How big is the 41 bin file? It should be 4,352 KB and although it is encrypted it should 'copy & paste' normally.
My AU 2595 is identical hardware and sw to your EU 2545 other than addionally having a mic and BT & ASR. Your unit will write and read to and from 1:/. Try the third card and if it's not brand new reformat it correctly to FAT16 or 32 as required using SDFormatter [google it, freeware] or RMPrepUSB which you'd already have. I simply don't trust the built-in Windows tool, occasional bad formats and never use a Mac. There's more than one way to format in FAT [rhymes with more than one way to skin a cat, lol!]. No need to worry with a brand new card as it's factory format will be fine. Remake the whole kit from scratch, don't copy the old one across. You can add an empty update.log if you want but it's not necessary with 2xx5 as it'll be created by it.
I have had problems occasionally with the card slot on some units when the contacts have become 'filmed' and read and/or write function is sporadic or unreliable. I've usually been able to fix that by working the microSD in and out of the slot several times. In stubborn cases, it's necessary to do a very short spray of dedicated electrical contact cleaner [not water dispersant-type cleaner such as WD-40, that's a big no-no] either onto the card contacts or in the slot followed by working the card in and out. If you do that, let it thoroughly air-dry with the card out before powering up.



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