1) Did you say you can transfer other files to the 2GB card that comes with the PocketPro?
If so that would suggest that the card is working fine and the issue is with the downloaded file.
2) Have you tried copying the file to a different SD card?
If that copies to a different SD card, then that would suggest that the issue is with the 2GB SD card that comes with the PocketPro.
If nothing will copy to any SD card then your SD card reader/writer may have a fault.
If the file will copy to another SD card and you can copy other files to the 2GB SD card that comes with the Pocket Pro, you may need to reformat the 2GB card and try copying the firmware files again.
These are my, off the top of my head, thoughts.
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