Sounds like you have encountered the 504/528MB BIOS limit. Seems likely that your BIOS is older than July 1994.
https://www.vogonswiki.com/index.php/Storage# … compatibilities
Systems with BIOS limitations can be configured to work with larger drives using one of these three techniques:
- Configure the drive with geometry with Cylinders < 1024, Heads <= 16, and Sectors <= 63 in the BIOS and install drive overlay software that replaces the BIOS routines when the boot sector is loaded
- Upgrade your BIOS using a new BIOS from the motherboard manufacturer or from a third party such as MR BIOS that works with your motherboard
- Install an add-in card with an option ROM extension that replaces the BIOS disk routines before BOOT such as XTIDE UniversalBIOS or SIIG Enhanced BIOS
The first option is usually the easiest / cheapest.
An assortment of old drive overlay tools can be found here: http://vogonsdrivers.com/index.php?catid=19&menustate=59,57
I find that EZ drive often is the best if you plan to move your SD between computers, because the partition types & drive geometries that it uses are usually compatible with modern computers.
Dos 6.22 is limited to 2GB partitions using FAT16x file system & normal cluster sizes, so don't make partitions larger than that.