You'll hit a hardware limit long before you hit the file system limit.
A 28-bit controller can only address 128 gigabytes; 2^28 sectors * 2^9
bytes/sector / 2^30 bytes/GB. That's why some folks buying 200 GB hard
drives ran into problems. Some IDE controllers or their drivers could
be updated to support 48-bit addressing or you had to get a new
controller to support up to 128 petabytes; 2^48 sectors * 2^9
bytes/sector / 2^50 bytes/PB. NTFS can address up to 2^64 bytes, or 16
exabytes. So in perspective:
28-bit IDE controller can handle 2^37 bytes, or 128 gigabytes.
48-bit IDE controller can handle 2^57 bytes, or 131,072 terabytes, or
128 petabytes.
NTFS can handle 2^64 bytes, or 16 exabytes.
kilobyte = 2^10 = 1024 bytes
megabyte = 2^20 = 1,048,576 bytes
gigabyte = 2^30 = 1,073,741,824 bytes
terabyte = 2^40 = 1,099,511,627,776 bytes
petabyte = 2^50 = 1,125,899,906,842,624 bytes
exabyte = 2^60 = 1,152,921,504,606,846,976 bytes
The limit above is just the theoretical limit for NTFS. See
http://support.microsoft.com/default.aspx?scid=kb;en-us;325722&Product=w
in2000 where it says the actual limit is 2 TB (maybe 256 TB with larger
sized clusters). So the 48-bit controllers are more than enough to
handle NTFS for quite awhile. Western Digital makes a 250 GB IDE hard
drive, so you would need about 34 million of them to hit the current
NTFS limit.
Warn us when before you power them all up so we'll know when to expect
the next power outage.