Hi Rupert,
Sorry you're having trouble. The FED3 requires a working SD card to boot up. If you take the SD card out the FED3 will give you the "Check SD Card" error at boot as a reminder to put one in. So that behavior is expected, and you should put the card in even if you don't plan to use the data on the card.
Given that you have one working device and one not working, can you swap the SD cards from the working device to see if that fixes the issue with the non-working device (and if the working device works with either card)? If the issue tracks with the device, and not the SD card, it would rule out a problem with the SD card.
Assuming it's not the card, you can try swapping the Adalogger board between the devices to see if the issue tracks with the Adalogger or the FED3 device. I have a
troubleshooting video here that shows how to do this around the 2:45 mark. Based on what you find here, if you determine there's a manufacturing defect I would contact the place you bought it from to get it replaced. I'm curious, where did you buy it from? I designed the FED3 but I don't sell it so I can't help with that aspect.
Feel free to post back for next steps! -Lex