Well done Roy,
Just thinking, when you formatted your Sandisk did you do a 'Full overwrite with Size Adjustment 'ON' * as per the PilotAware Users Manual. If only a 'Quick Format' was done, that could cause problems. Just a thought. Glad you've got it fixed.
Best Regards
Peter
Edit: * I use SD Formatter V4.0 - but understand that newer versions may do this automatically.