When formatting your USB pen drives make sure the main partition attribute is set to PRIMARY partition. For all of the "failed" drives this attribute was set to LOGICAL partition. The mikroE FAT32 library functions seem to have difficulty accessing those partitions set as logical. Using the windows format/partition application does not provide the user access to this attribute. I had to use a third party formatting/partitioning tool to change it (my tool of choice was EaseUS Partition Master).
This bit of information may also apply to SD cards too. I personally haven't verified this, but it would make sense and may explain why so many users have had difficulty accessing various MMC cards in the past if they weren't formatted correctly.
The FAT32 help file does mention about primary and logical partitions but I found it somewhat vague like...
To me this help file quote is confusing. Which is it, primary or logical??? Unfortunately mE sends you off to fend for yourself in understanding the nuances of mass storage devices and FAT allocation formats....the library will work with the first available primary (logical) partition that has non-zero size.
HTH.