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If you haven't already, you might also want to try a different SD card. I had a problem with my Gen3 where a bad SD card caused it to act all kinds of wonky. It would either lock up when I connected it to the computer, or all of the data on the SD card would disappear. Reformatting the card didn't work, it would format and check out ok until I put it back in the device and tried to connect it to the computer again. Of course the Gen3 is completely different hardware, but it might be worth a try if you happen to have an extra card laying around.
If you still can't get it to connect consistently, I would definitely contact Astak. They seem to be very committed to making sure everyone is happy with their device. If they want you to return it for an exchange, you could always ask them to cover the return shipping. They might just do it.
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