Just to be sure on the configuration you are using, how many hard drives are installed in the system?
Are you using 4 hard drives, and each RAID volume in pairs? If this is the current configuration, you should be able to do this just settings the desired volume to non RAID and following the information on this article:
If you are using 2 drives, using what is called Matrix RAID configuration, then this would not be possible. You would need to back up and create a new RAID one with the new drives.
I have 4 drives, set as 2 x Raid 1 volumes.
The first Raid 1 volume has the OS. The second Raid 1 volume has data.
It is the second Raid 1 volume that I wish to upgrade to larger drives, without messing with the first Raid 1 volume, that has the OS.
I have started following the instructions as you have advised. I have replaced one of the hard drives with the larger drive, have booted into windows and launched Intel Rapid Storage Technology.
However point 5. in the instructions say Click Rebuild to another disk. This option is not available or I can't find it.
The option to rebuild would be Under ‘Status’ or ‘Manage’, in the storage system view, click the volume you want to rebuild. The element properties are now displayed on the left. Then, next to the status you would see an option that says ‘Rebuild to another disk’. In the Rebuild Volume dialog, select the disk that will replace the failed disk. Only compatible disks in a normal state will be displayed. Click ‘OK’ to confirm. The volume starts rebuilding and the page refreshes displaying the progress of the operation. You can use other applications during this time and you will be notified when the process has successfully completed.
From what I see in your screenshot is that the rebuild option is not there, and this might be due t the size of the new drive and the limitations that your Option ROM would have as this would be an outdated version if this is using Intel(R) Matrix Storage Manager.
You can check for an updated BIOS for your computer/motherboard so this should update the RAID option ROM in your system. Also the computer should feature a recent SATA controller to be validated for 3 TB drives support.
So, to confirm:
Windows 7 sees my 4TB drive OK, but the Intel Option ROM (v.22.214.171.1244) has a drive size limitation, which is why I don't see the Rebuild Option?
What is the size limitation for Intel Option ROM v.126.96.36.1994?
(FYI, I am currently using Intel RST v.10.6.0.1022)
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A mature version such as 9.6 would not work with bootable volumes larger than 2 TB, at that time 2 TB or larger drives were not available yet. So a 4 TB drive would not be validated for your system configuration.