XigmaNAS

Okay so I'm pretty new to this but here is what I have done:

Downloaded: NAS4Free-x86-LiveUSB-9.1.0.1.847.img
Wrote to SD card with Win32DiskImager
Booted from SD card and selected embedded installation (2) and installed to USB stick (Memory stick micro adapter)
Installed fine
Shut down & removed SD card and started up again
-----------------
FATAL ERROR!
The device that contains the configuration file (config.xml) could not be
found. NAS4Free cannot continue booting.
-----------------

Shut down + insert SD = Boots fine
Logged in to webgui and started some services. No problem
Device manager, format SD card to unallocated, remove SD card in device manager, saved config
shut down + remove SD = Same problem
Insert SD card (remember this is now unallocated) + boot = working fine

I don't understand. Why doesn't N4F find the config file when the SD card is removed and why does it work when the SD card is inserted even though it's empty?

Mounted an UFS Data partition, backed up config file and restored. Didn't help anything

Is there a log file that I can provide?

I have formatted both USB and SD card a couple of times and reinstalled. Checked img hash. Don't know what else to do.

USB booting just sucks IMHO
great when it works and a PITA when it does not.

since the live USB stick boots and after using option #9 to install to the second USB flash does not...
here are some possible problems

the live USB seems OK but does not write correctly to the second
I would use standard fat partitioned USB flash 2Gb or smaller for both

most hardware needs to boot from such flash
large size and other than FAT may not boot correctly

what works when burning flash from an image file with an operating system
may not work directly with the limited hardware bios

as I do NOT trust USB booting I prefer industrial grade IDE flash either PATA or SATA
even a small Hdd will work to store the embedded OS

Wezz, boot from SD card with liveUSB, then insert your USB stick into server and post output command You need see, when you boot from SD card
da0 as SD
da1 as usb pen.
Sometimes devises have another names.
When you boot from liveUSB and make install procedure try to mount second flash to system and browse files.

Here are THREE screens I took yesterday.. (no idea why the first wont show) Yup SD is da0 and USB is da1

Will try to do what you described now

Aaah yes! i tried that actually yesterday and failed. In other words:
Booted from installed USB with SD inserted and tried to mount SD card but an error message appeared. Will try to replicate it now and post the error.

EDIT: Have no idea how to type " | " character/symbol with the nordic laptop keyboard. Tried every key using shift, alt, alt Gr, numlock keys but I don't find it.

By the way, what does the " GEOM: da1s1: geometry does not match label (16h,63s != 255h,63s) media size des not match label"
You can see it in screenshot 0023.jpg

It also happened when I tried to install embedded from USB to 1GB SD card and stops the process. The other way around it works but still got the message.

EDIT 2: Okay so here's what happens when trying to mount SD:

" The following input errors were detected:

Wrong partition type or partition number.
/dev/da0s1: Can't get UFS ID.
dumpfs: /dev/da0s1: could not find special device "

Even happened after I formatted the SD card to UFS again.