OK. So do the cards in question have a ".pmingest.dat" file on them? The Finder won't show files beginning with a '.' so you'll have to use the command-line Terminal application to check. To do this you first open the Terminal application from your Utilities folder inside your Applications folder. Then type:
ls -al (followed by a space)
And then from the Finder, drag and drop the camera card to the Terminal window and hit Enter/Return. Does the file get listed? If so, press the Up arrow and edit the line you just entered to read:
cat (path to your camera card supplied by the Finder)/.pmingest.dat (hit Enter/Return)
Now the contents of your card's .pmingest.dat file will be displayed and it should be a string of letters/numbers/hyphens surrounded by { and } like so:
{0ADED4FE-01AD-6647-83B3-81F078CC6ED9}
Make note of that value and look in PM's cache for a file with that name. By default, your PM cache will be in the following location: <your home folder>/Library/Caches/Photo Mechanic/
Once you find the PM cache, look into the "ingest/incremental/" folder for a file with the name you noted earlier. Back in the Terminal type:
cat (followed by a space)
And drag and drop that file from the Finder onto your Terminal window. Then hit Enter/Return. The list of files previously copied will be listed in the window. Does it seem reasonable given the contents of your card? Or is nothing listed? Or the data file doesn't exist?
Once you do the above and can answer some of these questions, we can proceed with solutions that may involve me adding logging code to the Incremental Ingest feature and giving you a special build of PM to test with.
-Kirk