Hi Charles,
thanks for your speedy and shrewd response: problem solved!
My SD Card was in fact formatted exFAT. I copied all files off and tried reformatting (still exFAT) on my Mac. When I then reinserted the SD Card, Android now reported "SD Card corrupt" and insisted on 'repairing' it, formatting it for 'portable storage'. This turns out to be a FAT32 filesystem. I've now managed to transfer all my books from Calibre without triggering the error again.
Thanks again for your work on CC: I really appreciate it.
Stuart
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