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The Cassini EPC requires a compatible formatted USB Mass Storage Device (MSD) with up to 2 GB Fat16 partition (not exFat, NTFS, etc.). ArcaOS based Cassini EPCs also support Fat32 filesystem up to 36Gb per partition. The biggest advantage of FAT16 is that it is compatible across a wide variety of operating systems, including Windows 95/98/Me, OS/2, Linux and some versions of UNIX. Compatible FAT partitions can be as large as 2 GB with a 32KB cluster size. While windows can format with 64KB cluster sizes (up to 4 GB), it will not work with the Cassini EPC. A USB drive with more capacity than 2 GB can be partitioned with at least one 2 GB drive Fat16 partition or 36Gb Fat32 partition. Additional partitions can be any size and any format, including additional Fat16 and Fat32

In order to create media that is compatible across all operating systems, including OS/2 and ArcaOS, the media must be partitioned and contain LVM data. This means that the media must be partitioned on an OS/2 type system with LVM like ArcaOS, and must be done using an LVM capable tool like the Installation Volume Manager, or the Logical Volume Manager. The Installation Volume Manager is the recommended tool and can be run by choosing Computer > System Setup > Logical Volume Management (Simple) or by opening a command window and typing minilvm. Once the media is properly partitioned, you can format the media as you like on any system and it will work on OS/2 and ArcaOS.

The USB drive can be partitioned using any native OS partitioning tool, including on the Cassini EPC or with the Cassini Virtual Workstation with appropriate Extension pack and drivers. Below are step by step instructions for formatting a USB drive with ArcaOS and Windows.

CAUTION: This will destroy everything on the USB drive.

ArcaOS: Preparing a New USB MSD Disk

To prepare USB MSD disk media where all the data on it can be deleted, follow these steps:

    1. Use the Installation Volume Manager (MiniLVM.exe) to delete all the “partitions” on the disk until you are left with only one line of type None/Free Space. If this doesn’t work, then use DFSee to “Wipe start of disk to ZERO”. Make absolutely certain you select the correct disk for this command. This command will destroy all the data on the selected disk. When the disk has been wiped, remove and reinsert the disk. Then restart step 1 to delete the 1 bogus “partition”. At the end of step 1 the Installation Volume Manager should look something like this (see Figure 1):
    2. Note the Type is None and Notes is Free Space. When you get to this point, then continue with step 2.
    3. Use the Installation Volume Manager (MiniLVM.exe) to create one or more partitions on the disk. USB sticks normally only have one partition but multiple partitions are allowed. Make sure each partition is assigned a drive letter. Using DFSee to create the partitions is not recommended. When finished the Installation Volume Manager should look something like this (see Figure 2):
    4. Close the Installation Volume Manager, saving your changes.
    5. Format the partition(s) on your device. The partition(s) can be formatted and will work on any system including ArcaOS. ArcaOS supports the FAT, HPFS, JFS, and Fat32 file systems.

Windows: Partition and Format USB Dive with DISKPART

To partition any USB drive larger than 4 GB into two or more partitions:
    1. Insert USB drive.
    2. Press Window+R on the keyboard to open Run. Type diskpart and press the Enter key. (press the enter key after every command below)
    3. DISKPART> list disk

      Disk ### Status Size Free Dyn Gpt
      -------- ---------- ------- ------- --- ---
      Disk 0 Online 40 GB 0 B
      Disk 1 Online 7538 MB 0 B
    4. Identify your USB is Disk 1 (7538 MB),select it:
      select disk 1
    5. Disk 1 is now the selected disk
      list part
      Partition ### Type Size Offset
      ------------- ---------------- ------- -------
      Partition 1 Primary 500 MB 1024 KB
    6. DISKPART> clean
      DiskPart succeeded in cleaning the disk.
      Note: You can use graphical Disk Management application to partition and format the "Unallocated" drive.
    7. Resize USB to 2000 MB:
      create part primary size=2046 (IMPORTANT, do not set or exceed 2048 for FAT, Use the Disk Management tool to partition and format the rest of the USB drive or make 32GB partition for FAT32)
      DiskPart succeeded in creating the specified partition.
    8. DISKPART> active
      DiskPart marked the current partition as active.
    9. Close the command window.
    10. Open the drive in File Explorer, select Format disk. (See Figure 3)
    11. Choose FAT as the File System and press Start. (See Figure 4)
      Note: ArcaOS supports Fat32, so can be chosen to support up to 36GB partition size. Use the
      Disk Management tool to partition and format.
    12. Eject the Disk and use with Cassini EPC.
Windows - https://www.diskpart.com/diskpart/diskpart-format-usb-4125.html

Figure 1: LVM Free

Figure 2: LVM Primary

Figure 3: Format Disk

Figure 4: Windows Format FAT

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