Hi Ian,
Yes, it needs to partition the card and unpack the software in the same way as a normal fresh PilotAware install, which can take about 20 minutes or so, then it has to run the setup. My concern would be why Adi says there is no sign of the SD light during this process, though it can show briefly then not be visible for fairly long periods while the partitioning is going on. If interrupted during that process that can of course corrupt the card.
Adi,
Have you checked that the cards are Full Overwrite formatted, with Size Adjustment ‘On’ and that the end result is a FAT32 formatted card? My guess would be some sort of corruption during unpacking and transferring the software to the microSD card or during the subsequent install. I agree with Keith - the best way to see what is going on is to attach a monitor via the HDMI port and follow progress on-screen.
Hope this helps
Regards
Peter