Hi George, I got a chance to look thru the trouble shooting you did with TJ . Connolly.
The only thing I can add, since I'm not sure if you tried this, but, personnaly, with my Raspberry Pi V2 and backing up the orignal boot SD Card, I had to try many different SD cards from Best Buy, Amazon, etc......before falling on 2 SD cards that actually worked.
With the ASIair, I purchased 2 EXACTLY same SAMSUNG Card, EVO Plus 32 Gig card on Amazon. I backed up the original as mentioned by ZWO, put in the back-up card to make sure it worked, and sure enough, I now have 3 SD Cards ready to work on the ASIair, the original, and 2 back-up cards.
I will post this also on ZWO Facebook.
Good luck and don't give up George. It has to be something simple like maybe using a different brand of SD card, using a different method of backup with a different software...........
Cal