For me, it only happened after the first 2gig file. It would then spit out 2kb (not 2mb) files.
If I had a 2gig file already on the card and then started recording, the Edirol would record perfectly until the card was full.
I don't know why, but having a 2gig file on there beforehand seemed to make it work. I think if it was any smaller than 2gig then it didn't work - but I haven't explored that fully yet.
I tried formatted my card on the Edirol, on my PC via the R-09's USB, and via Transcend's external card reader.
Formatting it on the R-09 meant the unit recognised the card immediately on start-up. The other 2 methods, the R-09 said "no card" for a short while, then recognised it.
And in none of the 3 cases did the R-09 split the first 2gig file correctly.
I'll be very interested to see what you find guysonic.