Really, believe it or not, you're already at the stage where you need scene programming.
You have 240 scenes to make, so might as well start getting creative. Plus, you can always over-ride by using the faders, but keep in mind the restrictions tied to the console via way of the scanner buttons(which are really just banks of 16 channels, not really fixtures unless you organize things that way, either way is fine).
I do agree that for many events, especially for DJ's, doing some basic "sound to lights" stuff is sufficient. Even at some of my events, where I am doing more higher-end stuff, having lights that are simply high-tech FX that can do sound to light work wonderful for my events.
This is why I think you need scenes:
1: Using one of the 6 chases you program, you can get sound to light with syncronization. Yes, it's a bit more complicate but I think the effort would be worth it. Chases are driven by scenes, and you need to program scenes to program chases. Sort of a one hand washes the other thing.
2: You want to bring up and do things to multi-channel fixtures, which is great, the controller can do that. But you're spread out over a "larger area" as far as DMX channels are concerned, which is where the console tends to be weak for live control, especially when it comes to multiple "scanners", which as I've explained, may or may not be accurate for your layout. Adding scenes will get around these problems.
3: You're planning to upgrade, and there's nothing wrong with your upgrade path plans and the fixtures you want to add. What you might do is what I think you're already doing: Logical address assignment and arrangement with the 8/16 channel layouts of your controller.(which may result in unused channels). But, again, you'll want some scenes to help simplify things.
Also, you may choose to buy some simple high-tech FX. As I've said, they work great, do what you want(sound active stuff only), are relatively inexpensive. Note that I'm not even suggesting getting rid of anything you've got, I'm only talking about adding options.
I'd also assign any high-tech FX to a single scanner set of channels, and ensure you have switcher packs(say, the DP-DMX20L) for the high-tech FX so you can have that easy access to them.
Another option might be softare-based solutions. I know this is the wrong forum, but I think Jingles will support me on this one(or edit it out), but you might want to consider MyDMX for XP/Vista/Windows7. That, along with a low-cost MIDI controller(such as a Korg nanoKONTROL) might be an option to investigate. You get more DMX channels. While your DMX Operator only has 192, MyDMX allows you access to all 512 DMX channels. There's other goodies in there as well. One of my favorites is the 3D Visualizer, which has really been a life saver for me, letting me design shows without so much as having to fire up a single light.
Regardless, the DMX Operator has a ton of features in it and is a great bit of gear, but it's not a great unit for what you have and how you want to use it. You definately want something with lots of faders since you're insisting on all live control. Even so, you'd still run into problems.
I'd say start getting creative and think "well, I have 240 scenes, what can I program into those" and then get busy. I think once you start getting into it, after the nuisance of the programming, you'll be glad you did it. Just document your settings so just in case something happens, you have fall-back on paper so you can get started quicker the second time around.
It sounds like you have plenty of options. Time to start having fun!