I had this problem from Akaio 1.5.1 to Akaio 1.6RC1. And no one could reproduce this error!!!
For me the solution was GParted - delete Partition --> New partition --> format this new partition (fat32), and all works!!
This error was only by one of my three TF, so i would say this is a problem with MicroSD (Mine was a Kingston 4GB).
I confirmed that GParted is worked! SD Formatter can't solve the soft reset - reset setting problem for some Microsd card. I founded that there is a small unallocated space between first sector to start point of partition's first sector that formatted by any Windows formatter. After deleted and recreate FAT32 and re-copy all backup file to microsd card, the soft reset never reset setting again. I guess there is no Windows software that can delete partition on MicroSD like GParted. I suggest anyone who didn't use Linux like me download Gparted from official site and burn or make bootable on flashdrive.
Edit: I confirmed that formating in Windows could be cause the problem for some Micro SD cards. My testing cards are two 4GB Kingston Micro SDHCs that bought from different date and shop which they have the same soft reset - reset AKAIO setting problem. Testing is ...
1) Format MSD with "Sony formatter" or "Windows formatter" reproduce the same problem.
2) Delete and Recreat Partition with GParted fixed the problem.
3) Resize Partition with GParted by filling small space between first sector to initial partition that produce by Sony / Windows formatter fixed the problem.
I founded that 3) is interesting because small space from Windows formatter could be real cause of the problem and it's not neccessary to delete the old data for fixing the problem.
Edit 2:
From woffi63 :-
QUOTE said:
The solution in both cases was GParted under Ubuntu 9.10!!
Delete the complete Partition ---> create new Partition ---> format fat32 ----> problem solved.(Akaio starts a little bit slower after formatting with GParted)
Because of GParted format process have no adjustable cluster unit size option and it format to default cluster size, for fat32 = 4K (I'm not sure that Gparted's default fat32 cluster size is 4K or not), which small cluster size is efficient for space usage but not efficient for transfering speed that may be the cause of slow down in Acekard process .
I suggest to format with Panasonic formatter or whatever formatter that provide the best speed and resize the partition with Gparted.
Alternative solution, use linux to delete partition and format to 32K cluster size which is the maximum usable fat32 cluster size and most efficient for transfering speed by using command :-
QUOTE
sudo mkdosfs /dev/[sdxx of your microsd card] -s 64 -S 512 -F 32