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You question is very similar to the following.
My car wont work. Other people's car's wont work either, even though they're the same make as mine. Whats wrong with the cars?
There is not any relation with my problem
You see the problem? lack of detail. Add more detail and maybe we can help. The SOF files for the same device will always be the same size as they set ALL the logic inside the chip. The contents being different will be because you changed something between compiles.
Nothing has changed between the compiles.
Have you testbenched your design? does it work in ALL cases?
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Its fine with testbench but in hardware case gets not worked