Hi Mark,
If you don't mind humoring me for a moment.
Please try the follow:
1 - Format the CF card and try these settings Fat32, 4096 bytes
2 - If you don't already have a seq converted. Convert one using xlights (I see you have a tclown.mp3, do you have a tclown seq file)
3 - Copy those two files to the CF
4 - Create new show files (using the new seq & mp3 files)
5 - Create new schedule using the new show file
6 - Create new password
7 - properly eject the CF
8 - Exit out of the Control Panel and unplug the dongle
9 - Insert the CF and power up the Dongle
10 - Start up the Control panel and enter the password
See if that gets it working. Hopefully it does it not that Denny could be on the right path (he normally is

)
Rick R.