive process, and anyone with a problem has not posted it (that I have found) . I think some people think it is simply an informational screen. In Raid 5, once that you have replaced the original drives with larger drives , (one at a time , and waited for each drive to be rebuilt before changing the next drive), go to the home screen and click on “change raid mode” and then you progress through the screens making your selections along the way ( you want to leave the raid mode as raid 5, and you want to indicate that you are NOT changing your drives because you have already done that ) , you will come to a screen with a slide bar on it that you use to indicate how much of the new capacity you want to use to expand your volume . The problem is that it doesn’t look like a slide bar (or I didn’t recognize it as a slide bar ) and if you don’t slide that little blue indicator on the bar so that you move it to the right, and then you proceed with the drive expansion, you will end up with the same size volume that you started with . That is what I did the first time that I attempted to expand the size of my volume . I suspect that is the same mistake that others made as well. As I am writing this my PR4100 is in the process of the (correct) expansion process. I recall that two days ago I saw the screen that had the slide bar on it , but I didn’t slide the bar . A couple of hours ago the PR4100 completed the volume expansion process that I attempted the first time … and I ended up with the same size volume that I started with . I went through the steps again to expand the size of the volume and this time I recognized the page with a slide bar on it for what it was (a page with a SLIDE BAR on it that I had to slide to the right to indicate how much of the unused space I wanted to include in the size of the expanded volume) .
One final note : I saw that I also had the option to simply create a different volume using the unused space … I read about the positives and negatives of doing that, and with a raid 5 configuration and a one person user, it didn’t make sense to me to have more than one volume. Hope this answer helps .