Dave,
The PilotAware WiFi Hotspot appears on your phone or tablet ‘WiFi Settings screen’ to allow the phone or tablet to connect to PilotAware after it has booted up. When you plug in a new card for the first time, it takes 15 - 20 minutes after powering up the unit for PilotAware to partition the card and unpack the software, before it boots up and gets to this point. I suspect you either haven’t left the unit long enough or have inadvertently interfered with the unpacking and setup process by for example unplugging the power supply or removing the card.
First check is to make sure the card is correctly installed in the card slot and hasn’t slipped inside the case (easy to do on a Classic).
Next, can you connect the unit to a monitor (or your home TV) with an HDMI cable, then power up the unit and let us know what you see on screen. You should get a rainbow coloured ‘splash’ screen, then see the software unpacking, then eventually a load of rolling text lines ending in a login prompt. ( You don’t actually ‘log in’ but the PAW WiFi Hotspot won’t appear ‘til the unit gets to this point.)
If it doesn’t get there, the card may have been corrupted during the unpacking process.
Regards
Peter