Did you check out the Rockbox link in my second post?
This says that it is an access issue. My computers see the drive and windows explorer can transfer info to/from it. It is only when I try to use it as an mp3 player and power it on that the error occurs.
I guess I'll just have to either wait for a response from mp3 (particularly Archos) types elsewhere.
If I get no joy there I guess its a new drive. Ho hum...
Once again thanks.