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Cracked it. My appologies for suspecting Calibre ... it was a mapped network drive that was pinching the drive letter previously used for the SD card on my laptop. I remapped the SD card so it didn't conflict and it now works fine. I hadn't added books since mapping the drive but hadn'#t suspected that because any other USB device just grabs the next available drive letter ... well normally anyway.
Thanks for the advice and quick support ... great site and great tool in Calibre and I still love my PRS-505 even though it can wind me up sometimes!!!
Cheers
Bob
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