Disk Restore Resize/Boot Issue

Hello,
We run Windows XP on compact flash cards which is used in industrial equipment. Each PC contains (2) CF cards, one for Windows and the other for data. Both are 1GB in size. After making a backup image, I can restore these cards successfully using the "Disk" method to the same size cards. If I repeat the same backup plan using "Volume" method, the CF cards fail to boot (no resizing was changed) with a flashing cursor at restart. If I take this same backup image and write this to (2) 2GB cards using "Disk" method, the disks are resized to 1GB and also fail to boot. I expect the disk to be smaller in size, but still be bootable because this method does not allow resizing. If I repeat this restoration using "Volume" method, I can resize the disks and the disks are resized but still fail to boot with flashing cursor at restart. In the old Echo version, you don't have a recovery option type, but I can write this image to any size disks and it will boot no problem. I'm pretty sure I'm performing the steps to restore a disk correctly in ABR10. Any comments?

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What your asking is pretty much over my head. All I know is this problem doesn't exist in the Echo series. I can resize with no issues and boot fine. I create all images on 1GB CF cards. If I restore to 1GB cards, everything boots fine. If I use the same image as I did it in the Echo series, I cannot get the larger cards to boot when I restore by Disks or Volumes (resize or default settings). The data disk is not dependant on Windows booting and the backup/restore is done in system (not with a media card reader, although the results are the same). The rescue media also does the same thing. The reason why I need resizing to work is because we cannot guarantee that we can provide the same size cards at a later date. Typically cards smaller in size get no longer produced and we have to provide the next size up at a reasonable cost. If we provide ABR10 as an aftermarket backup/recovery solution, it doesn't work, thats we downgrade to Echo. But as of the end of this month, we cannot get Echo from Acronis due to ABR11 release and the 2yr support period is expired. I do have cases pending, but Acronis is very slow on fixes.
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