I am having the EXACT same issue that @rtcneil is having!
I have tried many different brands of flash drives all giving me the same error. I have tried using the USB tool on both my mac and windows computers.
I boot from the USB drive, and get an error saying that the drive is not bootable.
My config is as follows:
Dell T710 server, dual X5630 CPUs, 48GB of RAM, 6x4TB WD Red Drives
Yes this server does have a PERC 700 controller... however I had everything working fine prior to trying to upgrade and change the USB drive. All the drives are set up as single drive raid 0 virtual disks in order for unRAID to control the disks independently.
Is there a possibility that the problem is with the USB creation tool?