> It is the STBs manual that says it records "System required FAT32."

Yes, we know what the manual says, but that doesn't necessarily mean it's actually correct. That's why it might be worth trying another format. However ...

> If it recognises any other protocol, it doesn't say so. It "Records in MPG" Which obviously (well, to me) converts on playback to something the TV recognises.

MPG is a video file format, that is it describes the internal layout of a video file. FAT32 is the file system format, that is it describes the way files are stores on the media. The two are quite different.

> This manual also says that the maximum file size will be 3.8Gb,(Approx 4 hours) at which length it will "automatically create new video file to continue recording your TV program."

Ok, so it is trying to split the video into suitably-sized chunks, but is obviously throwing a wobbly when it tries to do so.

> It is the lengthy gap between the two files that I'm complaining about.

It's some firmware bug or other.

> So far as I've found with the somewhat exhaustive but largely non-technical TV manual, it recognises several inputs but doesn't include NTFS. The default seems to be NTSC M, but includes six PALs and four SECAMs. The TV is not absolutely modern, but it is a plasma.

Those are the inputs it recognises via its cable connections to other video sources, such as a DVD-player, again nothing whatever to do with a File System format such as NTFS.

> More intensive reading has also revealed the STB manufacturers do not recommend use of "USB 1.1 or USB2.0 Key or Stick," because "A huge of different USB Key or Stick are indeed available in the market" and the STB may damage them.

And actually there's worse. Many cheap USB sticks are a scam - one that claims to be, say 16GB, actually turns out to be, say, 2GB. Thus it fills up after 2GB, when you think it should have another 14GB to go. Yet, when examined in Disk Manager, it may still say 14GB free!

I suggest putting it into your PC, copying off it any video or other files that you want to keep, then deleting them all off the stick, so that it's completely empty (don't forget to delete any files in any Recycle folders - the surest way to do that is simply delete the folder itself, it it exists; on a FAT32 drive it will simply be recreated next time it is required, though of course any deleted files that were formerly in it will have gone for ever). Then try copying a series of files to the stick until it fills up, and check how much you were actually able to copy. Choose a file of about 1GB, and copy it repeatedly giving it different names: Test1.ext, Test2.ext, etc. Then you can see at a glance when the process stops. If it's a lot less than the token size of the stick, then you've got a duff one, and should return it.

However note the following. Disk sizes are usually quoted in units of 1000s, whereas OS systems usually give directory and file information in units of 1024s (nearest power of 2, 2^10). Thus you will never copy as much as 16GB to a 16GB stick. The calculation runs as follows:

        1GB (stick manufacturer) = 1 x 1000^3 = 0.93 x 1024^3 = 0.93GB (OS)

So your 16GB according-to-the-manufacturer stick will fit about 14.9GB according-to-the-OS, actually a little less than that after allowing for file system overheads.

> And maybe HAS monstered the 16Gb 'stick.'

Maybe, or maybe it was duff to begin with.

Also, don't forget to check the manufacturer's website for firmware upgrades.