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This error seems to be happening more frequently. I get the same message, that it can't read the sd card and it needs to be formated in FAT32, about half the time, not every time. I have a 32gb SD card that is formated in FAT32 and it has about 7200 books on it, so I never remove it. It's not inserted incorrectly, if it reads it part of the time.
So far I've been able to get around it by inserting a pin in the Reset hole and it resets and works fine until I turn it off and back on again.
I accidentally found out that if I leave it sit until it times out and turns itself off, the next time I turn it on, it will read the SD card. However, that's not something I would want to do every time. But something to try, if the Reset option doesn't work for you.
I probably should find out how to upgrade the firmware as I don't know how to do that or even what firmware I have currently. But it sounds like that doesn't solve the problem, so better to leave well enough alone.
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