A few random questions:
Are you using a Mac or a Windows PC?
Can you please list out the file structure as you are putting it onto the card - everything has to be in the right directory (bank1, bank2 etc. containing the sound files and config files, with a prefs.txt file at the top level (for a NB, there are more with other cards))
Have you tried putting the default setup (can be downloaded from Plecter labs if you don't have it anymore)? This has the two default fonts and default config files.