Problem:

When trying to format a new volume in the Windows New Volume Wizard, the following error message appears:
  "The format operation did not complete because the cluster count is higher than expected."

 

Cause:

Larger volumes in Windows require a higher allocation size in order to format correctly. The following table illustrates the different sizes:


Volume Size

7 MB - 512 MB

NTFS Cluser Size

512 Bytes

513 MB - 1,024 MB
1 KB

1,025 MB - 2 GB
2 KB

2 GB - 2 TB
4 KB

2 TB - 4 TB
8 KB

4 TB - 8 TB
16 KB

8 TB - 16 TB
32 KB

16 TB - 32 TB
64 KB




Based on the volume size, select the appropriate cluster size:

 

Once the appropriate allocation unit size is selected, the volume should format properly.