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Error copying Windows 10 files to USB

I'm trying to do a fresh install of Windows 10 on a late 2015 iMac running El Capitan 10.11.3, but I'm getting errors.


I've downloaded the ISO file from Windows; it's the 64 bit English version. The file name is Win10_1511_English_x64.iso and I've checked the SHA1, so I know it's good.


I'm trying to make a USB drive in Boot Camp, but I'm getting errors when I try to set up the USB. I'm using a 16GB USB 2.0 flash drive, brand is PNY. I've used Disk Utility to format it to MS-DOS (FAT), with the Scheme set to Master Boot Record.


After I get to the stop where Boot Camp warns "The drive will be erased", I get this error: "Your bootable USB drive could not be created" and "An error occurred while formatting the disk"


If I click Continue and try it again, it seems to format OK, but then when it starts copying over the Windows files, I get this error: "Boot Camp installation failed" and "An error occurred while copying the Windows installation files."


I've Googled these errors and found a lot of responses, but none of the fixes seem to work for me. It's not a matter of the ISO image being mounted -- I've made sure it's unmounted when starting up Boot Camp, but that doesn't help.


I've recently used this USB flash drive to install Windows on my Macbook Pro successfully. And I tried another brand of USB flash drive, but I got the same problem.


Any Help? LonerT, my old friend??

iMac, OS X El Capitan (10.11.3)

Posted on Mar 5, 2016 11:03 PM

Reply
20 replies

Mar 6, 2016 10:12 AM in response to mikenmar

Still haven't figured out the problem. I did a fresh install of El Capitan, everything is up to date, no help.


I've got the ISO stored in the Documents folder. As noted above, the SHA1 checks out.


Screen shots of the errors:


This is the first one I get:


User uploaded file

If I click Continue, it seems to format, but then when it starts copying Windows files, I get this:


User uploaded file

Here's a couple shots with info about the USB drive I'm using:


User uploaded file


User uploaded file


User uploaded file


Loner T, you out there? You're my only hope!

Mar 6, 2016 3:42 PM in response to mikenmar

So I tried something else. My iMac has two hard drives: the 1 TB SSD, and a second, 6 TB SATA hard drive.


So I reinstalled El Capitan on the SATA hard drive, and reformatted the 1 TB SSD. Then I tried to install Windows on the 1 TB SSD drive. Again, I get errors at the partitioning stage in BCA. I tried erasing and just creating one partition, but I get this message: "An error occurred while erasing the disk."


User uploaded file


Checking Disk Utility, it seems like it created the BOOTCAMP partition just fine.


But if I click Continue and try to copy over the Windows files, I'm back to this error: An error occurred while copying the Windows Installation files.


User uploaded file

Mar 7, 2016 4:28 PM in response to mikenmar

The 1TB/6TB seems to be a non-standard disk configuration. Is it a TB-to-SATA/eSATA bridge for either of these drives? The Late 2015 Macs do not use USB Installer. They use an internal OSXRESERVED partition. Your BCA screen with three options is a non-2015 BCA. Did any of the OS X installations come from a non-2015 Mac?


Can you check the version of BCA?


Please also see https://help.apple.com/bootcamp/assistant/6.0/ .

Mar 7, 2016 5:07 PM in response to Loner T

The 1TB/6TB is nonstandard, yes. I bought this iMac from a reseller who added the 6TB drive. The 1TB is the OEM Apple SSD drive that comes as an upgrade with the new iMacs.


"Did any of the OS X installations come from a non-2015 Mac?"


No, I just downloaded El Capitan from the Apple Apps store and installed it yesterday. I'm using the Bootcamp version that came with the fresh install of El Capitan. Version 6.01 (522).


"Is it a TB-to-SATA/eSATA bridge for either of these drives?"


I'm not sure -- how can I check that?

Mar 7, 2016 5:12 PM in response to mikenmar

The simplest check is to look at System Report -> SATA and check both drives. The 2015 Macs allow Fusion drives, which means they have the ability to have two SATA connections. Such configurations are usually supported in a Fusion configuration instead of two separate physical volumes (PVs).


Your Mac support EFI boot, but it has a requirement for a small FAT partition at the beginning of the disk, where Windows MSR is stored. This is not the same as the standard EFI partition.


We can create a 2TB Fusion, and leave the remaining 5 TB as a partition and try a test. The 2TB Fusion can be split as 1TB Windows (which will be the first 1TB of the HDD), and the remaining 5 TB can be added as a third PV to the CS volume.

Mar 7, 2016 5:26 PM in response to Loner T

I just talked to the reseller and asked him your question whether the TB-to-SATA/eSATA bridge was used for either device.


He says:


No. These models of iMac use a PCIe interface for the Flash (solid state) drive and SATA for the HDD. Not like the older models.


I assume you can see the System Reports I posted above for the two devices.

Mar 7, 2016 5:33 PM in response to Loner T

"Please also see https://help.apple.com/bootcamp/assistant/6.0/ ."


Yes, I read through that several times. BCA doesn't give me the option of not using a USB. When I first start up BCA, it asks me to pick a drive, which I do. Then it tells me: "The installer disc could not be found. Insert your Windows installer disc and wait a few seconds for the disc to be recognized." Of course, there's no optical drive on the machine. I have the ISO sitting on my Desktop, but it seems not to see that. So them I click "Go Back" and that's when I see the option to create a USB. So I figured that's what I was supposed to do.


Here's a screenshot:


User uploaded file

Mar 7, 2016 6:14 PM in response to mikenmar

One Macs, with more than one physical volume (not a Fusion drive),


1. The OS X boot drive can be partitioned, but not erased.

2. The non-OSX Boot drive can be fully erased. Notice the two greyed-out choices. This screen has no indication of which disk is the 1TB and which is 6TB.


At this point the back logic mimics an old MacPro (Tower) which has multiple SATA/PCIe slots can host multiple drives. Unfortunately, this logic also brings in the assumed Optical drive available on all Tower MPs.


BCA has a very narrow set of variants it can handle.


If you want the Windows installation on the SSD, physically disconnect the HDD from the SATA bus. Install Windows using standard 2015 method, which also requires that you have OS X on the same disk. Once you have both functional, add the HDD, and extend the 1TB OS X side to include the 6TB HDD as part of the CS volume.


Windows Repair of any sort requires going back to the single-disk configuration and possibly re-building the CS volume.

Error copying Windows 10 files to USB

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