Wonko,
Thanks for your response and sorry if I gave any incorrect information or I misunderstood something.
To start from scratch... I have little embedded PC's that boot that have Win XPe installed on them. The currently used CF cards are iCF 4000 made by InnoDisk. The PC has a push-button on the side of an attached display that should be used to shut the PC down correctly, but either due to operator error or loss of power, the Windows file structure becomes corrupted. I would like to make a backup image file that I can use to reload the entire disk and change from the currently used iCF 2 GB industrial cards to a more available SanDisk Ultra 4 GB CF card. The reason I want to do this is two-fold... The current OS and all programs consume about 1.8 GB of the card, leaving very little space and obtaining the other cards is cost/time prohibitive.
So basically, I want to take a bootable 2GB iCF CF card and create a backup that can be loaded onto a 4GB SanDisk CF card and make it boot so that if the OS fails, I can simply swap out the card to get the machine back up and running quickly.
I used DSFOK to create an image of the disk after locking the drive with LockDismount; the following is the results from the command prompt:
C:\dsfok>dsfo \\.\PhysicalDrive1 0 0 Backup.img
\\.\PhysicalDrive1 - The drive cannot find the sector requested.
This error can probably be ignored.
OK, 2096889856 bytes, 140.073s, MD5 = cbf244f588e7688a90e768354a9c28f0
F:\>chkdsk
The type of the file system is NTFS.
The volume is in use by another process. Chkdsk
might report errors when no corruption is present.
WARNING! F parameter not specified.
Running CHKDSK in read-only mode.
CHKDSK is verifying files (stage 1 of 3)...
7104 file records processed.
File verification completed.
20 large file records processed.
0 bad file records processed.
0 EA records processed.
2 reparse records processed.
CHKDSK is verifying indexes (stage 2 of 3)...
9328 index entries processed.
Index verification completed.
0 unindexed files scanned.
0 unindexed files recovered.
CHKDSK is verifying security descriptors (stage 3 of 3)...
7104 file SDs/SIDs processed.
Security descriptor verification completed.
1112 data files processed.
Windows has checked the file system and found no problems.
2015968 KB total disk space.
1445020 KB in 5715 files.
1948 KB in 1114 indexes.
0 KB in bad sectors.
19744 KB in use by the system.
12128 KB occupied by the log file.
549256 KB available on disk.
4096 bytes in each allocation unit.
503992 total allocation units on disk.
137314 allocation units available on disk.
Next I placed in the new SanDisk 4 GB CF Card and formatted the card with HP USB Stck Format Utility and ran chkdsk on it:
F:\>chkdsk
The type of the file system is NTFS.
The volume is in use by another process. Chkdsk
might report errors when no corruption is present.
WARNING! F parameter not specified.
Running CHKDSK in read-only mode.
CHKDSK is verifying files (stage 1 of 3)...
256 file records processed.
File verification completed.
0 large file records processed.
0 bad file records processed.
0 EA records processed.
0 reparse records processed.
CHKDSK is verifying indexes (stage 2 of 3)...
274 index entries processed.
Index verification completed.
0 unindexed files scanned.
0 unindexed files recovered.
CHKDSK is verifying security descriptors (stage 3 of 3)...
256 file SDs/SIDs processed.
Security descriptor verification completed.
9 data files processed.
Windows has checked the file system and found no problems.
3903456 KB total disk space.
21568 KB in 5 files.
8 KB in 11 indexes.
0 KB in bad sectors.
22356 KB in use by the system.
21568 KB occupied by the log file.
3859524 KB available on disk.
4096 bytes in each allocation unit.
975864 total allocation units on disk.
964881 allocation units available on disk.
Then I used LockDismount to lock the drive then ran dsfok as below:
C:\dsfok>dsfi \\.\PhysicalDrive1 0 0 Backup.img
OK, written 2096889856 bytes at offset 0
I unlocked the the F: drive and ran chkdsk on the new card:
C:\dsfok>chkdsk f:
The type of the file system is NTFS.
WARNING! F parameter not specified.
Running CHKDSK in read-only mode.
CHKDSK is verifying files (stage 1 of 3)...
7104 file records processed.
File verification completed.
20 large file records processed.
0 bad file records processed.
0 EA records processed.
2 reparse records processed.
CHKDSK is verifying indexes (stage 2 of 3)...
9328 index entries processed.
Index verification completed.
0 unindexed files scanned.
0 unindexed files recovered.
CHKDSK is verifying security descriptors (stage 3 of 3)...
7104 file SDs/SIDs processed.
Security descriptor verification completed.
1112 data files processed.
Windows has checked the file system and found no problems.
2015968 KB total disk space.
1445020 KB in 5715 files.
1948 KB in 1114 indexes.
0 KB in bad sectors.
19744 KB in use by the system.
12128 KB occupied by the log file.
549256 KB available on disk.
4096 bytes in each allocation unit.
503992 total allocation units on disk.
137314 allocation units available on disk.
From everything I can see... It appears to have duplicated the card... The only apparent issue being that it has lost the extra 2 GB of storage.
Next I put the newly created card into the PC and tried to boot it up. After the Verifying DMI Pool Data... I get an error in German as this is where the PC's originate: "fehler beim lesen des datenträgers" Which is a Disk Read Error...
I think this may be due to the different size/manufacturer of the CF Card... Your thoughts on the next steps?