My typical routine is to download everything to the hard drive first, then program it out to the USB card.  This approach worked for at least two updates.  

Now, however, the initial download goes fine, but when I select the data and try to start the USB programming, the progress bar immediately reports, "FAILED".

Last cycle, when this happened the first time, I contacted Jeppesen support and they walked me through how to delete the downloaded data from my laptop so that I could download a clean set of data from their servers.  I got the same behavior, and they told me I'd need to talk to Avidyne.

I have tried reformatting the USB stick multiple times, both "Quick" and "Full" (wow, but the full format takes for-ev-er!!).  I'm using the default Windows settings:  FAT32 with 4096K blocks.  Same "FAILED" result every time.

I decided to wait until the next update cycle to see what would happen.  The new cycle is here now, and I'm getting the same behavior.

I don't have another USB stick handy to test with.  Thought I'd check to see if anyone else has run into this, or if Avidyne has any suggestions.

If I am reading you right, and the issue occurs in the programming of the USB card (JSUM/computer - > USB) step, is HAS to have to do with (1) JSUM, (2) some sort of data confusion on your computer, or a (3) faulty USB card.

I would try JSUM on a different computer. Also, would try using a different USB card, there is nothing special about the Avidyne one. I suspect that one or both of these will sidestep the problem. Once you have those results, if it turns out not to be the USB card, get back to Jepp to clear the issue on your original computer.

* Orest

Hard to explain why the nav and obs data write out to the USB with no problem, and only the charts have an issue.