the conversion to dual redundancy takes a long long time, I think it took 3 or 4 days when I last tried it.
expansion should take about 8-12 hours as i recall.
since you have no data, your best bet is to insert all disks and factory default using the boot menu, select dual redundancy from RAIDAR and you should be done with resync ~12 hours or so, if I recall correctly.
nv+ ~ 1gb ram ~ 4x WDC WD20EARS-00S8B1 ~ 5555 GB
ultra4 ~ 4 gb ram ~ 2x ST31500341AS ~ 2x ST4000DX000-1C5160 ~ 6471 GB
pro business ~ 4gb ram ~ dual redundancy ~ 4x Hitachi HDS724040ALE640 ~ 2x SAMSUNG HD204UI ~ 9130 GB
A/V streaming ---> Subsonic
---> EVO 3D